Temperature sensor for a battery

Abstract

An apparatus is described. The apparatus is arranged for measuring temperature of one or more cells of a battery. The battery includes a battery management system (BMS). At least one cell of the one or more cells is comprised in a cell can. The apparatus includes an arm couplable to the battery and including a tensioner. The apparatus also includes a flexible printed circuit (FPC) electrically couplable to the BMS. The FPC is wrapped around and secured to the arm. The tensioner and / or the FPC include a sensor electrically coupled to the FPC. The tensioner is arranged to cause at least the sensor to physically contact the cell can. The sensor is configured to measure a temperature associated with the one or more cells via the cell can.

Description

[0001] TEMPERATURE SENSOR FOR A BATTERY

[0002] TECHNICAL FIELD

[0003] This disclosure relates to batteries, in particular to a temperature sensor for a battery and related methods and systems.

[0004] BACKGROUND

[0005] Motor-powered and / or electrically powered vehicles tend to rely on using one or more batteries or battery systems for providing a starting power (e.g., power used to crank and start an engine) and / or at least a portion of a motion power for the vehicle. Such vehicles may include one or more of an air- or watercraft, a rail-guided vehicle, a street vehicle, etc., where a street vehicle may refer to, for example, cars, trucks, buses, recreational vehicles, etc.

[0006] Conventional processes for measuring temperature of battery components generally require complex sensors and / or placing the sensors in locations of the battery that do not provide accurate temperature measurements.

[0007] SUMMARY

[0008] Some embodiments advantageously provide a method and system for measuring temperature of a battery cell at least by placing a sensor on a battery cell can. The sensor may be comprised in flexible printed circuit (FPC) that is electrically coupled to a battery management system (BMS).

[0009] According to an aspect, an apparatus is described. The apparatus is arranged for measuring temperature of one or more cells of a battery. The battery includes a battery management system (BMS). At least one cell of the one or more cells is comprised in a cell can. The apparatus includes an arm couplable to the battery and including a tensioner. The apparatus also includes a flexible printed circuit (FPC) electrically couplable to the BMS. The FPC is wrapped around and secured to the arm. The tensioner and / or the FPC include a sensor electrically coupled to the FPC. The tensioner is arranged to cause at least the sensor to physically contact the cell can. The sensor is configured to measure a temperature associated with the one or more cells via the cell can.

[0010] According to another aspect, a battery is described. The battery includes a housing including one or more cell cans. Each cell can includes at least one battery cell of one or more battery cells. The battery also includes a cover coupled to the housing, where the cover and the housing define a cover space. In addition, the battery includes an arm, a battery management system (BMS), and a flexible printed circuit (FPC). The arm is coupled to one or both of the housing and the cover and includes a tensioner. The BMS is within the cover space and coupled to the cover. The FPC is electrically coupled to the BMS and is wrapped around and secured to the arm. The tensioner and / or the FPC include a sensor electrically coupled to the BMS via the FPC. The tensioner causes at least the sensor to physically contact at least one cell can of the one or more cell cans. The sensor is configured to measure a temperature associated with the one or more battery cells via the at least one cell can. The BMS is configured to determine a temperature value based on the measured temperature.

[0011] According to one aspect, a method of assembly of a battery configured to measure battery cell temperature is described. The battery includes a housing and a cover coupled to the housing. The housing includes one or more cell cans, where each cell can includes at least one battery cell of one or more battery cells. The cover and the housing define a cover space, and the battery includes an arm coupled to one or both of the housing and the cover. The arm includes a tensioner. The battery also includes: a battery management system (BMS) within the cover space and coupled to the cover; a flexible printed circuit (FPC); and a sensor within one of the FPC and the tensioner. The method includes wrapping the FPC around the arm, physically coupling the FPC to the arm, and physically and electrically coupling the FPC to the BMS. The method also includes electrically coupling the sensor to the FPC and causing the tensioner to apply a predetermined biasing force on the FPC. The predetermined biasing force causes the FPC and / or the sensor to physically contact at least one cell can of the one or more cell cans. The sensor is configured to measure a temperature associated with the one or more cells via the at least one cell can.

[0012] BRIEF DESCRIPTION OF THE DRAWINGS

[0013] A more complete understanding of embodiments described herein, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0014] FIG. 1 is a diagram of an example system according to principles disclosed herein; FIG. 2 shows an example battery constructed in accordance with the principles of the present disclosure; FIG. 3 is a block diagram of some entities in the system according to some embodiments of the present disclosure;

[0015] FIG. 4 shows an example sensor in a battery according to some embodiments of the present disclosure;

[0016] FIG. 5 shows another example sensor in a battery according to some embodiments of the present disclosure; and

[0017] FIG. 6 is a flowchart of an example method of assembly a battery according to some embodiments of the present disclosure.

[0018] DETAILED DESCRIPTION

[0019] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of apparatus components and processing steps related to temperature sensor for a battery. Accordingly, the system and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0020] As used herein, relational terms, such as “first” and “second,” “top” and “bottom,” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the concepts described herein. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and / or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0021] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0022] In embodiments described herein, the joining term, “in communication with” and the like, may be used to indicate electrical or data communication, which may be accomplished by physical contact, induction, electromagnetic radiation, radio signaling, infrared signaling or optical signaling, for example. The term “in communication with” may also refer to being in fluid communication, such as where two spaces are in fluid communication with each other. One having ordinary skill in the art will appreciate that multiple components may interoperate, and modifications and variations are possible of achieving the electrical and data communication.

[0023] In some embodiments, the general description elements in the form of “one of A and B” corresponds to A or B. In some embodiments, at least one of A and B corresponds to A, B or AB, or to one or more of A and B. In some embodiments, at least one of A, B and C corresponds to one or more of A, B and C, and / or A, B, C or a combination thereof.

[0024] Referring now to the drawing figures, in which like elements are referred to by like reference numerals, there is shown in FIG. 1 a diagram of a system 10, according to an embodiment, which comprises one or more vehicles 12, e.g., a car, motorcycle, scooter, golf cart, light utility vehicle, etc. The vehicle 12 comprises battery 14 for powering at least one function of vehicle 12. In some embodiments, battery 14 may be a lead-acid battery that includes one or more energy storage modules / cells. Although a lead-acid battery is described herein, the teachings described herein are equally applicable to other battery types. Battery 14 may include one or more batteries such as a first battery 14a, second battery 14b, third battery 14c, fourth battery 14d, etc., e.g., electrically connected (e.g., in parallel, series, etc.) as part of a battery pack. Although battery 14 is shown in conjunction with a vehicle 12, battery 14 is not limited as such and may be used in conjunction with any other component (e.g.., such as to power any other system component).

[0025] Battery 14 includes battery management system (BMS) 16 that is configured to perform one or more battery management functions described herein. In some embodiments, the BMS 16 may measure / determine certain battery parameters, e.g., resistance (e.g., battery resistance), voltage (e.g., cell voltage), current, state of charge (SoC), a time parameter, a frequency parameter, etc., and transmit / receive data (and / or signals such as control signals) to / from another system / device. A BMS 16 is configured to include a BMS management unit 18 (or battery management unit) that may be configured to perform one or more functions as described herein such as determining one or more parameters, steps, and / or processes associated with battery diagnostics.

[0026] It is contemplated that one or more entities of system 10 are in communication with each other via one or more of wireless communication, power communication, wired communication, fluid communication, etc. For example, vehicle 12 and battery 14 (and / or any other device or server) may communicate with each other directly or indirectly using wireless communication, power communication, wired communication, etc. Further, while it may be assumed in one or more embodiments that there is not data or signal communication between battery 14 and vehicle 12, the embodiments described herein are equally applicable to vehicles 12 where there are at least some data / signal communications between battery 14 and vehicle 12. Further, although battery 14 is shown as part of vehicle 12 may be a standalone battery, removably couplable to any component of system 10 such as vehicle 12, etc.

[0027] FIG. 2 shows an example battery 14 constructed in accordance with the principles of the present disclosure. Battery 14 includes a housing 20 into which one or more battery components may be positioned. The components may be electrically interconnected (not shown in the FIGS), such as via an electrically conductive bus bar system which electrically interconnects the components in an electrically serial, electrically parallel or combination of electrically serial and parallel manner, depending on the intended voltage and current requirements.

[0028] A battery monitoring system (BMS) 16 may be included. BMS 16 may include or be coupled to a monitoring connector 24 that allows for a removable external connection any other component of system 10 (e.g., to the vehicle’s data bus, to some other communication device, etc.) and / or internal connection, e.g., any components of battery 14 and / or BMS 16. Connector 24 may be comprised in BMS 16 and / or any other component of system 10. In some embodiments, connector 24 may be configured to removably couple and / or connect (electrically, physically) to another connector. The monitoring connector 24 can, in some embodiments, be integrated with the housing 20, such as in a cover 30 of the housing 20 or any other cover. Battery 14 also includes terminals, such as a positive terminal 28a and a negative terminal 28b (collectively referred to as terminals 28) to provide the contact points for electrical connection of the battery 14 (e.g., to power devices and / or the vehicle 12 and / or BMS 16). Battery 14 may also include cover 34 which may be arranged to couple to cover 30. Cover 30 may include one or more cover walls that may (e.g., along with cover 34) define cover space 32. Cover 30 may be arranged to receive BMS 16 in cover space 32 during assembly, e.g., such that BMS 16 is coupled to cover 30 and / or any other components of battery 14. Terminals 28 may be arranged to protrude through housing 20, such as protruding through cover 30 and / or cover 34. Terminals 28 may be electrically connected to the bus bars inside housing 20 and / or directly connected to cells 22 (bus bars and direct connection not shown). In some embodiments, a cell 22 may include cell can 38, where each cell can 38 is arranged to house the elements of cell 22 (e.g., plates, separators, etc.). In some other embodiments, cell can 38 is arranged to house the elements of cell 22 while having thermal conduction characteristics. For example, cell can 38 may be a container that receives the elements of cell 22, is sealed after receiving the elements of cell 22, and may exchange thermal energy between the interior space of the cell can 38 and the environment that is exterior to the cell can 38.

[0029] Further, battery 14 may be arranged to provide many power capacities and physical sizes, and to operate under various parameters and parameter ranges. It is also noted that implementations of battery 14 some can be scaled to provide various capacities. For example, in some embodiments, the power capacity of battery 14 can range from 25 Ah to 75Ah. It is noted, however, that this range is merely an example, and that it is contemplated that embodiments of battery 14 can be arranged to provide less than a 25 Ah capacity or more than a 75Ah capacity. Power capacity scaling can be accomplished, for example, by using higher or lower power capacity cells 22 in the housing 20, and / or by using fewer or more cells 22 in the housing 20. In some embodiments, battery 14 may be incorporated as part of a vehicle where battery power is needed. Other electrical parameters of the battery 14 can be adjusted / accommodated by using cells 22 that may cumulatively have the desired operational characteristics, e.g., current, voltage, charge, charging capacity / rate, discharge rate, etc. Thermal properties can be managed based on cell 22 characteristics, the use of heat sinks and / or thermal energy discharge plates, etc., within or external to the housing 20. Further, BMS 16 may be connected to at least one of the cells such as to determine / measure at least one parameter of battery 14 and / or cells 22.

[0030] Further, battery 14 may include a plurality of leads 26 (e.g., lead assembly, lead frame), where each lead is electrically connected to a cell 22 and BMS 16. BMS 16 may be configured to determine one or more parameters of each cell 22 via leads 26 such as cell temperature, cell pressure, etc.

[0031] In addition, battery 14 and / or BMS 16 may include a sensor 36 which may refer to one or more sensors 36. Sensor 36 may be arranged to couple to one or more components of battery 14. For example, sensor 36 may be coupled to BMS 16 and / or one or more cells 22 (e.g., via their respective cell cans 38) such that the sensor 36 measures temperature of the one or more cells 22 and / or BMS 16 determines a temperature value (e.g., based on the measured temperature). However, sensor 36 is not limited to being a temperature sensor and may be any other type of sensor. In some embodiments, cover space 32 extends to the space where sensor 36 is located.

[0032] Example implementations, in accordance with an embodiment, of BMS 16 discussed in the preceding paragraphs will now be described with reference to FIG. 3. BMS 16 may have hardware 40 that may include a communication interface 42 that is configured to communicate with one or more entities in system 10 via wired and / or wireless communication. The communication may be protocol based communications.

[0033] The hardware 40 includes processing circuitry 46. The processing circuitry 46 may include a processor 48 and memory 50. In particular, in addition to or instead of a processor, such as a central processing unit, and memory, the processing circuitry 46 may comprise integrated circuitry for processing and / or control, e.g., one or more processors and / or processor cores and / or FPGAs (Field Programmable Gate Array) and / or ASICs (Application Specific Integrated Circuitry) adapted to execute instructions. The processor 48 may be configured to access (e.g., write to and / or read from) memory 50, which may include any kind of volatile and / or nonvolatile memory, e.g., cache and / or buffer memory and / or RAM (Random Access Memory) and / or ROM (Read-Only Memory) and / or optical memory and / or EPROM (Erasable Programmable Read-Only Memory). Hardware 40 may also have one or more circuit elements 44 such as resistors, capacitors, inductors, diodes, transistors, ground connections, source elements, sink elements, sensors, etc. Circuit elements 44 may be arranged in any configuration or connection such as series, parallel, combinations thereof, etc.

[0034] Thus, the BMS 16 may further comprise software 52, which is stored in, for example, memory 50, or stored in external memory (e.g., database, etc.) accessible by the BMS 16. The software 52 may be executable by the processing circuitry 46.

[0035] The processing circuitry 46 may be configured to control any of the methods and / or processes described herein and / or to cause such methods, and / or processes to be performed, e.g., by BMS 16. The processor 48 corresponds to one or more processors 48 for performing BMS 16 functions described herein. The BMS 16 includes memory 50 that is configured to store data, programmatic software code and / or other information described herein. In some embodiments, the software 52 may include instructions that, when executed by the processor 48 and / or processing circuitry 46, causes the processor 48 and / or processing circuitry 46 to perform the processes described herein with respect to BMS 16. For example, the processing circuitry 46 of the BMS 16 may include BMS management unit 18 that is configured to perform any step and / or task and / or process and / or method and / or feature described in the present disclosure, e.g., determining one or more parameters, steps, and / or processes associated with battery 14. While BMS management unit 18 is illustrated as being part of BMS 16, BMS management unit 18 and associated functions described herein may be implemented in a device separate from BMS 16 such as in battery 14 or another device.

[0036] Further, BMS 16 may include sensor 36 arranged to perform the sensor functions described herein. However, sensor 36 is not limited as such and may be comprised in any other components of battery 14 or as a standalone element.

[0037] Although FIGS. 1 and 3 show one or more “units” such as BMS management unit 16 as being within a respective processor, it is contemplated that these units may be implemented such that a portion of the unit is stored in a corresponding memory within the processing circuitry. In other words, the units may be implemented in hardware, software or in a combination of hardware and software within the processing circuitry.

[0038] FIG. 4 shows an example sensor 36. Sensor 36 may be comprised in FPC 100 or coupled to (e.g., releasably coupled to) FPC 100. FPC 100 may be a ribbon type circuit board. Sensor 36 and / or FPC 100 may be physically and / or electrically coupled to BMS 16. For example, FPC 100 may be a circuit element 44 of BMS 16, flexible, and arranged to surround or wrap around arm 102. Arm 102 may be coupled or integrated with any component of battery 14 such as housing 20, cover 30, etc. In some embodiments, sensor 36 may be a thermistor. Also, it is contemplated that more than one sensor 36 can be affixed to and / or part of FPC 100. FPC 100 may also include a first end 104, and arm 102 may include tab 106. The first end 104 may be arranged to couple to tab 106 (e.g., via an opening through FPC 100 on first end 104), such that FPC 100 is secured to the arm 102, which may be coupled to or part of any other component of battery 14 (e.g., housing 20, cover 30, cover 34, etc.). The FPC 100 may also include a second end 105 that is opposite to the first end 104 and that is releasably couplable to BMS 16.

[0039] Arm 102 may include tensioner 108 which is arranged to provide a biasing force to FPC 100, specifically to push FPC contact area 110 of FPC 100 and force FPC contact area 110 to contact cell can contact area 112 of cell can 38. That is, tensioner 108 may cause the sensor 36 to be firmly pushed in direction A (or other directions) against (and directly / indirectly contact) the cell can 38 (e.g., cell can contact area 112), and as cell can 38 may be arranged to contain the elements of cells 22, sensor 36 may measure the temperature of the cell 22 and / or its elements. For example, tensioner 108 may be pushed in direction A where tensioner 108 travels a distance ‘d’ to make contact with or cause the FPC contact area 110 to contact cell can contact area 112. In some embodiments, tensioner 108 is arranged in one or more positions, such as retracted, extended, a dynamic position (e.g., being dynamically tensioned). In some other embodiments, tensioner 108 may, by itself, adjust its position according to the distance ‘d’ such that tensioner 108 causes FPC contact area 110 to make direct contact with cell can contact area 112. In some embodiments, tensioner 108 comprises one or more springs (i.e., the tensioner is spring loaded) to cause tensioner 108 to travel in direction A and provide a biasing force to FPC contact area 110. In some other embodiments, tensioner 108 is a push tensioner, a rotary tensioner, a screw tensioner, manual tensioner, etc. In some embodiments, tensioner 108 comprises sensor 36 or one or more components of sensor 36 (e.g., where sensor 36 is positioned within the arm 102 and a sensing element of sensor 36 is within tensioner 108). In some other embodiments, FPC contact area 110 comprises sensor 36 or one or more components of sensor 36.

[0040] In some embodiments, at least a portion of FPC contact area 110 and / or cell can contact area 112 may be arranged to transfer heat and have a heat transfer coefficient or any other energy transfer coefficient or parameter which can be used by BMS 16 to determine the temperature of a cell 22. In some embodiments, the temperature measurement is based on voltage between two circuit elements of sensor 36 and / or BMS 16. In some other embodiments, the temperature measurement is based on resistance. It is contemplated that other techniques / components for temperature measurement may be used and that implementations are not limited solely to voltage and / or resistance temperature measurement techniques.

[0041] Although a sensor 36 has been described, FPC 100 may include more than one sensor 36 in FPC contact area 110 or any other area of FPC 100. In some embodiments, at least one sensor 36 is coupled to more than one cell can 38 of battery 14. In some other embodiments, sensor 36 is directly coupled to its respective cell 22. In one or more embodiments, a gap may exist between at least a portion of sensor 36 and FPC contact area 110 and / or another gap may exists between FPC contact area 110 and cell can contact area 112. In some embodiments, sensor 36 comprises one or more of thermometers, thermostats, thermistors such as negative temperature coefficient (NTC) thermistors, resistance temperature detectors (RTDs), thermocouples, and semiconductor-based integrated (IC) sensors.

[0042] In a nonlimiting example, using an arm 102 made of plastic, the FPC 100, which may have one or more embedded temperature sensors 36, is extended to a location on the body of the cell can 38, which allows for a more accurate cell temperature reading (of the battery cell temperature) when compared to conventional methods and systems. The FPC 100 may be wrapped around the arm 102 to ensure there is tension to one the components of the FPC 100 (e.g., sensors 36). In some embodiments, the tension maximizes the contact area and energy / heat transfer between battery components and the sensor. In some embodiments, sensor 36, FPC 100, arm 102, tab 106, and / or tensioner 108 (and / or its elements) may be referred to apparatus 90, i.e., apparatus 90 may comprise sensor 36, FPC 100, arm 102, tab 106, and / or tensioner 108 (and / or its elements), etc.

[0043] FIG. 5 shows another example sensor 36 according to some embodiments. FPC 100 is coupled to BMS 16 (not shown) and wrapped around arm 102, where first end 104 is secured to arm 102 via tab 106 which is inserted through opening 116 of the FPC 100. Tensioner 108 may include tensioner element 120 (e.g., spring) which is arranged to cause tensioner to travel a predetermined distance or apply a predetermined biasing force. In some embodiments, arm 102 may include a first arm portion and a second arm portion, where the second arm portion is or comprises the tensioner 108 which may be arranged separate from the first arm portion. Tensioner 108 may be arranged to travel at least a predetermined distance ‘d’ and apply a biasing force which may be based on characteristics of tensioner 108, tensioner element 120, arm 102, FPC 100, sensor 36, can 38, etc. Characteristics of the tensioner 108 may include size characteristics, information related to materials used to make tensioner 108, hardness, elasticity, thermal resistance, thermal expansion coefficient, etc. Characteristics of tensioner element 120 may include a spring constant, size characteristics, type of spring, materials used to make tensioner element 120, tensioner type, linearity of the tensioner, etc. Characteristics of the arm 102 may include materials used to make arm 102, hardness, elasticity, stiffness, etc. Characteristics of FPC 100 may include elasticity, rigidity, etc. Characteristics of sensor 36 may include type of sensor 36, information about its components, size, sensor capabilities, etc. Characteristics of can 38 may include thermal conductivity, stiffness, size information, battery cell information, materials used to make cell can 38, etc. In some embodiments, tensioner 108 is configured to travel and maintain one or more positions along distance ‘d’. For example, tensioner 108 may be in an engaged position where tensioner 108 travels distance ‘d’, contacts FPC 100, and applies a biasing force to FPC 100 and / or cell can 38. Tensioner 108 may also be in a retracted position where the distance traveled d= 0 + / - a predetermined distance, i.e., the bottom portion of tensioner 108 is aligned with the bottom portion of arm 102. Further, tensioner 108 may be at any other positions between the retracted position and the engaged position.

[0044] In this nonlimiting example, tensioner 108 may include sensor 36 and has traveled a distance ‘d’ to apply a biasing force on FPC contact area 110, which in turn makes physical contact with cell can contact area 112 of cell can 38 that is coupled to housing 20. FPC contact area 110 and cell contact area 112 may be arranged to transfer heat from cell 22 to sensor 36 (or elements of sensor 36 (e.g., on FPC contact area 110)) for sensor 36 to measure the temperature of cell 22.

[0045] Arm 102 may be coupled or integrated with any component of battery 14 such as housing 20, cover 30, etc. For example, cover 30 which may include portion 122 which may be in proximity to or coupled to cell can 38, both of which can define space 124 for receiving arm 102, sensor 36, tensioner 108, etc. In some embodiments, space 124 is within cover space 32.

[0046] It is contemplated that the size of cells 22 may vary, e.g., where cells expand or swell causing the volume of cells 22 and / or cell can 38 to vary. In one or more embodiments, portion 122 is a portion of one or more cell stack restrainer plates which may be arranged to restrain cells 22 from swelling. The cell stack retainer plates may be referred to as a cell stack restrainer (CSR) which, as a unit may, provide cell restraining functions such as limiting cell swelling to a predetermined swelling threshold.

[0047] In some embodiments, when cell 22 swells, cell can 38 may also swell which may cause cell can contact area 112 to be displaced in a direction opposite to direction A (shown in FIG. 4) and / or any other direction. Arm 102 and / or tensioner 108 and / or sensor 36 may be arranged to respond to the displacement without compromising their corresponding features / functions. More specifically, displacement due to swelling of the cell can 38 in the direction opposite to direction A (e.g., perpendicular to the arm 102, along portion 122) may occur. Arm 102 may be arranged to elastically deform to comply with or to respond to such displacement without causing the tensioner 108 to compress beyond a predetermined threshold (e.g., without causing the tensioner 108 to over compress) and / or without deforming in predetermined manner (e.g., permanently deforming). Further, arm 102 may be arranged to elastically deform such that the displacement of due to the swell does not cause breakage of the arm 102 and / or the loss of biasing force (e.g., push-down force) of the tensioner 108. Conventional sensor arrangements do not offer such capabilities to respond to cell swelling, which result in inability to maintain the intended contact force with the cell can 38 for accurate temperature measurement. Furthermore, arm 102 may have an extended geometry (e.g., on the upper side of arm 102) arranged to contact portion 122 (e.g., the underside of the portion 122) which may work as a positive stop to provide column strength to limit the deformation of the arm 102 (e.g., beyond a deformation threshold) and maintain the predetermined biasing force (e.g., a predetermined compression of the tensioner 108).

[0048] Thus, in the cases of cell swelling (or expansion) when the cell contact surface 112 moves in a direction opposite to direction A (e.g., along the Z-axis, or upward direction) or any other direction, at least arm 102 and / or tensioner 108 and / or portion 122 (e.g., top plate of CSR) are arranged to maintain a predetermined compression corresponding to tensioner 108 and achieve reliable temperature reading. In cases where the cells contract, and the cell contact area 112 moves in the same direction of A (or other direction), tensioner 108 may be arranged to further travel and / or increase distance ‘d’ to maintain contact with and maintain the biasing force applied to the cell contact area 112. Arm 102 be arranged to elastically deform such that the displacement of due to the contraction does not cause breakage of the arm 102 and / or the loss of biasing force (e.g., push-down force) of the tensioner 108.

[0049] In one or more embodiments, battery components can be made of foam material (e.g., silicone foam, epoxy foam, polyurethane foam, or any other kind of foam). For example, arm 102 and / or tensioner 108 may be made of foam which may have elastic properties.

[0050] In some embodiments, a method of assembly of a battery 14 includes coupling sensor 36 to FPC 100 and coupling FPC 100 to BMS 16, which establishes an electrical connection between BMS 16 and sensor 36. Further, FPC 100 is wrapped around arm 102 and clipped or coupled to tab 106, such that FPC 100 is secured to the arm 102 and sensor 36 contacts (directly or indirectly) cell can 38. The method may also include performing a temperature measurement using sensor 36, e.g., where BMS 16 is configured to determine a temperature value associated with cell 22 using the electrical connection between BMS 16and sensor 36, via FPC 100. According to one aspect, a battery 14 is described. The battery 14 includes a housing 20. The housing 20 includes at least one cell 22 having a cell can 38. The battery 14 also includes an arm 102 coupled to the housing 20 and / or cover 30. The arm 102 includes a tensioner 108. In addition, battery 14 includes a BMS 16, a sensor 36, and an FPC 100. The sensor 36 is configured to measure a temperature associated with the at least one cell 22. The FPC 100 is electrically coupled to the sensor 36 and the BMS 16. The FPC 100 establishes an electrical connection between the BMS 16 and the sensor 36 and is secured to the arm 102. The tensioner 108 of the arm 102 exerts a biasing force against the sensor 36 and causes the sensor 36 to physically contact the cell can 38 to measure the temperature. Further, the BMS 16 is configured to determine a temperature value based on the measured temperature.

[0051] In some embodiments, the FPC 100 comprises an FPC contact area 110, and the cell can 38 comprises a cell can contact area 112. The tensioner 108 further causes FPC contact area 110 and the sensor 36 to physically contact the cell can contact area 112 to measure the temperature.

[0052] In some other embodiments, the arm 102 comprises a tab 106. The FPC 100 is coupled to the tab 106 and secured to the arm 102 at least via the coupling of the FPC 100 and the tab 106.

[0053] One or more embodiments allows placement of sensor 36 at a predetermined location on the cell can 38 (e.g., top of the cell can 38, side of the cell can 38, bottom of the cell can 38) at least by using the FPC 100 and arm 102 to couple the sensor 36 to cell can 38. In some embodiments, tab 106 and biasing elements (e.g., arm 102, tensioner 108, etc.) hold the sensor 36 on the cell can 38. In some other embodiments, sensor 36 and FPC 100 are a unitary structure which allows the sensor 36 to be on the FPC 100, which may provide a structure to make temperature data available to the BMS 16.

[0054] FIG. 6 is a flowchart of an example method of assembly a battery 14. The battery 14 is configured to measure battery cell temperature. The battery 14 includes a housing 20 and a cover 30 coupled to the housing 20. The housing 20 includes one or more cell cans 38, where each cell can 38 includes at least one battery cell 22 of one or more battery cells 22. The cover 30 and the housing 20 define a cover space 32, and the battery 14 includes an arm 102 coupled to the housing 20 and / or the cover 30. The arm 102 includes a tensioner 108. The battery 14 also includes: a battery management system (BMS) 16 within the cover space 32 and coupled to the cover 30; a flexible printed circuit (FPC) 100; and a sensor 36 within one of the FPC 100 and the tensioner 108. The method includes wrapping (Block S100) the FPC 100 around the arm 102, physically coupling (Block S102) the FPC 100 to the arm 102, and physically and electrically coupling (Block S104) the FPC 100 to the BMS 16. The method also includes electrically coupling (Block S106) the sensor 36 to the FPC 100 and causing (Block S108) the tensioner 108 to apply a predetermined biasing force on the FPC 100. The predetermined biasing force causes the FPC 100 and / or the sensor 36 to physically contact at least one cell can 38 of the one or more cell cans 38. The sensor 36 is configured to measure a temperature associated with the one or more cells 22 via the at least one cell can 38.

[0055] In some embodiments, the BMS 16 is electrically coupled to the sensor 36, and the method further includes determining, by the BMS 16, a temperature value based on the measured temperature.

[0056] In some other embodiments, the FPC 100 has a first end 104 and a second end 105 opposite the first end 104, and the method further includes physically coupling the first end 104 to the arm 102 and the second end 105 to the BMS 16.

[0057] In some embodiments, the arm 102 includes a tab 106, and the first end 104 includes an opening 116. The method further includes securing the FPC 100 to the arm 102 by inserting the tab 106 through the opening 116 (e.g., thereby affixing the FPC 100 to the arm 102).

[0058] The method is not limited to the steps described and may include any other step to assemble any of the components described in the present disclosure.

[0059] It will be appreciated by persons skilled in the art that the embodiments described herein are not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings and following claims.

Claims

What is claimed is:

1. An apparatus arranged for measuring temperature of one or more cells (22) of a battery, the battery (14) comprising a battery management system, BMS, (16) at least one cell (22) of the one or more cells (22) being comprised in a cell can (38), the apparatus comprising: an arm (102) couplable to the battery (14) and comprising a tensioner (108); a flexible printed circuit, FPC, (100) electrically couplable to the BMS (16), the FPC (100) being wrapped around and secured to the arm (102), one of the tensioner (108) and the FPC (100) comprising: a sensor (36) electrically coupled to the FPC (100), the tensioner (108) being arranged to cause at least the sensor (36) to physically contact the cell can (38), the sensor (36) being configured to measure a temperature associated with the one or more cells (22) via the cell can (38).

2. The apparatus of Claim 1, wherein the FPC (100) includes an FPC contact area (110) arranged to physically contact the cell can (38).

3. The apparatus of any one of Claims 1 and 2, wherein at least a portion of FPC contact area (110) is arranged to transfer heat to the sensor (36) to measure the temperature.

4. The apparatus of any one of Claims 1-3, wherein the tensioner (108) is arranged to apply a predetermined biasing force on the FPC (100) and the sensor (36) to cause at least the sensor (36) to physically contact the cell can (38) for measuring the temperature.

5. The apparatus of any one of Claims 1-4, wherein the sensor (36) comprises a sensing element, and when the tensioner (108) comprises the sensor (36), the tensioner (108) is arranged to cause the sensing element to physically contact the cell can (38).

6. The apparatus of any one of Claims 1-5, wherein the tensioner (108) is spring-loaded.

7. A battery (14) comprising:a housing (20) comprising one or more cell cans (38), each cell (22) can comprising at least one battery cell (22) of one or more battery cells (22); a cover (30) coupled to the housing (20), the cover (30) and the housing (20) defining a cover space (32); an arm (102) coupled to one or both of the housing (20) and the cover (30), the arm (102) comprising a tensioner (108); a battery management system, BMS, (16) within the cover space (32) and coupled to the cover (30); a flexible printed circuit, FPC, (100) electrically coupled to the BMS (16), the FPC (100) being wrapped around and secured to the arm (102), one of the tensioner (108) and the FPC (100) comprising: a sensor (36) electrically coupled to the BMS (16) via the FPC (100), the tensioner (108) causing at least the sensor (36) to physically contact at least one cell can (38) of the one or more cell cans (38), the sensor (36) being configured to measure a temperature associated with the one or more battery cells (22) via the at least one cell can (38), the BMS (16) being configured to determine a temperature value based on the measured temperature.

8. The battery (14) of Claim 7, wherein the FPC (100) includes an FPC contact area (110), and the at least one can comprises a cell can contact area (112), the FPC contact area (110) being arranged to physically contact the cell can contact area (112).

9. The battery (14) of Claim 8, wherein the tensioner (108) further causes the FPC contact area (110) to physically contact the cell can contact area (112).

10. The battery (14) of any one of Claims 8 and 9, wherein the FPC contact area (110) and the cell can contact area (112) are arranged to transfer heat to the sensor (36) to measure the temperature.

11. The battery (14) of any one of Claims 8-10, wherein the tensioner (108) causes the FPC contact area (110) to be separated a predetermined distance, d, from the arm (102) to physically contact the cell can contact area (112).

12. The battery (14) of any one of Claims 7-11, wherein the tensioner (108) is arranged to apply a predetermined biasing force on the FPC (100) and the sensor (36) to cause at least the sensor (36) to physically contact the cell can (38) for measuring the temperature.

13. The battery (14) of any one of Claims 7-12, wherein the sensor (36) comprises a sensing element, and when the tensioner (108) comprises the sensor (36), the tensioner (108) is arranged to cause the sensing element to physically contact the cell can (38).

14. The battery (14) of any one of Claims 7-13, wherein the tensioner (108) is spring-loaded.

15. The battery (14) of any one of Claims 7-14, wherein the FPC (100) has a first end (104) and a second end (105) opposite the first end (104), the first end (104) being physically coupled to the arm (102), and the second end (105) being physically coupled to the BMS (16).

16. The battery (14) of Claims 7-15, wherein the arm (102) comprises a tab (106), and the first end (104) comprises an opening (116), the FPC (100) being secured to the arm (102) via the tab (106) and the opening (116).

17. A method of assembly of a battery (14) configured to measure battery cell temperature, the battery (14) comprises a housing (20) and a cover (30) coupled to the housing (20), the housing (20) comprising one or more cell cans (38), each cell can (38) comprising at least one battery cell (22) of one or more battery cells (22), the cover (30) and the housing (20) define a cover space (32), the battery (14) including an arm (102) coupled to one or both of the housing (20) and the cover (30), the arm (102) comprising a tensioner (108), the battery (14) including a battery management system, BMS, (16) within the cover space (32) and coupled to the cover (30), the battery (14) including a flexible printed circuit, FPC (100), and a sensor (36) within one of the FPC (100) and the tensioner (108), the method comprising: wrapping (S100) the FPC (100) around the arm (102); physically (S102) coupling the FPC (100) to the arm (102);physically (S104) and electrically coupling the FPC (100) to the BMS (16); electrically coupling (S106) the sensor (36) to the FPC (100); and causing (S108) the tensioner (108) to apply a predetermined biasing force on the FPC (100), the predetermined biasing force causing one or both of the FPC (100) and the sensor (36) to physically contact at least one cell can (38) of the one or more cell cans (38), the sensor (36) being configured to measure a temperature associated with the one or more cells (22) via the at least one cell can (38).

18. The method of Claim 17, wherein the BMS (16) is electrically coupled to the sensor (36), and the method further includes: determining, by the BMS (16), a temperature value based on the measured temperature.

19. The method of any one of Clams 17 and 18, wherein the FPC (100) has a first end (104) and a second end (105) opposite the first end (104), and the method further includes: physically coupling the first end (104) to the arm (102) and the second end (105) to the BMS (16).

20. The method of Claim 19, wherein the arm (102) includes a tab (106) , and the first end (104) includes an opening (116), the method further including: securing the FPC (100) to the arm (102) by inserting the tab (106) through the opening (116).

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