阅读说明：本技术 用于蓄电池模块的汇流条桥的卡扣式延伸部和引导壁 (Snap-in extension and guide wall for a bus bar bridge of a battery module ) 是由 罗伯特·J·麦克 理査德·M·德克斯特 詹妮弗·L·查尔内基 肯·中山 马修·R·泰勒 克 于 2015-12-03 设计创作，主要内容包括：本公开包括蓄电池模块,所述蓄电池模块具有一组电气互连的电化学电池单元、配置成联接到负载以为所述负载供电的蓄电池模块端子,以及延伸在所述一组电气互连的电化学电池单元与所述蓄电池模块端子之间的电通路,其中所述电通路包括汇流条桥。所述蓄电池模块还包括外壳,其中所述一组电气互连的电化学电池单元设置在所述外壳内,并且所述外壳包括一对延伸部,所述一对延伸部沿所述汇流条桥的侧面定位,并且配置成保持所述汇流条桥并且阻挡所述汇流条桥沿至少一个方向移动。(The present disclosure includes a battery module having a set of electrically interconnected electrochemical cells, a battery module terminal configured to be coupled to a load to power the load, and an electrical path extending between the set of electrically interconnected electrochemical cells and the battery module terminal, wherein the electrical path includes a bus bar bridge. The battery module also includes a housing, wherein the set of electrically interconnected electrochemical cells is disposed within the housing, and the housing includes a pair of extensions positioned along sides of the bus bar bridge and configured to retain the bus bar bridge and block movement of the bus bar bridge in at least one direction.)

1. A lithium-ion (Li-ion) battery module, comprising:

a set of electrically interconnected electrochemical cells;

a battery module terminal configured to be coupled to a load to power the load;

an electrical path extending between the set of electrically interconnected electrochemical cells and the battery module terminals, wherein the electrical path includes a bus bar bridge; and

a housing, wherein the set of electrically interconnected electrochemical cells is disposed within the housing, and the housing includes a pair of extensions positioned along sides of the bus bar bridge and configured to retain the bus bar bridge and block movement of the bus bar bridge in at least one direction.

2. The lithium ion battery module of claim 1, wherein the pair of extensions are configured to block movement of the bus bar bridge only along a lateral axis of the bus bar bridge.

3. The lithium ion battery module of claim 1, wherein the pair of extensions are configured to block movement of the bus bar bridge only along a lateral axis of the bus bar bridge and a longitudinal axis of the bus bar bridge that is perpendicular to the lateral axis.

4. The lithium ion battery module of claim 1, wherein the pair of extensions are configured to block movement of the bus bar bridge only along a lateral axis of the bus bar bridge, a longitudinal axis of the bus bar bridge perpendicular to the lateral axis, and an axis along a thickness of the bus bar bridge perpendicular to both the lateral and longitudinal axes.

5. The lithium ion battery module of claim 1, wherein the bus bar bridge comprises an S-shape having a first base, a second base, and an S-shaped bend extending between the first base and the second base.

6. The lithium ion battery module of claim 5, wherein the first base of the bus bar bridge extends between extensions of the pair of extensions.

7. The lithium ion battery module of claim 5, wherein an S-shaped bend extends between extensions of the pair of extensions.

8. The lithium ion battery module of claim 5, wherein the housing comprises a pair of additional extensions positioned along sides of the bus bar bridge and configured to retain the bus bar bridge and block movement of the bus bar bridge in at least one direction, wherein the first base of the bus bar bridge extends between extensions of the pair of extensions, wherein the second base of the bus bar bridge extends between additional extensions of the pair of additional extensions, and wherein the pair of extensions and the pair of additional extensions extend in a first perpendicular direction that is generally parallel to at least a portion of the S-shaped bend of the bus bar bridge.

9. The lithium ion battery module of claim 1, wherein each extension of the pair of extensions comprises a hook extending toward the other extension of the pair of extensions and over at least a portion of the bus bar bridge.

10. The lithium ion battery module of claim 9, wherein the hook of each extension comprises a corresponding right triangle having a base facing and parallel to a first portion of the bus bar bridge.

11. The lithium ion battery module of claim 1, wherein the set of electrically interconnected electrochemical cells comprises a set of electrically interconnected prismatic lithium ion (Li-ion) electrochemical cells.

12. The lithium ion battery module of claim 1, wherein the bus bar bridge is positioned adjacent to the pair of extensions such that a first weld of the bus bar bridge is exposed with sufficient clearance to contact via a welding tool on a first side of the pair of extensions and such that a second weld of the bus bar bridge is exposed with sufficient clearance to contact via a welding tool on a second side of the pair of extensions opposite the first side.

13. The lithium ion battery module of claim 1, wherein the battery module comprises a shunt, and the bus bar bridge is welded to the shunt.

14. The lithium ion battery module of claim 1, wherein the pair of extensions extend above a first surface of the first base of the bus bar bridge.

15. The lithium ion battery module of claim 1, wherein the battery module comprises a relay switch mechanism, and the bus bar bridges to components of the relay switch mechanism.

16. The lithium ion battery module of claim 1, wherein the housing and the pair of extensions are plastic, and the pair of extensions are integrally formed with the housing.

17. A lithium-ion (Li-ion) battery module, comprising:

a housing;

a plurality of electrochemical cells disposed in the housing;

a primary terminal of the battery module; and

an electrical pathway extending between the plurality of electrochemical cells of the battery module and the primary terminal, wherein the electrical pathway comprises an S-shaped bus bar bridge having a first base, a second base, and an S-shaped bend extending between the first base and the second base, wherein the housing comprises a first extension extending upward and near a first side of the S-shaped bus bar bridge and a second extension extending upward and near a second side of the S-shaped bus bar bridge opposite the first side, and wherein the first and second extensions are configured to block movement of the S-shaped bus bar bridge along at least one axis of the S-shaped bus bar bridge.

18. The lithium ion battery module of claim 17, wherein the first and second extensions are collectively configured to block movement of at least the S-shaped bus bar bridge along a first axis of the S-shaped bus bar bridge and a second axis of the S-shaped bus bar bridge that is perpendicular to the first axis.

19. The lithium ion battery module of claim 17, wherein the first and second extensions are collectively configured to block movement of at least the S-shaped bus bar bridge along a first axis of the S-shaped bus bar bridge, a second axis of the S-shaped bus bar bridge that is perpendicular to the first axis, and a third axis of the S-shaped bus bar bridge that is perpendicular to the first and second axes.

20. The lithium ion battery module of claim 17, wherein the first extension comprises a first pointed edge extending toward the second extension, and the second extension comprises a second pointed edge extending toward the first extension.

21. A lithium-ion (Li-ion) battery module, comprising:

an electrical path extending between a set of electrically interconnected electrochemical cells of the battery module and a terminal, wherein the terminal is configured to be coupled to a load to power the load;

a bus bar bridge of the electrical path; and

at least one snap-in extension integrally formed with a housing of the battery module and disposed proximate to the bus bar bridge, wherein the at least one snap-in extension includes a hook that extends over the bus bar bridge and is configured to at least temporarily block movement of the bus bar bridge in at least one direction.

22. The lithium ion battery module of claim 21, wherein the hook comprises a first right triangle having a flat lower surface facing and parallel to a base of the bus bar bridge.

23. The lithium ion battery module of claim 21, wherein the bus bar bridge is an S-shaped bus bar bridge having a first base, a second base, and an S-shaped bend extending between the first base and the second base.

24. The lithium ion battery module of claim 21, wherein the at least one snap-in extension is disposed proximate the base of the bus bar bridge such that the hook extends above the base of the bus bar bridge.

Background

The present disclosure relates generally to the field of batteries and battery modules. More particularly, the present disclosure relates to positioning and retaining bus bar bridges of battery modules.

This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

A vehicle that uses one or more battery systems to provide all or part of its power to the vehicle may be referred to as an xEV, where the term "xEV" is defined herein to include all vehicles described below (which use electric power for all or part of their vehicle power), or any variation or combination thereof. For example, xevs include Electric Vehicles (EVs) that use electricity for all powers. As will be understood by those skilled in the art, a Hybrid Electric Vehicle (HEV), also known as an xEV, combines an internal combustion engine propulsion system and a battery-powered electric propulsion system, such as a 48 volt (V) or 130V system. The term HEV may include any variation of a hybrid electric vehicle. For example, a full hybrid powertrain system (FHEV) may provide power and other electrical power to a vehicle using one or more electric motors, using only an internal combustion engine, or using both. In contrast, a mild hybrid system (MHEV) deactivates the internal combustion engine when the vehicle is idling and utilizes a battery system to continue providing electrical power to the air conditioning unit, radio or other electronic devices and to restart the engine when propulsion is required. Mild hybrid systems may also apply a degree of power assist (e.g., during acceleration) to supplement the internal combustion engine. Mild hybrids are typically 96V to 130V and recover braking energy through a belt or crank integrated starter generator. Additionally, micro-hybrid electric vehicles (mhevs) also use a "start-stop system similar to mild hybrids, but the micro-hybrid system of the mhevs may or may not provide power assist to the internal combustion engine and operate at voltages below 60V. For the purposes of the present discussion, it should be noted that a mHEV generally does not technically use the electrical power provided directly to the crankshaft or transmission for powering any portion of the vehicle, but the mHEV may still be considered an xEV because it also uses electrical power to supplement the power requirements of the vehicle when the vehicle is idling (with the internal combustion engine deactivated) and braking energy is recovered through an integrated starter-generator. Further, a plug-in electric vehicle (PEV) is any vehicle that can be charged from an external power source, such as a wall outlet, and the energy stored in the rechargeable battery pack can drive or contribute to driving the wheels. PEVs are a subclass of EVs, including all-electric or Battery Electric Vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and hybrid electric vehicles and transition-type electric vehicles of conventional internal combustion engine vehicles.

The xevs described above may provide several advantages over more traditional fuel-powered vehicles that use only an internal combustion engine and a traditional electrical system, which is typically a 12V system powered by a lead-acid battery. For example, xevs may produce fewer undesirable emission products and may exhibit higher fuel efficiency relative to conventional internal combustion engine vehicles, and in some cases, such xevs may eliminate the use of gasoline altogether, as may certain types of EVs or PEVs.

As technology continues to evolve, there is a need to provide improved power sources, particularly battery modules, for such vehicles. For example, in conventional configurations, a battery module may include components configured to provide electrical communication between one or more terminals of the battery module and a set of electrically interconnected electrochemical cells of the battery module. Unfortunately, conventional configurations may include expensive components for providing electrical communication (e.g., an electrical pathway) between the set of electrically interconnected electrochemical cells and the one or more terminals of the battery module. Furthermore, the manufacturing process to position the components and enable electrical communication may be expensive and inefficient. Accordingly, it is now recognized that improved components and manufacturing processes for electrically coupling electrochemical cells and terminals of a battery module are needed.

Disclosure of Invention

The following outlines certain embodiments disclosed herein. It should be understood that these aspects are presented merely to provide the reader with a summary of certain embodiments and that these aspects are not intended to limit the scope of the disclosure. Indeed, the disclosure may encompass a variety of aspects that may not be set forth below.

The present disclosure relates to a battery module having a set of electrically interconnected electrochemical cells, a battery module terminal configured to be coupled to a load to power the load, and an electrical path extending between the set of electrically interconnected electrochemical cells and the battery module terminal, wherein the electrical path includes a bus bar bridge. The battery module also includes a housing, wherein the set of electrically interconnected electrochemical cells is disposed within the housing, and the housing includes a pair of extensions positioned along sides of the bus bar bridge and configured to retain the bus bar bridge and block movement of the bus bar bridge in at least one direction.

The present disclosure also relates to a battery module having a housing, an electrochemical cell disposed within the housing, a primary terminal, and an electrical pathway extending between the electrochemical cell and the primary terminal. The electrical pathway includes an S-shaped bus bar bridge having a first base, a second base, and an S-shaped bend extending between the first base and the second base. The housing includes: a first extension extending upward and near a first side of the S-shaped bus bar bridge; a second extension extending upward and near a second side of the S-shaped bus bar bridge opposite the first side. The first and second extensions are configured to block movement of the S-shaped bus bar bridge along at least one axis of the S-shaped bus bar bridge.

The present disclosure also relates to a battery module having an electrical pathway extending between a set of electrically interconnected electrochemical cells of the battery module and a terminal, wherein the terminal is configured to be coupled to a load to power the load. The battery module also includes a bus bar bridge of the electrical path. Further, the battery module includes at least one snap-in extension integrally formed with a housing of the battery module and disposed proximate to the bus bar bridge, wherein the at least one snap-in extension includes a hook extending over the bus bar bridge and configured to at least temporarily block movement of the bus bar bridge in at least one direction.

Drawings

Various aspects of the disclosure may be better understood upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is a perspective view of a vehicle having a battery system configured in accordance with an embodiment of the present disclosure for providing power to various components of the vehicle;

FIG. 2 is a cross-sectional schematic view of an embodiment of the vehicle and battery system of FIG. 1;

FIG. 3 is a top exploded perspective view of one embodiment of a battery module for use in the vehicle of FIG. 1, according to one aspect of the present disclosure;

FIG. 4 is a perspective view of one embodiment of the battery module of FIG. 3, according to one aspect of the present disclosure;

FIG. 5 is a front view of one embodiment of the battery module of FIG. 3, according to one aspect of the present disclosure;

FIG. 6 is a schematic front view of one embodiment of a snap-in extension and bus bar bridge of the battery module used in FIG. 3, taken along line 6-6 in FIG. 5, in accordance with an aspect of the present disclosure;

FIG. 7 is a side schematic view of one embodiment of snap-in extensions, bus bar bridges, and other components used in the battery module of FIG. 3, according to one aspect of the present disclosure;

fig. 8 is a schematic front view of one embodiment of a guide wall and bus bar bridge for use in the battery module of fig. 3, according to one aspect of the present disclosure;

fig. 9 is a side view schematic of one embodiment of a guide wall, bus bar bridge, and other components used in the battery module of fig. 3, according to one aspect of the present disclosure;

FIG. 10 is a top schematic view of one embodiment of a bus bar bridge according to one aspect of the present disclosure; and

FIG. 11 is a schematic view of one embodiment of electrical paths for use in the battery module of FIG. 3, according to one aspect of the present disclosure; and

fig. 12 is a process flow diagram of one embodiment of a method for securing a bus bar bridge of the battery module of fig. 3, according to one aspect of the present disclosure.

Detailed Description

One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

The battery systems described herein may be used to provide power for various types of electric vehicles (xevs) and other high-voltage energy storage/consumption applications (e.g., grid power storage systems). Such battery systems may include one or more battery modules, each having a plurality of battery cells (e.g., lithium ion (Li-ion) electrochemical cells) arranged and electrically interconnected to provide a particular voltage and/or current that may be used to power one or more components of, for example, an xEV. As another example, battery modules according to these embodiments may be incorporated into or power a stationary power system (e.g., a non-automotive system).

According to embodiments of the present disclosure, the battery module may include a set of electrically interconnected electrochemical cells disposed in a housing of the battery module. The battery module may also include two terminals (e.g., module terminals or primary terminals) extending outwardly from the housing and configured to be coupled to a load to power the load. Two corresponding electrical pathways may be defined between the set of electrically interconnected electrochemical cells of the battery module and the two corresponding terminals. For example, a first electrical path may be established between the set of electrically interconnected electrochemical cells of the battery module and a first terminal (e.g., a first primary terminal). A second electrical path may be established between the set of electrically interconnected electrochemical cells of the battery module and a second terminal (e.g., a second primary terminal).

In certain embodiments, the electrical path between the set of electrically interconnected electrochemical cells and the two terminals of the battery module may include a corresponding transition between the first material and the second material. For example, the electrochemical cells may be electrically interconnected via a bus bar comprising a first material (e.g., aluminum). The two primary terminals (and/or other components of the battery module, such as a shunt) configured to be coupled to a load may include a second material (e.g., copper) that may be less costly than the first material, but may be incompatible with the electrochemical cells and therefore unusable for the bus bars. Thus, components that transition between the first material and the second material (e.g., which are the material of the bus bar and the primary terminal, respectively) may be included in the first electrical path and the second electrical path. For example, a bimetallic busbar may be disposed in the first and second electrical pathways to enable a transition in each pathway from a first material (of the busbar) to a second material (of the primary terminal). The bi-metallic bus bars may be bi-metallic and may each include a first end having a first material and coupled to a first component of the electrical path having the first material (e.g., a terminal of one electrochemical cell or a bus bar extending from one terminal of one electrochemical cell) and a second end having a second material and coupled to a second component of the electrical path having the second material (e.g., a bus bar bridge). The bus bar bridge of each electrical path may extend between the corresponding bi-metallic bus bar and another corresponding component of the battery module (e.g., a shunt or relay having the second material). Additional bus bar bridges of the second material may also be included in each electrical via, as described below with reference to the figures, to couple the electrical via with the primary terminal of the second material.

To connect the bus bar bridge to the appropriate components of the electrical pathway, the bus bar bridge may be welded at either end (e.g., to a bimetallic bus bar on a first end and a shunt or relay on a second end, as described above). However, to enable efficient production of the battery module according to the embodiments of the present disclosure, the housing of the battery module may include snap-in extensions or guide walls to temporarily hold or support the bus bar bridges in one or more directions. For example, the snap-in extensions or guide walls may be integrally formed with the housing of the battery module and may be configured to receive the bus bar bridge and enable retention of the bus bar bridge (e.g., by blocking movement of the bus bar bridge in one or more directions) while facilitating exposure of the weld points of the bus bar bridge to a welding tool. In other words, in certain embodiments, the snap-in extensions or guide walls enable retention of the bus bar bridge when the battery modules are oriented in one or more directions. Thus, due to the complementary retention capabilities of the snap-in extensions or guide posts, and due to the positioning of the welding tool along the weld points of the bus bar bridge to weld the bus bar bridge to the appropriate components of the electrical pathway, the bus bar bridge may be held in place while the battery module is oriented. Additionally, the retention mechanism (e.g., snap-in feature) may be minimally invasive (e.g., sized and/or positioned by the retention mechanism) such that a welding tool may access the weld of the bus bar bridge to more permanently secure the bus bar bridge in the electrical path.

To assist in this description, FIG. 1 is a perspective view of one embodiment of a vehicle 10 that may utilize a regenerative braking system. Although the following description is made with respect to a vehicle having a regenerative braking system, the techniques described herein may be adapted to other vehicles that use batteries to capture/store electrical energy, which may include electric and fuel-powered vehicles.

As noted above, it is desirable that the battery system 12 be largely compatible with conventional vehicle designs. Accordingly, the battery system 12 may be disposed in a location in the vehicle 10 where a conventional battery system would otherwise be housed. For example, as shown, the vehicle 10 may include a battery system 12 similarly disposed at a location similar to a lead-acid battery of a conventional internal combustion engine vehicle (e.g., under the hood of the vehicle 10). Further, as described in detail below, the battery system 12 may be positioned to facilitate managing the temperature of the battery system 12. For example, in some embodiments, positioning the battery system 12 under the hood of the vehicle 10 may enable an air passage to deliver airflow over the battery system 12 and cool the battery system 12.

A more detailed view of the battery system 12 is shown in fig. 2. As shown, the battery system 12 includes an energy storage component 13 coupled to an ignition system 14, an alternator 15, a vehicle console 16, and optionally an electric motor 17. Generally, the energy storage component 13 may capture/store electrical energy generated in the vehicle 10 and output the electrical energy to power electrical devices in the vehicle 10.

In other words, the battery system 12 may provide power to components of the vehicle electrical system, which may include a radiator cooling fan, a climate control system, an electric steering system, an active suspension system, an automatic parking system, an electric oil pump, an electric supercharger/turbocharger, an electric water pump, a heated windshield/defogger, a window glass lift motor, a reading light, a tire pressure monitoring system, a sunroof motor controller, an electric seat, an alarm system, an infotainment system, a navigation feature, a lane departure warning system, an electric parking brake, an exterior light, or any combination thereof. Illustratively, in the illustrated embodiment, the energy storage component 13 provides electrical power to a vehicle console 16 and an ignition system 14, which may be used to start (e.g., crank) an internal combustion engine 18.

Additionally, the energy storage component 13 can capture electrical energy generated by the alternator 15 and/or the electric motor 17. In some embodiments, the alternator 15 may generate electrical energy when the internal combustion engine 18 is running. Specifically, the alternator 15 may convert mechanical energy generated by the rotation of the internal combustion engine 18 into electrical energy. Additionally or alternatively, when the vehicle 10 includes an electric motor 17, the electric motor 17 may generate electrical energy by converting mechanical energy generated by movement of the vehicle 10 (e.g., rotation of wheels) into electrical energy. Thus, in some embodiments, the energy storage component 13 may capture electrical energy generated by the alternator 15 and/or the electric motor 17 during regenerative braking. Accordingly, the alternator 15 and/or the electric motor 17 are generally referred to herein as a regenerative braking system.

To facilitate the capture and supply of electrical energy, the energy storage component 13 may be electrically coupled to the vehicle's electrical system via a bus 19. For example, the bus 19 may enable the energy storage component 13 to receive electrical energy generated by the alternator 15 and/or the electric motor 17. Further, the bus 19 may enable the energy storage component 13 to output electrical energy to the ignition system 14 and/or the vehicle console 16. Thus, when a 12 volt battery system 12 is used, the bus 19 may carry power typically between 8-18 volts.

Further, as shown, the energy storage component 13 may include a plurality of battery modules. For example, in the illustrated embodiment, the energy storage component 13 includes a lithium ion (e.g., first) battery module 20 and a lead-acid (e.g., second) battery module 22 that each include one or more battery cells. In other embodiments, the energy storage component 13 may include any number of battery modules. Further, although the lithium ion battery module 20 and the lead-acid battery module 22 are illustrated adjacent to each other, they may be located in different areas of the vehicle. For example, the lead-acid battery module 22 may be positioned in or around the interior of the vehicle 10, while the lithium ion battery module 20 may be located under the hood of the vehicle 10.

In some embodiments, the energy storage component 13 may include a plurality of battery modules that utilize a plurality of different battery chemistries. For example, when using the lithium ion battery module 20, the performance of the battery system 12 may be improved because lithium ion battery chemistries typically have higher coulombic efficiencies and/or higher charge acceptance rates (e.g., higher maximum charge current or charge voltage) relative to lead acid battery chemistries. Thus, the capture, storage, and/or distribution efficiency of the battery system 12 may be improved.

To facilitate controlling the capture and storage of electrical energy, the battery system 12 may also include a control module 24. More specifically, the control module 24 may control the operation of components in the battery system 12, such as relays (e.g., switches) within the energy storage component 13, the alternator 15, and/or the electric motor 17. For example, the control module 24 may adjust the amount of electrical energy captured/supplied by each battery module 20 or 22 (e.g., to reduce or reset the electrical performance of the battery system 12), perform load balancing between the battery modules 20 and 22, determine the state of charge of each battery module 20 or 22, determine the temperature of each battery module 20 or 22, control the voltage output by the alternator 15 and/or the electric motor 17, and so forth.

Accordingly, the control unit 24 may include one or more processors 26 and one or more memories 28. More specifically, the one or more processors 26 may include one or more Application Specific Integrated Circuits (ASICs), one or more Field Programmable Gate Arrays (FPGAs), one or more general purpose processors, or any combinations thereof. Further, the one or more memories 28 may include volatile memory (e.g., Random Access Memory (RAM)) and/or non-volatile memory, such as Read Only Memory (ROM), optical disk drives, hard disk drives, or solid state drives. In some embodiments, control unit 24 may include portions of a Vehicle Control Unit (VCU) and/or a separate battery control module.

An exploded top perspective view of one embodiment of a battery module 20 for use in the vehicle 10 of fig. 2 is shown in fig. 3. In the illustrated embodiment, the battery module 20 (e.g., a lithium-ion (Li-ion) battery module) includes a housing 30 and electrochemical cells 32 (e.g., prismatic lithium-ion (Li-ion) electrochemical cells) disposed within the housing 30. In the illustrated embodiment, six prismatic lithium-ion electrochemical cells 32 are disposed within the housing 30 in two battery packs 34, with three electrochemical cells 32 in each battery pack 34. However, in other embodiments, the battery module 20 may include any number of electrochemical cells 32 (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more electrochemical cells), include any type of electrochemical cells 32 (e.g., lithium-ion, lithium-polymer, lead-acid, nickel-cadmium or nickel-metal hydride, prismatic and/or cylindrical electrochemical cells), and include any arrangement of electrochemical cells 32 (e.g., stacked, individual, or partitioned batteries).

As shown, the electrochemical cell 32 may include terminals 36 (e.g., cell terminals, secondary terminals) that extend upward (e.g., in direction 37). Furthermore, the terminals 36 may extend into openings 38 provided in an upper side 40 of the housing 30 or in a surface of the housing 30. For example, the electrochemical cell 32 may be inserted into the housing 30 from the opening 38 in the upper side 40 and positioned within the housing 30 such that the terminal 36 of the electrochemical cell 32 is disposed in the opening 38. A bus bar carrier 42 may be disposed in the opening 38 and may hold bus bars 44 disposed thereon and configured to interact with the terminals 36 of the electrochemical cells 32. For example, the bus bars 44 may interact with the terminals 36 to electrically couple adjacent electrochemical cells 32 together (e.g., to form a group of electrically interconnected electrochemical cells 32). The bus bars 44 may be mounted or disposed on an upper or lower surface or surfaces of the bus bar carrier 42, or mounted or disposed adjacent to an upper or lower surface or surfaces of the bus bar carrier 42 (e.g., facing away from the electrochemical cells 32 or facing the electrochemical cells 32). However, in other embodiments, battery module 20 may not include bus bar carrier 42 and bus bars 44 may be disposed directly on terminals 36.

According to this embodiment, the bus bars 44 may connect the electrochemical cells 32 in series, in parallel, or connect some of the electrochemical cells 32 in series, or connect some of the electrochemical cells 32 in parallel. Generally, the bus bars 44 implement a set of electrically interconnected electrochemical cells 32. Further, certain bus bars 44 may be configured to electrically couple the set of electrically interconnected electrochemical cells 32 with a primary terminal 46 (e.g., a module terminal) of the battery module 20, wherein the primary terminal 46 is configured to be coupled to a load (e.g., a component of the vehicle 10) to power the load. A cover 54 may be disposed over the bus bar carrier 42 to seal the opening 38 in the housing 30 of the battery module 20 and/or to protect the bus bars 44, other components disposed on the bus bar carrier 42, and/or other components of the battery module 20.

According to embodiments of the present disclosure, the bus bar 44 (e.g., disposed on the bus bar carrier 42) may include two primary bus bars 56, the two primary bus bars 56 configured to enable electrical communication between the set of electrically interconnected electrochemical cells 32 and the primary terminal 46. For example, the two primary bus bars 56 may extend beyond the perimeter 58 of the bus bar carrier 42 (e.g., in direction 61) and may each define at least a portion of a corresponding electrical path between the set of electrically interconnected electrochemical cells 32 and the primary terminals 46. The primary bus bars 56 may include a first material (e.g., aluminum) corresponding to the material of the terminals 36 of the electrochemical cells 32, and corresponding to the bus bars 44 (e.g., secondary bus bars or cell bus bars). In accordance with embodiments of the present disclosure, each primary bus bar 56 may extend from the set of electrically interconnected electrochemical cells 32 to another component of the corresponding electrical pathway extending between the set of electrically interconnected electrochemical cells 32 and the corresponding primary terminal 46.

For example, the primary terminals 56 may each extend toward a corresponding bi-metallic bus bar 59, thereby facilitating the transition of the electrical path from a first material (e.g., aluminum) to a second material (e.g., copper), as will be described in more detail below with reference to subsequent figures. In the illustrated embodiment, only one bi-metallic bus bar 59 is shown in one electrical path, but it should be noted that other electrical paths may also include a bi-metallic bus bar 59. As shown, the bi-metallic bus bar 59 may be coupled to the primary bus bar 56 on a first end and to another component of the electrical pathway on a second end. For example, in the illustrated embodiment, one of the electrical pathways (e.g., with the illustrated bi-metallic bus bar 59) includes a shunt 60 coupled to a Printed Circuit Board (PCB)62 of the battery module 20, wherein the shunt 60 comprises a second material (e.g., copper), and the PCB 62 typically detects the voltage, temperature, and/or other important parameters of the electrical pathway and the battery module 20 in the shunt 60. According to embodiments of the present disclosure, a bus bar bridge 64 having a second material (e.g., copper) may be included in the electrical path on either end of the shunt 60. For example, one bus bar bridge 64 extends between and is coupled to the second end (e.g., copper end) of the bi-metallic bus bar 59 and the shunt 60. It should be noted that in the illustrated embodiment, the coupling of the bus bar bridge 64 to the bi-metallic bus bar 59 is not visible due to the obstruction of the housing 30. Another bus bar bridge 64 extends between and is coupled with the shunt 60 and another component of the electrical path (e.g., the primary terminal 46 or a connection feature between the bus bar bridge 64 and the primary terminal 46). It should be noted that in the illustrated embodiment, the coupling of the bus bar bridge 64 to the other component of the electrical path (e.g., the primary terminal 46 or a connecting feature between the primary terminal 46 and the bus bar bridge 64) is not visible due to the obstruction of the housing 30.

In accordance with the present disclosure, the bus bar bridge 64 may be at least temporarily retained (e.g., prior to welding to the components of the electrical path described above) by a snap-in extension or guide wall extending from the housing 30 (e.g., integrally formed with the housing 30), wherein the snap-in extension or guide wall blocks movement of the bus bar bridge 64 in at least one direction or along one axis (e.g., along axis 37[ relative to a longitudinal axis of the bus bar bridge 64 ], axis 61[ axis along a thickness of the bus bar bridge 64 ], or axis 66[ axis along a width of the bus bar bridge 64 ]). It should be noted that the bus bar bridge 64 may be coupled to components other than the PCB 62 in the battery module 20 (e.g., to relays or switches). For example, in the illustrated embodiment, the bus bar bridge 64 is illustrated for only one electrical path, but other electrical paths may also include a bus bar bridge 64 coupled to a relay or switch. It should also be noted that in other embodiments, the electrical pathway may include other components that facilitate the transition between the first material and the second material, and the bus bar bridge 64 may be coupled to such other components.

Referring now to fig. 4 and 5, a perspective view and a front view of one embodiment of the battery module 20 of fig. 3 are shown, respectively. In the illustrated embodiment, as described above, the shunt 60 of one electrical path may be coupled to the PCB 62, wherein the PCB 62 (or the PCB 62 or a signal of the battery module 20) detects and/or analyzes an operating parameter or condition of the battery module 20 (e.g., the electrical path with the shunt 60). The electrical path also includes a bus bar bridge 64 that electrically couples the shunt 60 to the electrically interconnected electrochemical cells 32 within the housing 30 of the battery module 20, and to the primary terminals 46 of the battery module 20 (e.g., the primary terminals 46 are configured to be coupled to a load). Further, as described above, the housing 30 may include a snap-in extension 70 (or guide wall) through which the bus bar bridge 64 extends, wherein the snap-in extension 70 retains the bus bar bridge 64 (e.g., blocks movement of the bus bar bridge 64) in one or more directions (e.g., along axis 37, axis 61, axis 66, or a combination thereof).

As shown in the illustrated embodiment, the battery module 20 may include one electrical path for each primary terminal 46. For example, as shown, one electrical path extends through the shunt 60 coupled to the PCB 62, while the other electrical path extends through the relay 71 of the battery module 20. The relay 71 may be a switch (or include a switching mechanism) that enables the electrical path to be coupled or uncoupled. For example, the switching mechanism of the relay 71 may open to break the electrical circuit between the two primary terminals 46 of the battery module 20 (the electrical circuit having the set of electrically interconnected electrochemical cells 32 and two electrical paths). The switching mechanism of the relay 71 may be closed to connect the circuit between the two primary terminals 46 of the battery module 20. The electrical path with the relay 71 (or coupled to the relay 71) may also include a bus bar bridge 64, where the bus bar bridge 64 extends from one end of the relay 71 or a component of the relay 71. Thus, an electrical path extends from the electrochemical cell 32, through the bi-metallic bus bar 59, through one of the bus bar bridges 64, through the relay 71 (or a component thereof), through the other bus bar bridge 64, and to the primary terminal 46.

It should be noted that the snap-in extension 70 may include hooks 72 that extend inwardly over the bus bar bridge 64. For example, a cross-sectional schematic view of one embodiment of a pair of snap-in extensions 70 taken along line 6-6 in fig. 5 and used in the battery module 20 in fig. 3 is shown in fig. 6. In the illustrated embodiment, each snap-on extension 70 includes a hook 72 (e.g., triangular, right triangular, triangular prism, pointed hook) that extends toward the other extension 70 of the pair. For example, each hook 72 may include a tip 73 directed toward the other extension 70. In other words, each hook 72 may be a triangle (e.g., a right triangle) having a downwardly and inwardly inclined surface 74 that is inclined toward the tip 73. The surface 74 may enable pushing the bus bar bridge 64 through the surface 74 into a position below the flat lower surface 77 of each hook 72, wherein the flat lower surface 77 of each hook 72 may be substantially parallel to the upper surface 79 of the bus bar bridge 64. Further, the hook 72 may facilitate at least temporarily retaining the bus bar bridge 64 along the direction 61 (e.g., by blocking movement of the bus bar bridge 64 along the direction 61). The wall studs 75 of the snap-in extension 70 may facilitate at least temporarily retaining the bus bar bridge 64 in the direction 66 (e.g., by blocking movement of the bus bar bridge 64 in the direction 66).

A side view schematic of one embodiment of snap-in extension 70, bus bar bridge 64, shunt 60, and PCB 62 is shown in fig. 7. In the illustrated embodiment, the bus bar bridge 64 is S-shaped and includes a first base portion 80, a second base portion 82, and an S-shaped bend 84 extending between the first and second base portions 80, 82. The first base 80 is configured to be coupled (e.g., welded) to a component (not shown) of an electrical pathway (e.g., as described with reference to fig. 3-5). As described above, the second base 82 may be configured to be coupled (e.g., welded) to the flow splitter 60. In the illustrated embodiment, snap-in extension 70 is disposed generally adjacent to (e.g., in line with) first base 80 along direction 37. However, in other embodiments, the snap-in extension 70 may be disposed proximate (e.g., in line with) the S-shaped bend 84 of the bus bar bridge 64, the second base 82 of the bus bar bridge 64, the first base 80 (as described above), or a combination thereof. Generally, snap-in extension 70 retains (e.g., blocks at least a portion of the movement of) bus bar bridge 64 in at least one direction (e.g., direction 66, direction 37, direction 61, or a combination thereof). For example, snap-in extension 70 may block at least some movement of bus bar bridge 64 via hook 72 (e.g., shown in fig. 6) contacting an upper surface 79 (shown in fig. 7) of bus bar bridge 64 (e.g., along direction 61), via hook 72 (shown in fig. 6) contacting an S-shaped bend 84 (shown in fig. 7) of bus bar bridge 64 (e.g., along direction 37), and via snap-in extension 70 (e.g., along direction 66) contacting a side of bus bar bridge 64. However, in some embodiments, the snap-in extension 70 may extend above the upper surface 79 of the bus bar bridge 64 and above the S-shaped bend 84, as indicated by arrow 99 (shown in fig. 7), such that the S-shaped bend 84 does not contact the hook 72 (shown in fig. 6) when sliding in the direction 37. In such embodiments, snap-in extension 70 may only block movement of bus bar bridge 64 in directions 66 and 61.

It should be noted that in some embodiments, guide walls 90 (e.g., extensions) may be provided instead of or in addition to snap-in extensions 70. For example, a cross-sectional schematic view of a portion of the guide wall 90 and the bus bar bridge 64 is shown in fig. 8. In the illustrated embodiment, the guide wall 90 includes only the wall studs 75 (e.g., no hooks). Thus, the guide wall 90 may only block movement of the bus bar bridge 64 in the direction 66 (at least temporarily). However, in another embodiment, the guide wall 90 may include a hook (e.g., the hook 72 shown in fig. 3-7), and thus, in embodiments having a hook, may be referred to as a snap-in extension. Further, it should be noted that "extension" includes both snap-in extension 70 and guide wall 90.

A schematic side view of the guide wall 90 is shown in fig. 9. In the illustrated embodiment, the guide wall 90 is disposed adjacent to (e.g., in line with) the S-bend 84. However, the guide wall 90 may be disposed adjacent to (e.g., in line with) any portion of the bus bar bridge 64, including the S-shaped bend 84, the first base 80, the second base 82, or a combination thereof.

It should also be noted that in certain embodiments, the guide walls 90 (or snap-in extensions 70) may not be provided in pairs and/or may be provided along other surfaces of the bus bar bridge 64. For example, a schematic top view of the bus bar bridge 64 is shown in fig. 10. In the illustrated embodiment, the bus bar bridge 64 includes two longitudinal sides 100, 102 extending along the first base 80, the S-shaped bend 84, and the second base 82 of the bus bar bridge 64. The bus bar bridge further comprises two lateral sides 104, 106 extending between the longitudinal sides 100, 102, wherein a first lateral side 104 extends along the first base 80 of the bus bar bridge 64 and a second lateral side 106 extends along the second base 82 of the bus bar bridge 64. One or more guide walls 90 or snap-in extensions 70 may be provided along either longitudinal side 100, 102 and/or lateral side 104, 106.

It should be noted that in the illustrated embodiment, the bus bar bridge 64 is sized and shaped such that if rotated 180 degrees about the axis 66, the bus bar bridge 64 is generally positioned in the same location and is capable of achieving the same intended function and connection as before the bus bar bridge 64 was rotated 180 degrees about the axis 66. In other words, due to the S-shaped nature of the bus bar bridge 64, the bus bar bridge 64 may be flipped 180 degrees about the axis 66 and still fit in place in the electrical path. This feature may improve the ease of production and interchangeability of parts. It should also be noted that, according to embodiments of the present disclosure, the shape and size of all of the bus bar bridges 64 of one electrical pathway may be substantially the same. This feature also improves the ease of production and interchangeability of parts. In some embodiments, all of the bus bar bridges 64 of the entire battery module 20 may be interchangeable.

A schematic diagram of one embodiment of the electrical path 120 of the battery module 20 is shown in FIG. 11. The electrical path 120 extends between one electrochemical cell 32 or two or more electrically interconnected electrochemical cells 32 (e.g., optionally illustrated as a dashed line) of the battery module 20 and one primary terminal 76 (e.g., a module terminal). In the illustrated embodiment, the electrical path 120 includes the bus bar bridge 64 and may include any number of other components. The illustrated embodiment also includes one or more snap-in extensions 70 and/or guide walls 90. As shown, the snap-in extension 70 and/or the guide wall 90 may be disposed along any side or surface of the bus bar bridge 64. It should also be noted that multiple bus bar bridges 64 and corresponding snap-in extensions 70 and/or guide walls 90 may be provided, as previously described. The snap-in extension 70 and/or the guide wall 90 provide at least temporary retention of the bus bar bridge 64 before, during, and/or after welding the bus bar bridge in place in the electrical pathway 120.

A process flow diagram of one embodiment of a method 150 for securing the bus bar bridge 64 of the battery module 20 of fig. 3 is shown in fig. 12. The method 150 includes positioning the bus bar bridge 64 adjacent to one or more extensions (e.g., snap-in extensions 70 or guide walls 90) (block 152). For example, the bus bar bridge 64 may be positioned between a pair of extensions, wherein the extensions block movement of the bus bar bridge 64 in at least one direction.

The method 150 also includes positioning the bus bar bridge 64 within the electrical path 120 (block 154). For example, the bus bar bridge 64 may be positioned within the electrical pathway 120 such that the bus bar bridge 64 is in position to be welded to one or more components (e.g., the bi-metallic bus bar 59, the shunt 60, the relay 71, or some other component of the electrical pathway 120). In practice, the bus bar bridge 64 may be positioned to contact one or more components of the electrical path 120.

Further, the method 150 includes orienting the battery module 20 such that a welding tool can contact the weld of the bus bar bridge 64 (block 156). For example, as described above, the extensions (e.g., snap-in extensions 70 and/or guide walls 90) may be positioned to enable a welding tool to contact the weld of the bus bar bridge 64 and to hold the bus bar bridge 64 in place during the welding process. Thus, the battery module 20 can be moved to enable the welding tool to contact the welding points while the extensions can hold the bus bar bridge 64 in place.

Further, the method 150 includes welding the bus bar bridge 64 to the appropriate components of the electrical pathways 120 (block 158). For example, the welding tool may heat the weld of the bus bar bridge 64 and/or press against the bus bar bridge 64 to weld the bus bar bridge 64 to the appropriate components of the electrical path 120. Additionally or alternatively, other welding processes may be used to weld the bus bar bridge 64 in place. Any welding process (e.g., ultrasonic welding, laser welding, diffusion welding) suitable for welding the bus bar bridge 64 to the appropriate components of the electrical pathways 120 is within the scope of the embodiments of the present disclosure.

One or more of the disclosed embodiments, alone or in combination, may provide one or more technical effects useful in manufacturing battery modules and portions of battery modules. In general, embodiments of the present disclosure include battery modules having an electrical path extending between a set of electrically interconnected electrochemical cells of the battery module and a primary terminal (e.g., a module terminal). The electrical pathways may each include one or more bus bar bridges. The snap-in extension or guide wall of the housing may enable at least temporary retention of the bus bar bridge before, during and/or after welding of the bus bar bridge into place in the electrical pathway. The technical effects and technical problems in the specification are merely exemplary, but are not limiting. It should be noted that the embodiments described in this specification may have other technical effects and may solve other technical problems.

The foregoing specific embodiments have been described by way of example, but it should be understood that the embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling within the spirit and scope of this disclosure.