Battery pack

Abstract

The present invention relates to a battery pack. The battery pack comprises one or more battery modules (100). Each of the one or more battery modules (100) comprises one or more battery cells (106). Each of the one or more battery modules (100) is provided with a printed circuit board (102) and one or more battery management modules (104) of a battery management system (BMS). The printed circuit board (102) is arranged on the battery module (100), and the one or more battery management modules (104) are mounted on the printed circuit board (102). The technical problem of efficiently mounting the printed circuit board (102) and one or more battery management modules (104) within a high-voltage battery pack is solved by the present invention.

Description

Technical Field

[0001] The present invention relates to a battery pack. More particularly, the present invention relates to a battery management system of a battery pack.

Background Art

[0002] Conventional battery packs operate at a low voltage, for example, less than 60 volts. For this reason, a single battery management system (BMS) functions as a master and a slave, and both the master and the slave are used to operate the battery pack. In the case of a battery pack with a higher voltage such as 400 volts, a single BMS is not feasible. Battery packs with higher voltages are used in various high-end applications such as electric vehicles and luxury cars, but are not limited to these. Using a single BMS for a high-voltage battery pack poses a high risk of short circuits during the assembly of the battery pack. Furthermore, a single BMS in a high-voltage battery pack is difficult to handle and dangerous to operate. Separating signals and communications within a single BMS used for a high-voltage battery pack is difficult.

[0003] Also, in conventional battery packs, the BMS cannot be mounted on the battery module. The BMS is mounted at the battery pack level, which means that the entire battery module is assembled, and then the BMS is mounted and connected to the module using wires. These wire connections often become messy and are damaged. Furthermore, wire connections are difficult to handle and routing the wires is troublesome. Separately from this, in conventional low-voltage battery packs, multilayer printed circuit boards (PCBs) are used. Multilayer PCBs are rigid PCBs that are not very flexible and cannot be bent to fit within the existing space. Multilayer PCBs occupy more space within the battery pack. Also, a large number of fasteners are used to attach the multilayer PCB, making the attachment difficult and time-consuming. Furthermore, the fasteners increase the weight of the battery pack, which is undesirable.

Summary of the Invention

[0004] In light of the above, it is necessary to overcome the aforementioned shortcomings of conventional technology. [Means for solving the problem]

[0005] In one aspect of the present invention, a battery pack is disclosed. The battery pack comprises one or more battery modules. Each battery module comprises one or more battery cells. Each battery module in the battery pack is provided with a printed circuit board, and the printed circuit board is arranged on the battery module. Each battery module is provided with one or more battery management modules of a battery management system, and the one or more battery management modules are mounted on the printed circuit board.

[0006] In one embodiment, one or more battery management modules are slave modules. The slave modules are communicatively coupled to the master module.

[0007] In one embodiment having multiple battery management modules, one of the battery management modules is a master module, the remaining battery management modules are slave modules, and the slave modules are operably connected to the master module.

[0008] In one embodiment, the printed circuit board is a flexible printed circuit board. In a non-limiting example, the printed circuit board is made of a flexible material such as polyethylene terephthalate (PET), but is not limited to this.

[0009] In one embodiment, the battery module comprises an upper holder, a bottom holder, an upper plate, and a bottom plate. The upper and bottom holders are fitted to receive the ends of one or more battery cells. The upper plate comprises one or more first interconnectors. One or more first interconnectors are fitted to allow contact with terminals on one end of one or more battery cells. The bottom plate comprises one or more second interconnectors. One or more second interconnectors are fitted to allow contact with terminals on another end of one or more battery cells. Each of the one or more battery modules defines at least four sides between the upper holder and the bottom holder. A printed circuit board is positioned on at least three sides of each of the one or more battery modules. The printed circuit board comprises a first set of connectors and a second set of connectors. The first set of connectors is fitted to establish contact with one or more first interconnectors and one or more second interconnectors. The first set of connectors comprises nickel strips for establishing contact with one or more first interconnectors and one or more second interconnectors. The first set of connectors is spot-welded onto one or more first interconnectors and one or more second interconnectors. The second set of connectors is adapted to establish contact with one or more battery management modules.

[0010] We will now refer to embodiments of the present invention, some of which are shown in the accompanying figures. These figures are illustrative and not limiting. While the present invention will be generally described in the context of these embodiments, it should be understood that the scope of the invention is not intended to be limited to these specific embodiments. [Brief explanation of the drawing]

[0011] [Figure 1]This is an exploded view of a battery module, including a printed circuit board and a battery management module, according to one embodiment of the present invention. [Figure 2] This is a perspective view of a battery module comprising a printed circuit board and a battery management module according to the above embodiment of the present invention. [Figure 3] This is a perspective view of a battery module comprising a printed circuit board and a battery management module according to the above embodiment of the present invention. [Figure 4] This is a perspective view of a flexible printed circuit board according to the present invention. [Modes for carrying out the invention]

[0012] Next, various features and embodiments of the present invention will be understood from the following further description of the invention, as set forth below.

[0013] Figure 1 is an exploded view of a battery module 100 (shown in Figure 2) comprising a printed circuit board 102 and a battery management module 104, according to one embodiment of the present invention. Figures 2 and 3 are perspective views of the battery module 100 comprising a printed circuit board 102 and a battery management module 104, according to the above embodiment of the present invention.

[0014] The present invention relates to a battery pack comprising one or more battery modules 100. Each battery module 100 comprises one or more battery cells 106. The battery module 100 comprises an upper holder 108, a bottom holder 110, an upper plate 112, and a bottom plate 114. The upper holder 108 and the bottom holder 110 are fitted to receive the ends of one or more battery cells 106. The upper plate 112 comprises one or more first interconnectors 116 fitted to allow contact with terminals on one end of one or more battery cells 106. The bottom plate 114 comprises one or more second interconnectors 118 fitted to allow contact with terminals on another end of a battery cell 106. As shown in the figure, the battery module 100 is rectangular in shape and defines four sides between the upper holder 108 and the bottom holder 110. However, the rectangular shape of the battery module 100 should not be interpreted as limiting, and other shapes between the upper holder 100 and the bottom holder 110 are also possible.

[0015] A printed circuit board 102 is provided on each battery module 100 of the battery pack. The printed circuit board 102 is positioned on the battery module 100. In one non-limiting example, the printed circuit board 102 is flexible. In other words, the printed circuit board 102 can be bent to conform to the shape and size of at least three sides of the battery module 100 between the upper holder 108 and the bottom holder 110. The flexible printed circuit board 102 is generally made of a polymer such as polyethylene terephthalate (PET), but is not limited to this. In another non-limiting example, the printed circuit board 102 can be manufactured to a standard shape and size to conform to the shape and size of at least three sides of the battery module 100 between the upper holder 108 and the bottom holder 110. In yet another non-limiting example, the printed circuit board 102 is positioned on at least three sides of the battery module 100 using adhesive material or double-sided tape. In another non-limiting example, the thickness of the printed circuit board 102 is in the range of 0.3 to 0.6 mm.

[0016] The printed circuit board 102 includes a first set of connectors 120 (shown in Figure 4) and a second set of connectors 122. The first set of connectors 120 is adapted to establish contact with one or more first interconnectors 116 on the upper plate 112 and one or more second interconnectors 118 on the bottom plate 114. The first set of connectors 120 includes nickel strips for establishing contact with one or more first interconnectors 116 and one or more second interconnectors 118. The second set of interconnectors 118 establishes connection with one or more battery management modules 104 of the battery management system (BMS).

[0017] The BMS comprises multiple battery management modules 104. Each battery module 100 is provided with one or more battery management modules 104. The battery management modules 104 are mounted on a printed circuit board 102. As already mentioned, the printed circuit board 102 comprises a first set of connectors 116 and a second set of connectors 118. The first set of connectors 116 establish contact with the terminals of one or more battery cells 106, and the second set of connectors 118 establish connections with one or more battery management modules 104 mounted on the printed circuit board 104. Through these connections, different parameters of the battery module 100 are received by one or more battery management modules 104. These different parameters include the charge state (SoC), health (SoH), temperature, voltage, and current of the battery module.

[0018] In a non-exclusive example, one or more battery management modules 104 mounted on a printed circuit board 102 are slave modules communicatively coupled to a master module. In such a scenario, parameters of the battery modules 100 received by the slave modules are sent to the master module. The master module can be located at the battery pack level or outside the battery pack, such as at the vehicle level. The parameters received by the master module are processed to control the operation of the battery modules 100, including but not limited to charging and discharging the one or more battery modules 100.

[0019] In another non-exclusive example, one of the battery management modules 100 in a battery pack is a master module, and the remaining battery management modules in the battery pack are slave modules, with the slave modules being communicatively coupled to the master module. In other words, of all the battery management modules 104 received within one or more battery modules 100, one of the battery management modules 104 is a master module, and the remaining battery management modules 104 are slave modules, with all slave modules being communicatively coupled to the master module. In such a scenario, the parameters of the battery modules 100 are received by the master module and the slave modules for each corresponding battery module. The parameters of the slave modules are sent to the master module, which processes the data sent and received by the slave modules to control the operation of the battery modules, including but not limited to charging and discharging one or more battery modules.

[0020] It should be understood that the master module and the slave module are communicably coupled via a network. The network can be a controller area network, a wireless network, an Ethernet AVB network, or a combination thereof. Further, the network can be a public network such as the Internet, a private network such as an intranet, or a combination thereof, and can utilize various communication protocols that are currently available or will be developed later.

[0021] The construction and operation of the slave module and the master module of the battery management system are already known in the art and will not be discussed in detail for the sake of brevity. The present invention basically relates to mounting a printed circuit board and one or more battery management modules, that is, slave modules and / or master modules, not at the battery pack level, but on the battery module 100.

[0022] In FIGS. 2 and 3, a flexible printed circuit board 102 is disposed on the battery module 100, and a battery management module 104 is mounted on the printed circuit board 102. FIG. 3 shows that a cover 124 (also shown in FIG. 1) covers the battery management module 104.

[0023] FIG. 4 is a perspective view of the flexible printed circuit board 102 according to the present invention.

[0024] As shown in the illustration, a U-shaped printed circuit board 102 adapted to be disposed on three sides of the battery module 100 is shown. As already described, in a non-limiting example, the printed circuit board 102 can be made of a flexible material that can be bent to form the U-shaped structure shown in FIG. 4. Also, in another non-limiting example, the printed circuit board 102 can be manufactured in a U-shape to conform to the shape and size of the battery module 100. In another non-limiting example, the printed circuit board 102 can cover all four sides of the battery module 100 based on the design of the battery pack. The printed circuit board 102 is disposed on the battery module 100. The term "disposed" in this context means that the printed circuit board 102 is attached to the side of the battery module using an adhesive or double-sided tape. The printed circuit board 102 includes a first set of connectors 120 and a second set of connectors 122. The first set of connectors 120 is adapted to establish connection with the first and second interconnects 118, 120 of the battery module 100. In FIG. 4, the first set of connectors 120 is L-shaped, and the portion that contacts the interconnects 116, 118 is made of nickel strip or contains nickel. However, this shape of the first set of connectors 120 should not be construed as limiting, and other shapes capable of establishing connection with the first interconnect 116 and the second interconnect 118 are included within the scope of the present invention.

[0025] The second set of connectors 122 is for connecting the battery management module 104 to the battery module 100. In FIG. 4, two connectors 122 that can be used to receive two battery management modules 104 are shown. However, this number should not be construed as limiting, and the second set of connectors 122 can include one connector (for receiving only one battery management module) or three or more connectors for receiving three or more battery management modules 104.

[0026] The claimed features / method steps of the present invention discussed above are not common, conventional, or well understood in the art, because they enable the following solutions to existing problems in the prior art. Specifically, the present invention solves the technical problem of efficiently mounting a printed circuit board and one or more battery management modules within a high-voltage battery pack.

[0027] In this invention, both the printed circuit board and the battery management module are located / mounted at the battery module level, thereby facilitating the assembly of the battery pack.

[0028] In this invention, the printed circuit board and battery management module are arranged / mounted at the battery module level, so the distance between the interconnector and the battery management module is smaller compared to conventional battery packs, and therefore the need for wire connections between the aforementioned components is eliminated, thereby promoting the safe operation of the high-voltage battery pack and the ease of assembling the aforementioned components into the battery pack.

[0029] In this invention, the printed circuit board is adapted to conform to the shape and size of the battery module, thereby saving space within the battery pack and providing flexibility when mounting the PCB on the battery module.

[0030] In this invention, the thickness of the printed circuit board is in the range of 0.3 to 0.6 mm, which is significantly smaller than the thickness of printed circuit boards used in conventional battery packs. In conventional battery packs, the thickness of the printed circuit board is at least 10 mm. Therefore, this invention saves space within the battery pack, which in turn provides the printed circuit board with greater flexibility in mounting on the battery module.

[0031] In this invention, the printed circuit board is formed to adhere to the battery module, thereby completely eliminating the need for fasteners. The elimination of fasteners simplifies the assembly process and reduces the cost, space requirements, and weight of the battery pack. Because the printed circuit board is formed to adhere to the battery module, the possibility of connection failure between the printed circuit board and the battery module is also eliminated.

[0032] In this invention, a first set of connectors on a printed circuit board is spot-welded onto a first interconnector and a second interconnector on a battery module. In conventional battery packs, the printed circuit board was fastened through fasteners with higher resistance values. In this invention, since spot welding is used to establish the connection between the interconnector on the battery module and the first set of connectors, the resistance path is reduced, thereby reducing losses and increasing the performance, efficiency, and safety of the battery pack.

[0033] In this invention, the assembly of the printed circuit board and grass management module onto the battery module is simplified, thereby reducing assembly costs. Furthermore, in conventional battery packs, mounting means, wiring harnesses, etc., were required to attach the printed circuit board and grass management module at the grass pack level, but these are eliminated in this invention, thereby reducing the cost and weight of the battery pack.

[0034] Although the present invention has been described above with respect to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the scope of the invention as defined in the appended claims. [Explanation of Symbols]

[0035] 100 Battery Modules 102 Printed circuit board 104 Battery Management Module 106 battery cells 108 Upper holder 110 Bottom holder 112 Top plate 114 Bottom plate 116 First interconnector 118 Second interconnector 120 First set of connectors 122 Second set of connectors 124 Cover

Claims

1. One or more battery modules (100), each comprising one or more battery cells (106) Equipped with, Each of the one or more battery modules (100) is provided with a printed circuit board (102) and one or more battery management modules (104) of a battery management system (BMS). A battery pack in which the printed circuit board (102) is arranged on the battery module (100), and one or more battery management modules (104) are mounted on the printed circuit board (102).

2. The battery pack according to claim 1, wherein one or more battery management modules (104) are slave modules that are communicatively coupled to a master module.

3. The battery pack according to claim 1, wherein one battery management module (104) in the battery pack is a master module, the remaining battery management modules (104) in the battery pack are slave modules, and the slave modules are communicatively coupled to the master module.

4. The battery pack according to claim 2 or 3, wherein the printed circuit board (102) is a flexible printed circuit board.

5. The battery pack according to claim 4, wherein the printed circuit board (102) is made of polyethylene terephthalate (PET).

6. Each of the one or more battery modules (100) is - An upper holder (108) and a bottom holder (110) fitted to receive the ends of one or more battery cells (106), - An upper plate (112) having one or more first interconnectors (116) for enabling contact with terminals on one end of one or more battery cells (106), - A bottom plate (114) having one or more second interconnectors (118) for enabling contact with terminals on other ends of one or more battery cells (106) and The battery pack according to claim 1, comprising:

7. The battery pack according to claim 6, wherein each of the one or more battery modules (100) defines at least four sides between the upper holder (108) and the bottom holder (110), and the printed circuit board (102) is arranged on at least three sides of each of the one or more battery modules (100).

8. The battery pack according to claim 7, wherein the printed circuit board (102) is placed on each of the one or more battery modules (100) using an adhesive material.

9. The battery pack according to claim 8, wherein the printed circuit board (102) comprises a first set of connectors (120), the first set of connectors (120) being adapted to establish contact with one or more first interconnectors (116) and one or more second interconnectors (118).

10. The battery pack according to claim 9, wherein the first set of connectors (120) comprises a nickel strip for establishing contact with one or more first interconnectors (116) and one or more second interconnectors (118).

11. The battery pack according to claim 10, wherein the first set of connectors (120) is spot-welded onto one or more first interconnectors (116) and one or more second interconnectors (118).

12. The battery pack according to claim 11, wherein the flexible printed circuit board (102) comprises a second set of connectors (122), the second set of connectors (122) being adapted to establish contact with one or more battery management modules (104).

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