阅读说明：本技术 连接电池阵列中的电池单元的方法 (Method of connecting battery cells in a battery array ) 是由 阿卜杜勒·拉蒂夫 丹尼尔·罗伯茨 弗朗西斯科·费尔南德斯-加林多 于 2020-09-25 设计创作，主要内容包括：本公开提供了“连接电池阵列中的电池单元的方法”。一种方法和设备除了其他之外包括多个电池单元,所述多个电池单元彼此相邻地放置,使得来自一个电池单元的电池单元接片与来自相邻电池单元的电池单元接片重叠以形成一组重叠的电池单元接片。每组重叠的电池单元接片在连接接口处直接彼此接合。电压感测电路直接附接到所述电池单元接片。(The present disclosure provides a "method of connecting battery cells in a battery array. A method and apparatus include, among other things, a plurality of battery cells positioned adjacent to one another such that battery cell tabs from one battery cell overlap battery cell tabs from an adjacent battery cell to form a set of overlapping battery cell tabs. Each set of overlapping cell tabs directly engage one another at a connection interface. A voltage sensing circuit is directly attached to the battery cell tab.)

1. A method, comprising:

(a) placing the battery cells adjacent to each other such that at least one battery cell tab from one battery cell overlaps with at least one battery cell tab from an adjacent battery cell;

(b) directly joining the overlapping battery cell tabs to each other;

(c) placing the battery cell in a final assembled position; and

(d) a voltage sensing circuit is mounted directly to the battery cell tab.

2. The method of claim 1, wherein step (c) comprises folding the battery cell.

3. The method of claim 1, wherein the one battery cell has a first battery cell tab comprising an aluminum material and the adjacent battery cell has a second battery cell tab comprising a copper material, and the method comprises placing the first battery cell tab over the second battery cell tab such that the first battery cell tab directly faces a laser welding tool.

4. The method of claim 1, wherein step (b) comprises one of the following joining methods: ultrasonic welding, laser welding, fastening, riveting or adhering.

5. The method of claim 1, wherein the battery cells comprise at least one first battery cell and at least one second battery cell, and the method comprises placing the at least one second battery cell proximate to the at least one first battery cell such that the battery cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another.

6. The method of claim 5, wherein the at least one first cell comprises a plurality of first cells stacked on top of each other to form a first cell stack, and wherein the at least one second cell comprises a plurality of second cells stacked on top of each other to form a second cell stack, and the method comprises placing the second cell stack proximate to the first cell stack such that the cell tabs of the first and second cell stacks overlap each other.

7. The method of claim 1, further comprising:

(e) mounting the battery cells in an array, an

(f) Cables are connected to the battery cell terminals of the battery cells to connect the array to a group wiring harness or sensor module.

8. The method of claim 1, wherein step (d) comprises connecting the voltage sensing circuit directly to the battery cell tab using ultrasonic welding.

9. The method of claim 1, wherein step (d) comprises directly connecting the voltage sensing circuit to the battery cell tab using a conductive rivet.

10. The method of claim 2, wherein the battery cells comprise at least one first battery cell and at least one second battery cell, and the method comprises placing the at least one second battery cell proximate to the at least one first battery cell such that the battery cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another.

11. The method of claim 10, wherein the at least one first cell comprises a plurality of first cells stacked on top of each other to form a first cell stack, and wherein the at least one second cell comprises a plurality of second cells stacked on top of each other to form a second cell stack, and the method comprises placing the second cell stack proximate to the first cell stack such that the cell tabs of the first and second cell stacks overlap each other.

12. An apparatus, comprising:

a plurality of battery cells positioned adjacent to one another such that battery cell tabs from one battery cell overlap battery cell tabs from an adjacent battery cell to form a set of overlapping battery cell tabs, and wherein each set of overlapping battery cell tabs directly engage one another at a connection interface; and

a voltage sensing circuit directly attached to the battery cell tab.

13. The apparatus of claim 12, wherein the battery cells comprise at least one first battery cell and at least one second battery cell, and wherein the at least one second battery cell is placed proximate to the at least one first battery cell such that the battery cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another prior to engaging the battery cell tabs with one another.

14. The apparatus of claim 13, wherein the at least one first cell comprises a plurality of first cells stacked on top of each other to form a first cell stack, and wherein the at least one second cell comprises a plurality of second cells stacked on top of each other to form a second cell stack, and wherein the second cell stack is placed proximate to the first cell stack such that the cell tabs of the first and second cell stacks overlap each other prior to engaging the cell tabs to each other.

15. The apparatus of claim 12, wherein the battery cells are positioned within an array, and the apparatus comprises a cable connected to battery cell terminals of the battery cells to connect the array to a group wiring harness or a sensor module.

Technical Field

The present disclosure generally relates to a method of connecting battery cells in a battery array of an electrically powered vehicle.

Background

Current array configurations utilize interconnect board assemblies (ICBs) to facilitate attachment of battery cells to battery cells using copper bus bars. The ICB is a plastic and metal component that is welded to the battery cell terminals during array assembly. The plastic part of the ICB is used to hold the bus bars in place prior to installation in the array. Once the battery cells are welded to the ICB assembly, the function of the bus bars is to provide an electrical path from the battery cells to the motorized vehicle components.

Disclosure of Invention

A method according to an exemplary aspect of the present disclosure includes, among other things, (a) placing battery cells adjacent to each other such that at least one battery cell tab from one battery cell overlaps with at least one battery cell tab from an adjacent battery cell; (b) directly joining the overlapping battery cell tabs to each other; (c) placing the battery cell in a final assembled position; and (d) mounting a voltage sensing circuit directly to the battery cell tab.

In another non-limiting embodiment of the foregoing method, step (c) comprises folding the battery cell.

In another non-limiting embodiment of any of the foregoing methods, the one cell has a first cell tab comprising an aluminum material and the adjacent cell has a second cell tab comprising a copper material, and the method includes positioning the first cell tab over the second cell tab such that the first cell tab directly faces a laser welding tool.

In another non-limiting embodiment of any of the foregoing methods, step (b) comprises one of the following joining methods: ultrasonic welding, laser welding, fastening, riveting or adhering.

In another non-limiting embodiment of any of the foregoing methods, the battery cells comprise at least one first battery cell and at least one second battery cell, and the method comprises placing the at least one second battery cell proximate to the at least one first battery cell such that the battery cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another.

In another non-limiting embodiment of any of the foregoing methods, the at least one first cell unit comprises a plurality of first cell units stacked on top of each other to form a first cell stack, and wherein the at least one second cell unit comprises a plurality of second cell units stacked on top of each other to form a second cell stack, and the method comprises placing the second cell stack proximate to the first cell stack such that the cell tabs of the first cell stack and the second cell stack overlap each other.

In another non-limiting embodiment of any of the foregoing methods, the method includes (e) installing the battery cells into an array, and (f) connecting cables to battery cell terminals of the battery cells to connect the array to a gang wiring harness or a sensor module.

In another non-limiting embodiment of any of the foregoing methods, step (d) comprises connecting the voltage sensing circuit directly to the battery cell tab using ultrasonic welding.

In another non-limiting embodiment of any of the foregoing methods, step (d) comprises directly connecting the voltage sensing circuit to the battery cell tab using a conductive rivet.

A method according to yet another exemplary aspect of the present disclosure includes, among other things, (a) placing battery cells adjacent to each other such that at least one battery cell tab from one battery cell overlaps with at least one battery cell tab from an adjacent battery cell; (b) directly joining the overlapping battery cell tabs to each other; (c) folding the battery cell in a final assembled position; and (d) mounting a voltage sensing circuit directly to the battery cell tab.

In another non-limiting embodiment of any of the foregoing methods, step (b) comprises laser welding, ultrasonic welding, fastening, riveting, or adhering the cell tabs to each other.

In another non-limiting embodiment of any of the foregoing methods, the battery cells comprise at least one first battery cell and at least one second battery cell, and the method comprises placing the at least one second battery cell proximate to the at least one first battery cell such that the battery cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another.

In another non-limiting embodiment of any of the foregoing methods, wherein the at least one first cell comprises a plurality of first cells stacked on top of each other to form a first cell stack, and wherein the at least one second cell comprises a plurality of second cells stacked on top of each other to form a second cell stack, and the method comprises placing the second cell stack proximate to the first cell stack such that the cell tabs of the first cell stack and the second cell stack overlap each other.

In another non-limiting embodiment of any of the foregoing methods, the method includes (e) installing the battery cells into an array, and (f) connecting cables to battery cell terminals of the battery cells to connect the array to a gang wiring harness or a sensor module.

In another non-limiting embodiment of any of the foregoing methods, step (d) comprises connecting the voltage sensing circuit directly to the battery cell tab using ultrasonic welding.

In another non-limiting embodiment of any of the foregoing methods, step (d) comprises directly connecting the voltage sensing circuit to the battery cell tab using a conductive rivet.

An apparatus according to another exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells positioned adjacent to each other such that battery cell tabs from one battery cell overlap battery cell tabs from an adjacent battery cell to form a set of overlapping battery cell tabs. Each set of overlapping cell tabs directly engage one another at a connection interface. A voltage sensing circuit is directly attached to the battery cell tab.

In another non-limiting embodiment of the foregoing apparatus, the battery cells comprise at least one first battery cell and at least one second battery cell, and wherein the at least one second battery cell is positioned proximate to the at least one first battery cell such that the battery cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another prior to engaging the battery cell tabs with one another.

In another non-limiting embodiment of any of the foregoing apparatus, the at least one first cell unit comprises a plurality of first cell units stacked on top of each other to form a first cell stack, and wherein the at least one second cell unit comprises a plurality of second cell units stacked on top of each other to form a second cell stack, and wherein the second cell stack is placed proximate to the first cell stack such that the cell tabs of the first and second cell stacks overlap each other prior to engaging the cell tabs with each other.

In another non-limiting embodiment of any of the foregoing apparatus, the battery cells are positioned within an array, and the apparatus includes cables connected to battery cell terminals of the battery cells to connect the array to a gang wiring harness or a sensor module.

The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings (including any of their various aspects or respective individual features) may be employed independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

Drawings

Various features and advantages of the disclosed examples will become apparent to those skilled in the art from the detailed description. The drawings that accompany the detailed description can be briefly described as follows:

fig. 1A shows one battery cell placed next to another battery cell.

Fig. 1B is similar to fig. 1A, but shows a stack of battery cells placed adjacent to each other.

Fig. 2A schematically illustrates the use of ultrasonic welding to directly connect the overlapping cell tabs of fig. 1A to each other.

Fig. 2B schematically illustrates the use of ultrasonic welding to directly connect the overlapping cell tabs of fig. 1B to each other.

Fig. 3A shows the cell-to-cell connection after the cells have been laser welded and folded for the configuration of fig. 1A.

Fig. 3B shows the cell-to-cell connection after the cells have been laser welded and folded for the configuration of fig. 1B.

FIG. 4 is a flow diagram of an exemplary assembly method for the configuration of FIGS. 1A and 1B.

Fig. 5 schematically shows a folding process for the configuration of fig. 1B.

Fig. 6 is a final assembly configuration for the battery cell of fig. 5.

Detailed Description

The present disclosure details a method of connecting battery cells in a battery array of an electrically powered vehicle. Fig. 1A shows a plurality of battery cells 10, each having a first end 12 and an opposite second end 14. One or more battery cell tabs 16 are located at first end 12 and second end 14. Each battery cell 10 has a positive battery cell tab (+) and a negative battery cell tab (-) as shown in fig. 1A and 1B. For example, first cell 10a includes at least one first cell tab 16a at first end 12 and at least one second cell tab 16b at second end 14. First adjacent cell 10b includes a third cell tab 16c at second end 14 and second adjacent cell 10c includes a fourth cell tab 16d at first end 12.

A method of connecting a first adjacent battery cell 10b and a second adjacent battery cell 10c to a first battery cell 10a includes the following steps. The battery cells 10a, 10b, 10c are placed adjacent to each other such that the battery cell tabs 16a, 16b from a first battery cell 10a overlap with the corresponding battery cell tabs 16c, 16d from adjacent battery cells 10b, 10 c. Thus, first cell tab 16a at first end 12 of first cell 10a overlaps third cell tab 16c at second end 14 of first adjacent cell 10b, and second cell tab 16b at second end 14 of first cell 10a overlaps fourth cell tab 16d at first end 12 of second adjacent cell 10 c.

Fig. 1A shows an example in which battery cell 10 includes individual battery cells 10a, 10b, 10c that are placed adjacent to one another such that their respective battery cell tabs overlap. Fig. 1B shows another example, in which the battery cell 10 includes a plurality of first battery cells 10a stacked on top of each other to form a first battery cell stack S1; a plurality of second battery cells 10b stacked on top of each other to form a second battery cell stack S2; and a plurality of third battery cells 10c stacked on top of each other to form a third battery cell stack S3. The cell stacks S1, S2, S3 are placed adjacent to each other such that their respective cell tabs overlap each other before the cell tabs are engaged with each other.

Next, for each of the exemplary configurations of fig. 1A-1B, the overlapping cell tabs 16a/16c and 16B/16d are connected to each other by being directly welded to each other. The joining process may be accomplished using, for example, laser welding or ultrasonic welding, or by other joining techniques including, for example, adhesive, fastening, riveting, bolting, and the like. Fig. 2A to 2B show an example of ultrasonic welding. In one example, the back plate 18 supports the anvil 20 on a first side 22 of the overlapping cell tabs 16a, 16c and the ultrasonic generator 24 having the transducer 26 is positioned on an opposite second side 28 of the overlapping cell tabs 16a, 16 c. The power supply 30 converts low frequency electricity to high frequency electricity and the transducer 26 changes the high frequency electricity to high frequency sound. The ultrasonic generator 24 focuses ultrasonic vibrations at the overlapping cell tabs 16a, 16c held by the anvil 20 and welds the tabs 16a, 16c together.

Once all of the overlapping cell tabs 16 have been welded together for all of the cells 10, the cells 10 are placed in a final assembly position. In one example, battery cell 10 is folded at the junction area 32 of the overlapping tabs 16, as shown in fig. 3A-3B. Thus, the overlapping tabs 16 are provided with a weld interface 34 for each joining region 32. In the example shown in fig. 3A-3B, the overlapping tab 16 has a flat portion 36 in which the weld interface 34 is disposed, and the first cell tab 16a is folded at a first fold edge 38 at the first end 12 of the first cell 10. The third cell tab 16c is folded at the second folded edge 40 at the second end 14 of the first adjacent cell 10 b. This prevents folding at the location of the weld interface 34.

Fig. 4 shows a flowchart of an example assembly process for each of the example configurations of fig. 1A-1B. At step 50, the battery cells 10a, 10b, 10c are arranged adjacent to each other such that the battery cell tabs 16a, 16b from the first battery cell 10a overlap with the corresponding battery cell tabs 16c, 16d from the adjacent battery cells 10b, 10c, as described above. In this example, laser 52 is used to directly connect battery cell tabs 16 to each other. In one example, the first cell tab 16a comprises an aluminum material and the first adjacent cell 10 has a third cell tab 16c comprising a copper material. First cell tab 16a is placed over third cell tab 16c such that first cell tab 16a directly faces laser 52. Power supply 30 powers laser 52 to weld the overlapping tabs directly to each other. By placing the aluminum tab on top, the laser 52 uses less power, which may be advantageous; however, there are other factors that also affect the required welding power. The reverse configuration, with copper cell tabs on top, may also be used; however, such a configuration would require additional power.

At step 60, the overlapping tabs 16 are directly welded to one another in the desired electrical configuration such that there is a weld interface 34 at each of the joining regions 32. At step 70, the battery cells 10 are then folded in an alternating manner into a final folded assembly position. Fig. 5 and 6 illustrate folding processes for the first cell stack S1, the second cell stack S2, and the third cell stack S3. One weld interface 34 is used to connect tabs of the first cell stack S1 to the second cell stack S2, and one weld interface 34 is used to connect tabs of the first cell stack S1 to the third cell stack S3.

At step 80, the voltage sensing circuit is mounted directly to the battery cell tab 16. In one example, the voltage sensing circuit includes a flexible Printed Circuit Board (PCB)82 as shown; however, other types of voltage sensing circuits may also be used. As is known, the flexible PCB 82 is used to sense/monitor characteristics of the battery cell. The folded battery cell 10 is then installed into the array 84, as shown at step 90. The array 84 includes a housing or casing 92 that protects the battery cells 10.

In one example, a Flat Flex Cable (FFC)94 is connected to the flexible PCB 82 to connect the array 84 to additional electrical components 96, such as, for example, a wiring harness or a sensor module. The step of directly connecting flexible PCB 82 to battery cell tab 16 may be accomplished by using ultrasonic welding or conductive rivets, as shown at 98 in fig. 4.

Current array configurations utilize separate ICB assemblies to facilitate cell-to-cell attachment using copper bus bars. By directly engaging the cell tabs to one another, significant metal cost savings and weight savings are achieved by eliminating an ICB assembly made of plastic and copper bus bars. The present disclosure further reduces weight by completely removing the bus bar material, and supporting the bus bar in the correct position for the structure required for tab attachment. The cost savings are also significant since the amount of copper and plastic used for ICB is completely eliminated.

Additional benefits include the following. The array and bank energy densities increase. Furthermore, the array is easier to manufacture. As the weld thickness decreases, direct tab to tab welding is more effective. The tabs are also more prone to pressing directly onto each other, which reduces porosity and reduces other welding problems. The manufacturing process is also more open to automation because it is no longer necessary to thread the cell tabs through the ICB prior to welding. It is also easier to meet creepage and clearance requirements because there are fewer parts to package and the connection is more reliable because there are fewer parts and connection interfaces.

Although particular component relationships are shown in the drawings of the present disclosure, the illustrations are not intended to limit the disclosure. In other words, the placement and orientation of the various components shown may vary within the scope of the present disclosure. Furthermore, the various drawings that accompany the present disclosure are not necessarily drawn to scale, and some features may be exaggerated or minimized to show certain details of particular components.

The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. Accordingly, the scope of legal protection given to this disclosure can only be determined by studying the following claims.

According to the present invention, a method includes (a) placing battery cells adjacent to each other such that at least one battery cell tab from one battery cell overlaps with at least one battery cell tab from an adjacent battery cell; (b) directly joining the overlapping battery cell tabs to each other; (c) placing the battery cell in a final assembled position; and (d) mounting a voltage sensing circuit directly to the battery cell tab.

In one aspect of the present invention, step (c) includes folding the battery cell.

In one aspect of the invention, the one battery cell has a first battery cell tab comprising an aluminum material and the adjacent battery cell has a second battery cell tab comprising a copper material, and the method includes placing the first battery cell tab over the second battery cell tab such that the first battery cell tab directly faces a laser welding tool.

In one aspect of the invention, step (b) comprises one of the following joining methods: ultrasonic welding, laser welding, fastening, riveting or adhering.

In one aspect of the invention, the battery cells include at least one first battery cell and at least one second battery cell, and the method includes placing the at least one second battery cell proximate to the at least one first battery cell such that the cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another.

In one aspect of the invention, the at least one first cell unit comprises a plurality of first cell units stacked on top of each other to form a first cell stack, and wherein the at least one second cell unit comprises a plurality of second cell units stacked on top of each other to form a second cell stack, and the method comprises placing the second cell stack next to the first cell stack such that the cell tabs of the first and second cell stacks overlap each other.

In one aspect of the invention, the method includes (e) installing the battery cells into an array, and (f) connecting cables to battery cell terminals of the battery cells to connect the array to a gang wiring harness or sensor module.

In one aspect of the invention, step (d) comprises connecting the voltage sensing circuitry directly to the battery cell tab using ultrasonic welding.

In one aspect of the invention, step (d) comprises connecting the voltage sensing circuit directly to the battery cell tab using a conductive rivet.

According to the present invention, a method includes (a) placing battery cells adjacent to each other such that at least one battery cell tab from one battery cell overlaps with at least one battery cell tab from an adjacent battery cell; (b) directly joining the overlapping battery cell tabs to each other; (c) folding the battery cell in a final assembled position; and (d) mounting a voltage sensing circuit directly to the battery cell tab.

In one aspect of the present invention, step (b) comprises laser welding, ultrasonic welding, fastening, riveting or adhering the battery cell tabs to each other.

In one aspect of the invention, the battery cells include at least one first battery cell and at least one second battery cell, and the method includes placing the at least one second battery cell proximate to the at least one first battery cell such that the cell tabs of the at least one first battery cell and the at least one second battery cell overlap one another.

In one aspect of the invention, the at least one first cell unit comprises a plurality of first cell units stacked on top of each other to form a first cell stack, and wherein the at least one second cell unit comprises a plurality of second cell units stacked on top of each other to form a second cell stack, and the method comprises placing the second cell stack next to the first cell stack such that the cell tabs of the first and second cell stacks overlap each other.

In one aspect of the invention, the method includes (e) installing the battery cells into an array, and (f) connecting cables to battery cell terminals of the battery cells to connect the array to a gang wiring harness or sensor module.

In one aspect of the invention, step (d) comprises connecting the voltage sensing circuitry directly to the battery cell tab using ultrasonic welding.

In one aspect of the invention, step (d) comprises connecting the voltage sensing circuit directly to the battery cell tab using a conductive rivet.

According to the present invention, there is provided an apparatus having a plurality of battery cells positioned adjacent to one another such that battery cell tabs from one battery cell overlap battery cell tabs from an adjacent battery cell to form a set of overlapping battery cell tabs, and wherein each set of overlapping battery cell tabs directly engage one another at a connection interface; and a voltage sensing circuit directly attached to the battery cell tab.

According to one embodiment, the battery cells comprise at least one first battery cell and at least one second battery cell, and wherein the at least one second battery cell is placed in close proximity to the at least one first battery cell such that the battery cell tabs of the at least one first battery cell and the at least one second battery cell overlap each other before engaging the battery cell tabs with each other.

According to one embodiment, the at least one first battery cell comprises a plurality of first battery cells stacked on top of each other to form a first battery cell stack, and wherein the at least one second battery cell comprises a plurality of second battery cells stacked on top of each other to form a second battery cell stack, and wherein the second battery cell stack is placed next to the first battery cell stack such that the battery cell tabs of the first and second battery cell stacks overlap each other before engaging the battery cell tabs with each other.

According to one embodiment, the battery cells are positioned within an array, and the apparatus includes cables connected to battery cell terminals of the battery cells to connect the array to a group wiring harness or sensor module.