CN107278337B - 具有引导延伸部系统的蓄电池模块汇流条载体及方法 - Google Patents
具有引导延伸部系统的蓄电池模块汇流条载体及方法 Download PDFInfo
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- CN107278337B CN107278337B CN201680003917.4A CN201680003917A CN107278337B CN 107278337 B CN107278337 B CN 107278337B CN 201680003917 A CN201680003917 A CN 201680003917A CN 107278337 B CN107278337 B CN 107278337B
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Abstract
本公开包括一种蓄电池模块,所述蓄电池模块具有电化学电池的电池组、外壳和汇流条载体,其中,所述电化学电池的所述电池组包括端子,所述外壳接纳所述电化学电池的所述电池组,所述汇流条载体设置于所述电化学电池的所述电池组上方,使得设置于所述汇流条载体上的汇流条与所述电化学电池的所述电池组的所述端子介接。所述汇流条载体包括相对的第一引导延伸部和第二引导延伸部,所述电化学电池的所述电池组设置于所述相对的第一引导延伸部和第二引导延伸部之间,并且所述相对的第一引导延伸部和第二引导延伸部分别物理地接触所述电化学电池的所述电池组的第一外侧电化学电池和第二外侧电化学电池,以将所述电化学电池的所述电池组的所述端子引导朝向设置于所述汇流条载体上的对应的所述汇流条。
Description
相关申请的交叉引用
本申请要求于2015年1月5日提交的标题为“具有竖直和水平配置的锂离子蓄电池模块的机械和电气方面(MECHANICAL AND ELECTRICAL ASPECTS OF LITHIUM ION BATTERYMODULE WITH VERTICAL AND HORIZONTAL CONFIGURATIONS)”的申请序列号为62/100,001的美国临时申请以及于2015年2月27日提交的标题为“具有引导延伸部系统的蓄电池模块汇流条载体及方法(BATTERY MODULE BUS BAR CARRIER HAVING GUIDE EXTENSIONSSYSTEM AND METHOD)”的申请序列号为14/634,516的美国临时申请的优先权和权益,这两个申请出于所有目的据此以引用方式并入。
背景技术
本公开整体涉及蓄电池和蓄电池模块领域。更具体地,本公开涉及蓄电池模块载体(例如,汇流条载体)。
本章节旨在向读者介绍可能涉及本公开的各个方面的本领域的各个方面,这些方面在下文中进行描述。该论述据信有助于向读者提供背景信息,以有利于更好地理解本公开的各个方面。因此,应当理解,这些陈述从这个角度来解读,而不应视为对现有技术的承认。
使用一个或多个蓄电池系统以用于为车辆提供所有或部分原动力的车辆可称为xEV,其中术语“xEV”在本文中定义为包括所有下述车辆或其任何变型或组合:这类车辆将电力用作其所有或部分的车辆原动力。例如,xEV包括将电力用于所有原动力的电动车辆(EV)。如本领域的技术人员将理解的,同样视为xEV的混合动力电动车辆(HEV)将内燃机推进系统和蓄电池供电的电动推进系统(诸如48伏特(V)或130V系统)相组合。术语HEV可包括混合动力电动车辆的任何变型。例如,全混合动力系统(FHEV)可利用一个或多个电动机,仅利用内燃机或利用两者将原动力和其它电力提供至车辆。相比之下,轻度混合动力系统(MHEV)当车辆怠速运转时停用内燃机并利用蓄电池系统来继续对空调单元、收音机或其它电子装置供能,并当需要推进时重新启动发动机。轻度混合动力系统还可施加一定程度的动力辅助,例如在加速期间,以对内燃机作出补充。轻度混合动力通常为96V至130V,并且通过皮带或曲柄集成式起动发电机回收制动能量。另外,微混合动力电动车辆(mHEV)也使用类似于轻度混合动力的“启-停”系统,但是mHEV的微混合动力系统可向内燃机提供或不提供助动力辅助,并且以低于60V的电压操作。出于当前讨论的目的,应当指出的是,mHEV通常在技术上不将直接提供至曲柄或传动装置的电力用于车辆的任何部分的原动力,但是mHEV仍可视为xEV,因为其在车辆怠速运转(此时内燃机停用)时的确使用电力来对车辆的动力需求作出补充并通过集成式起动发电机回收制动能量。此外,插电式电动车辆(PEV)为可从外部电源(诸如墙壁插座)进行充电的任何车辆,并且存储于可充电电池组中的能量可驱动或有助于驱动车轮。PEV为EV的子类,其包括所有电动或蓄电池电动车辆(BEV)、插电式混合动力电动车辆(PHEV),以及混合动力电动车辆和传统内燃机车辆的电动车辆改型。
相对于仅使用内燃机和传统电动系统的更传统的气动车辆而言,上述xEV可提供若干优势,其中所述传统电动系统通常是由铅酸蓄电池提供动力的12V系统。例如,相比传统内燃机车辆,xEV可以产生较少的不期望的排放产物并且可以呈现出较高的燃料效率,并且在一些情况下,此类xEV可以完全省去汽油的使用,如同某些类型的EV或PEV一样。
随着技术的持续演进,需要为此类车辆提供改进的动力源,尤其是蓄电池模块。例如,在传统配置中,蓄电池模块可包括电化学电池,所述电化学电池经由单独汇流条彼此电连通地联接,所述单独汇流条设置于电化学电池的相邻端子之上或上方。传统配置中的汇流条可单独联接至相邻端子,从而降低传统蓄电池模块的制造效率和精度。另外,传统蓄电池模块可包括具有某些特征(例如,端子)的电化学电池,这些特征由于工程公差未恰当地对准,从而使用于联接相邻端子的汇流条的对准变得复杂。因此,存在对电化学电池、其对应端子和联接其对应端子的汇流条的对准和联接进行改善的需求。
发明内容
本文所公开的某些实施例的概述在下文中予以阐述。应当理解,这些方面仅用于向读者提供某些实施例的简要概述,并且这些方面不旨在限制本公开的范围。实际上,本公开可涵盖下文可能未阐述的各个方面。
本公开涉及一种蓄电池模块,所述蓄电池模块具有电化学电池的电池组、外壳和汇流条载体,其中,所述电化学电池的电池组包括端子,所述外壳接纳电化学电池的电池组,所述汇流条载体设置于电化学电池的电池组上,以使得设置于汇流条载体上的汇流条与电化学电池的电池组的端子介接。汇流条载体包括相对的第一引导延伸部和第二引导延伸部,所述电化学电池的电池组设置于相对的第一引导延伸部和第二引导延伸部之间,并且相对的第一引导延伸部和第二引导延伸部分别物理地接触电化学电池的电池组的第一外侧电化学电池和第二外侧电化学电池,以将电化学电池的电池组的端子引导朝向设置于汇流条载体上的对应汇流条。
本公开还涉及一种具有电化学电池的蓄电池模块,所述电化学电池以电池组方式设置,使得端子延伸自邻近电池组的端部的电化学电池。蓄电池模块还包括汇流条和汇流条载体,所述汇流条配置成与端子介接,所述汇流条载体设置成相邻于电池组的端部并且具有设置于其上的汇流条。汇流条载体包括第一引导延伸部,所述第一引导延伸部物理地接触设置于电池组的第一侧上的第一电化学电池,汇流条载体包括第二引导延伸部,所述第二引导延伸部物理地接触第二电化学电池,该第二电化学电池设置于电池组的与第一侧相对的第二侧上,并且第一引导延伸部和第二引导延伸部将电池组的电化学电池压缩在一起,使得电化学电池的端子与对应的汇流条对准。
本公开还涉及一种制造蓄电池模块的方法。所述方法包括将电化学电池设置在电池组中,使得电化学电池的端子沿着电池组的端子侧至少部分地对准。所述方法还包括将汇流条载体设置于电池组的端子侧上,使得设置于汇流条载体上的汇流条电联接于电化学电池的端子,其中将汇流条载体设置于电池组的端子侧上包括沿着电化学电池的电池组的外侧电化学电池的横向面引导汇流条载体的相对的引导延伸部,使得引导延伸部物理地接触横向面以致使电化学电池的端子与对应的汇流条对准。
附图说明
本公开的各个方面在阅读下述具体实施方式以及在参考附图时可更好地理解,其中:
图1为具有根据这些实施例配置成为车辆的各种部件提供动力的蓄电池系统的车辆的立体图;
图2为图1中的车辆和蓄电池系统的实施例的剖面示意图;
图3为根据本公开的一个方面的图2中的车辆中使用的蓄电池模块的实施例的分解立体图;
图4为根据本公开的一个方面的图3中的蓄电池模块的实施例的一部分的分解立体图;
图5为根据本公开的一个方面的图3中的蓄电池模块的实施例的一部分的立体图;
图6为根据本公开的一个方面的图4中的汇流条载体和汇流条的实施例的底部立体图;
图7为根据本公开的一个方面的图4中的汇流条载体和汇流条的实施例的侧视图;
图8为根据本公开的一个方面的沿着图7中的剖切线8-8截取的图7中的汇流条载体的引导延伸部的实施例的放大图;
图9为根据本公开的一个方面的图4中的汇流条载体的引导延伸部的实施例的放大图;
图10为根据本公开的一个方面的图4中的汇流条载体的引导延伸部的实施例的放大图;
图11为图4中的汇流条载体的引导延伸部的实施例的放大图;以及
图12为根据本公开的一个方面的制造图2中的车辆中使用的蓄电池模块的方法的实施例的工艺流程图。
具体实施方式
下文将描述一个或多个具体实施例。为简要描述这些实施例,本说明书中并未描述实际实施方式的所有特征。应认识到,在开发任何此类实际实施方式时,如同在进行任何工程或设计项目一样,必须做出众多特定于具体实施方式的决定,以实现开发人员的具体目标,例如是否符合系统相关和业务相关约束,这些约束可能会随着实施方式的不同而有所不同。此外,应认识到,此类开发工作可能较为复杂并且耗时,但是尽管如此,这也应当是受益于本公开的普通技术人员在设计、生产和制造中的常规任务。
本文所描述的蓄电池系统可用于为各种类型的电动车辆(xEV)和其它高电压储能器/消耗应用(例如,电网储能系统)提供电力。此类蓄电池系统可包括一个或多个蓄电池模块,每个蓄电池模块均具有多个蓄电池单元(例如,锂离子(Li离子)电化学电池),所述多个蓄电池单元被布置和电互连以提供可用于为例如xEV的一个或多个部件提供动力的特定电压和/或电流。作为另一个实例,根据本实施例的蓄电池模块可纳入有固定动力系统(例如,非机动车系统)或为所述固定动力系统提供动力。
根据本公开的实施例,蓄电池模块可包括外壳和汇流条载体,所述外壳配置成通过外壳的开放侧接纳电化学电池,所述汇流条载体设置于外壳的开放侧中并且具有设置于汇流条载体上的汇流条,这些汇流条与电化学电池介接以电联接于电化学电池的相邻端子。另外,汇流条载体可包括例如从汇流条载体的周界延伸出的翼部或引导延伸部。引导延伸部配置成有利于将汇流条载体简单定位于外壳的开放侧中和电化学电池上方。例如,引导延伸部在电化学电池的电池组的相对两侧上施加力,以将电化学电池引导至适当位置,使得电化学电池的端子与设置于汇流条载体上的汇流条恰当地对准。
为便于说明,图1为车辆10的实施例的立体图,车辆10可利用再生制动系统。虽然下述讨论涉及具有再生制动系统的车辆,但是本文所描述的技术可适用于用蓄电池捕获/存储电能的其它车辆,所述其它车辆可包括电动车辆和气动车辆。
如上文所讨论的,将期望的是,蓄电池系统12在很大程度上与传统车辆设计兼容。因此,蓄电池系统12可放置于车辆10本应容纳传统蓄电池系统的位置。例如,如所示的,车辆10可包括蓄电池系统12,蓄电池系统12类似于典型内燃机车辆的铅酸蓄电池进行定位(例如,在车辆10的发动机盖之下)。此外,如下文将更详细描述的,蓄电池系统12可定位成有利于管理蓄电池系统12的温度。例如,在一些实施例中,将蓄电池系统12定位于车辆10的发动机盖之下可允许空气导管在蓄电池系统12上方引导空气流并且冷却蓄电池系统12。
蓄电池系统12的更详细视图示出于图2中。如所示的,蓄电池系统12包括储能器部件13,储能器部件13联接至点火系统14、交流发电机15、车辆控制台16,并且可选地联接至电动机17。一般来讲,储能器部件13可捕获/存储车辆10中所生成的电能,并且输出电能以为车辆10中的电气装置供能。
换句话讲,蓄电池系统12可将功率供应至车辆电气系统的部件,这些部件可包括散热器冷却风扇、气候控制系统、电动助力转向系统、主动悬架系统、自动泊车系统、电动油泵、电动超级/涡轮增压器、电动水泵、加热挡风玻璃/除霜器、车窗升降电机、梳妆灯、胎压监测系统、天窗电机控制器、电动座椅、警示系统、信息娱乐系统、导航特征、车道偏离报警系统、电动驻车制动器、外部灯,或其任何组合。示例性地,在所示实施例中,储能器部件13将功率供应至车辆控制台16和点火系统14,点火系统14可用于起动(例如,曲柄起动)内燃机18。
另外,储能器部件13可捕获由交流发电机15和/或电动机17所生成的电能。在一些实施例中,当内燃机18运行时,交流发电机15可生成电能。更具体地,交流发电机15可将内燃机18的旋转所产生的机械能转换成电能。另外或另选地,当车辆10包括电动机17时,电动机17可通过将车辆10的移动(例如,车轮的旋转)所产生的机械能转换成电能而生成电能。因此,在一些实施例中,储能器部件13可捕获由交流发电机15和/或电动机17在再生制动期间所生成的电能。因此,交流发电机15和/或电动机17在本文中统称为再生制动系统。
为有利于捕获和供应电能,储能器部件13可经由总线19电联接至车辆的电力系统。例如,总线19可允许储能器部件13接收由交流发电机15和/或电动机17所生成的电能。另外,总线19可允许储能器部件13将电能输出至点火系统14和/或车辆控制台16。因此,当使用12伏特蓄电池系统12时,总线19可承载通常在8伏特至18伏特之间的电力。
另外,如所示的,储能器部件13可包括多个蓄电池模块。例如,在所示的实施例中,储能器部件13包括锂离子(例如,第一)蓄电池模块20和铅酸(例如,第二)蓄电池模块22,其各自包括一个或多个蓄电池单元。在其它实施例中,储能器部件13可包括任何数量的蓄电池模块。另外,虽然锂离子蓄电池模块20和铅酸蓄电池模块22示出为彼此邻近,但是它们可定位于车辆周围的不同区域。例如,铅酸蓄电池模块22可位于车辆10的内部或其附近,而锂离子蓄电池模块20可位于车辆10的发动机盖之下。
在一些实施例中,储能器部件13可包括多个蓄电池模块以利用多种不同的蓄电池化学性质。例如,当使用锂离子蓄电池模块20时,蓄电池系统12的性能可改善,因为锂离子蓄电池化学性质相比于铅酸蓄电池化学性质一般具有较高的库仑效率和/或较高的功率充注接收速率(例如,较高的最大充电电流或充电电压)。因此,蓄电池系统12的捕获、存储和/或分配效率可改善。
为便于控制电能的捕获和存储,蓄电池系统12可额外包括控制模块24。更具体地,控制模块24可控制蓄电池系统12中的部件的操作,诸如储能器部件13、交流发电机15和/或电动机17内的继电器(例如,开关)。例如,控制模块24可调控由每个蓄电池模块20或22所捕获/供应的电能的量(例如,以对蓄电池系统12降低额定值和重新确定额定值),执行蓄电池模块20和22之间的负载平衡,确定每个蓄电池模块20或22的充电状态,确定每个蓄电池模块20或22的温度,控制由交流发电机15和/或电动机17所输出的电压等等。
因此,控制单元24可包括一个或多个处理器26和一个或多个存储器28。更具体地,一个或多个处理器26可包括一个或多个专用集成电路(ASIC)、一个或多个现场可编程门阵列(FPGA)、一个或多个通用处理器,或其任何组合。另外,一个或多个存储器28可包括易失性存储器,诸如随机存取存储器(RAM),和/或非易失性存储器,诸如只读存储器(ROM)、光驱、硬盘驱动器或固态驱动器。在一些实施例中,控制单元24可包括车辆控制单元(VCU)的一些部分和/或独立蓄电池控制模块。
图2中的车辆10中使用的蓄电池模块20的实施例的分解立体图示出于图3中。在所示实施例中,蓄电池模块20包括外壳30(例如,塑料外壳),外壳30具有配置成接纳蓄电池模块20的电化学电池32的开放侧31。一个或多个盖可设置于外壳30的开放侧31中和/或之上以与电化学电池32介接,以密封外壳30的开放侧31,或既与电化学电池32介接又密封外壳30的开放侧31。例如,在所示实施例中,汇流条载体34配置成接合住外壳30的开放侧31并保持多个汇流条36(和,在一些实施例中,与汇流条36介接并从汇流条36延伸出的传感器37和引线39),多个汇流条36与电化学电池32的端子38介接。另外,在将汇流条载体34设置于开放侧31中之后,独立盖40可设置于外壳30的开放侧31上以密封开放侧31。然而,在一些实施例中,汇流条载体34和盖40可为一个集成部件。
如所述实施例中所示的,电化学电池32可以电池组42的方式定位于外壳30内。例如,电化学电池32可为具有横向面44的棱柱形锂离子(Li离子)电化学电池32,棱柱锂离子电化学电池32彼此抵靠地叠加以形成电化学电池32的一个电池组42。蓄电池模块20的所示外壳30配置成容纳各自具有三个电化学电池32的两个电池组42,其中所述电池组42在外壳30中彼此相邻地定位以使得相邻的电化学电池32(例如,跨过两个电池组42)的横向面44大体设置于相同平面中。然而,应当指出的是,每个电池组42可包括多于或少于三个的电化学电池32(例如,2个、3个、4个、5个、6个、7个、8个或更多个电化学电池32/电池组42),并且电化学电池32和对应电池组42可在外壳30中以其它方式取向,使得电化学电池32的端子38均从每个电池组42的端子侧46延伸出,其中每个电池组42的端子侧46均包括电化学电池32的端子端48(具有端子38)。换句话讲,电化学电池32总体设置于外壳30中,使得电化学电池32的端子38均在大体相同的方向50上延伸并且从大体等同的平面(例如,每个电池组42的端子侧46)延伸出,以便可通过汇流条载体34予以访问。
在一些实施例中,汇流条36设置于汇流条载体34上和/或固定至汇流条载体34。例如,汇流条36可卡扣至汇流条载体34的某些区域中。因此,当汇流条载体34设置于外壳30的开放侧31中并且设置于电化学电池32的电池组42的端子侧46上方时,固定至汇流条载体34的某些区域的汇流条36可与电化学电池32的端子38介接以串联、并联地电联接电化学电池32,或串联地电联接某些电化学电池32并且并联地电联接某些电化学电池32。然而,由于制造的不一致性、工程公差和其它因素,电化学电池32的端子38可不在期望位置延伸以与电化学电池32的适当的端子38介接。例如,某些端子38可不在方向50、方向52、方向55或其组合上对准。
为促进汇流条36和适当的端子38之间的适当介接,汇流条载体34可包括引导延伸部54,引导延伸部54从汇流条载体34(例如,从或邻近于汇流条载体34的周界56)向下(例如,与方向50相反)朝向电化学电池32延伸,以将汇流条载体34和电化学电池32引导至适当位置,以用于使设置于汇流条载体34上的汇流条36与电化学电池32的端子38介接。例如,引导延伸部54可配置成配合在外壳30的内表面58和每个电池组42的两个最外侧电化学电池32的横向面44之间。另外,引导延伸部54可配置成物理地接触每个电池组42的两个最外侧电化学电池32的横向面44以将电化学电池32压缩在一起,以相对于设置在汇流条载体34上的汇流条36的位置引导端子38的位置,或实现上述两者的组合。应当指出的是,分隔物或隔板60可包括在各电池组电化学电池32的横向面44之间,以使电化学电池32的本体电绝缘,以有助于使不打算被电联接的某些端子38电绝缘,或实现上述两者的组合。引导延伸部54在此类实施例中则可将电化学电池32和分隔物60压缩在一起,其中每个电池组42均包括电化学电池32和分隔物60两者。
现转向图4和图5,其分别示出了图3中的蓄电池模块20的实施例的一部分的分解立体图和立体图。在所示实施例中,汇流条载体34设置于电化学电池32上方(例如,设置于电化学电池32的电池组42的端子侧46上方,所述端子侧46具有电化学电池32的端子端48)。如图4所示,电化学电池32可包括某些端子38,这些端子38从电化学电池32的端子端48向上延伸到汇流条载体34的周界56之外。因此,某些汇流条36可设置于汇流条载体34上,使得汇流条36延伸到汇流条载体34的周界56之外以与对应的端子38介接。另外,应当指出的是,汇流条36可包括开口70(如图4所示)以接纳电化学电池32的端子38;或汇流条36可为如图5所示的平板(例如,不具有开口),使得端子38接触平板汇流条36并且例如焊接至平板汇流条36。在两个实施例中,汇流条载体34包括卡扣特征73,该卡扣特征73配置成接纳汇流条36。卡扣特征73可将汇流条36永久地保持于汇流条载体34上,或卡扣特征73可将汇流条36暂时地保持于汇流条载体34上,直至汇流条36经由其它手段(例如,粘合剂、紧固件、焊接)固定至汇流条载体34或直至汇流条36经由其它手段(例如,焊接)固定至例如端子38。在一些实施例中,汇流条36可嵌入汇流条载体34中或与汇流条载体34一起包覆模制。
如两个实施例中所示的,引导延伸部54可向下(例如,与方向50相反)延伸,并且可在每个电池组42的两个最外侧电化学电池32的横向面44部分上方延伸。因此,电化学电池32的每个电池组42设置在两个相对的引导延伸部54之间,所述两个相对的引导延伸部54将电化学电池32的电池组42压缩在一起和/或将电化学电池32引导至适当位置,使得端子38接触适当的汇流条36和/或适当的汇流条36的适当区域。例如,在汇流条36包括开口70的情况下,引导延伸部54可将端子38引导至汇流条36的开口70中。在图4和图5所示的实施例中,引导延伸部54各自包括长度74和高度76。另外,每个电化学电池32均包括长度78和高度80。引导延伸部54的长度74可至少为每个电化学电池32的长度78的约一半(50%)、三分之二(67%)、四分之三(75%)、五分之四(80%)或更大(其中,每个电化学电池32的长度78在方向55上沿着电化学电池32的横截面进行测量,或在方向55上沿着电化学电池32的端子端48进行测量)。每个引导延伸部54的高度76可至少为每个电化学电池32的高度80的约三分之一(33%)、四分之一(25%)、五分之一(20)、十分之一(10%)或更小(例如,其中每个电化学电池32的高度80在方向50上沿着电化学电池32的横截面进行测量或从电化学电池32的端子端48至电化学电池32的与端子端48相反的底部端82进行测量)。引导延伸部54的尺寸可设定成适应对抗对应电池组42的电化学电池32的期望力(例如,以确保端子38相对于设置于汇流条载体34上的汇流条36的适当定位),适应汇流条载体34和对应引导延伸部54的结构刚度,减小汇流条载体34的材料总量,或实现上述三者的组合。
具有汇流条36的汇流条载体34的实施例的底部立体图示出于图6中。如先前所描述的,汇流条36可设置于(例如,固定至)汇流条载体34上。某些汇流条36可延伸到汇流条载体34的周界56之外,以与蓄电池模块20的部件(例如,电化学电池32的端子38)介接。其它汇流条36可配置成通过汇流条载体34中的暴露部89(例如,开口)与蓄电池模块20的部件(例如,电化学电池32的端子38)介接。实际上,在一些实施例中,所有汇流条36可包含在汇流条载体34的周界56内,使得所有汇流条36通过汇流条载体34中的暴露部或开口89接触蓄电池模块20的一个或多个部件(例如,电化学电池32的端子38)。另外,汇流条36包括开口70,但是在其它实施例中,汇流条36可为平板。
引导延伸部54从汇流条载体34的周界56延伸或从周界56附近延伸。应当指出的是,周界56一般可指汇流条载体34的一个或多个外壁。因此,引导延伸部54可从汇流条载体34的周界56延伸(例如,从汇流条载体34的外壁延伸),即使引导延伸部54可能与形成周界56的外壁的外表面90不齐平。
现转向图7,其示出了其上设置有汇流条36的汇流条载体34的实施例的侧视图。在所示实施例中,汇流条载体34包括顶表面100,所述顶表面100接纳或保持汇流条36。汇流条载体34还包括与顶表面100相反的底表面102,其中底表面102面向例如图3至图6中所示的电化学电池32。汇流条载体34的厚度104延伸于底表面102和顶表面100之间。在某些实施例中,厚度104可包括暴露部或开口,如先前所描述的,所述暴露部或开口允许将汇流条36联接于顶表面100上,以访问图3至图6中所示的电化学电池32的端子38。在某些实施例中,一些或所有汇流条36可设置于底表面102上。另外,如先前所描述的,汇流条载体34还包括周界56,引导延伸部54从周界56延伸。周界56可由汇流条载体34的一个或多个外壁限定。例如,汇流条载体34的唇部106可从汇流条载体34的底表面102向下(例如,与方向50相反)延伸,其中唇部106限定周界56的至少一部分。在一些实施例中,引导延伸部54可从唇部106延伸。另外或另选地,引导延伸部54可从汇流条载体34的底表面102和唇部106的内侧延伸。
沿着图7中的剖切线8-8截取的汇流条载体34的其中一个引导延伸部54的实施例的放大图示出于图8中。在所示实施例中,引导延伸部54包括内表面110(例如,配置成接触图3至图6中所示的其中一个最外侧电化学电池32)和与内表面110相对的外表面112。在所示的实施例中,内表面54向下延伸,与方向50大体平行。外表面112以角度114相对于方向50成角度。一般来讲,外表面112成角度,使得外表面112从引导延伸部54的基部116(例如,在引导延伸部54和汇流条载体34之间的连接点处)至引导延伸部54的末端118(例如,从引导延伸部54的近端至远端)朝向内表面110削锥。因此,引导延伸部54的厚度120从基部116至末端118减小。引导延伸部54的基部116处的较大厚度120使得引导延伸部54的结构刚度增大。因此,随着将电化学电池32压入到引导延伸部54中(例如,在将汇流条载体34定位于图3至图6中的电化学电池32上方期间和/或在这之后),较厚的基部116可阻止引导延伸部54弯曲和/或受不利影响。
然而,应当指出的是,引导延伸部54的内表面110和外表面112可在其它实施例中以其它方式取向。例如,内表面110可向外成角度,如图9所示,使得相对的引导延伸部54之间的开口在相对的引导延伸部54的末端118附近比在相对的引导延伸部54的基部116附近更大,从而有利于将电化学电池32接纳于开口内,使得电化学电池32在相对的引导延伸部的末端118和基部116之间的一些点处接触相对的引导延伸部54。
在一些实施例中,内表面110可向内成角度(例如,与外表面112背离),如图10所示,使得相对的引导延伸部54之间的开口在相对的引导延伸部54的基部116附近比在相对的引导延伸部54的末端118附近更大。在此类实施例中,汇流条载体34可倾斜或以其它方式操纵以有利于将电化学电池32接纳于相对的引导延伸部54的末端118之间。另外,在此类实施例中,引导延伸部54可向外弯曲以有利于将电化学电池32接纳于相对的引导延伸部54的末端118之间。因此,在将电化学电池32定位于相对的引导延伸部54之间之后,相对的引导延伸部54可在相对的引导延伸部54的末端118处对着电化学电池32施加力。
在其它实施例中,外表面112可向下延伸(例如,与方向50大体平行),使得角度114为约0度。例如,图11示出了具有与方向50大体平行延伸的外表面112的汇流条载体34的实施例。在所示实施例中,外表面112与方向50平行延伸,并且内表面110从基部116至末端118朝向外表面112成角度,使得引导延伸部54的基部116包括比末端118更大的厚度120。因此,汇流条载体34在末端118附近具有比基部116附近更大的开口,从而有利于将汇流条载体34定位于电化学电池32之上并且增强引导延伸部54和引导延伸部54在基部116附近与汇流条载体34的连接点的结构整体性。
制造蓄电池模块20的方法130的实施例的工艺流程图示出于图12中。在所示实施例中,方法130包括将电化学电池32设置成一个或多个电池组42,使得电化学电池32的端子38沿着电池组42的端子侧46至少部分地对准(框132)。例如,如先前所描述的,电化学电池32可横向面44抵着横向面44地叠加以形成一个电池组42。在一些实施例中,这包括将隔板60放置于横向面44之间。
方法130还包括将汇流条载体34设置于电化学电池32的电池组42的端子侧46上方,使得设置于汇流条载体34上的汇流条36与电化学电池32的端子38介接(框134)。例如,汇流条36可设置于汇流条载体34的与底表面102相反的顶表面100上,其中底表面102面向电化学电池32的电池组42的端子侧46。汇流条36可通过暴露部89(例如,开口)与电化学电池32的端子38介接,暴露部89从汇流条载体的底表面102延伸至汇流条载体的顶表面100。另外或另选地,某些汇流条36可与汇流条载体34的周界56之外的某些端子38介接。
另外,方法130还包括经由汇流条载体34的引导延伸部54将端子38引导朝向适当的汇流条36,汇流条载体34接触电池组42的最外侧电化学电池32的横向面44(框136)。
应当指出的是,在上文所描述的所有实施例中,汇流条36可经由焊点联接至电化学电池32的端子38。出于这个和其它原因,引导延伸部54可仅引导电化学电池32及其相关端子38的定位,直至端子38联接至适当汇流条36中的适当区域。引导延伸部54在将端子38联接至汇流条36之后可持续物理地接触电化学电池32(例如,电化学电池32的横向面44),或引导延伸部54在将端子38联接至汇流条36之后可不持续物理地接触电化学电池32(例如,电化学电池32的横向面44)。另外,引导延伸部54可根据蓄电池模块20的操作条件暂时地接触电化学电池32。例如,在操作期间,电化学电池32可朝向引导延伸部54热膨胀,从而致使引导延伸部54物理地接触电化学电池32。因此,应当理解,根据本公开的“物理接触”可指两个或更多个实体或部件之间的暂时关系、短暂关系或永久关系。
所公开实施例中的一个或多个(单独或组合)可提供可用于制造蓄电池模块和蓄电池模块的一些部分的一个或多个技术效果。一般来讲,本公开的实施例包括蓄电池模块和汇流条载体,所述蓄电池模块具有设置于外壳内的电化学电池,所述汇流条载体设置于电化学电池上方。汇流条载体包括设置于其上的汇流条,所述汇流条与电化学电池的端子介接。另外,汇流条载体包括引导延伸部,所述引导延伸部从汇流条载体朝向电化学电池延伸,并且配置成将电化学电池及其对应端子的位置引导朝向适当汇流条的适当区域。引导延伸部的尺寸可设定成和/或成形为适应抵抗电化学电池的特定量的力,以允许电化学电池及其对应端子相对于设置于汇流条载体上的汇流条的前述定位,所述汇流条载体具有引导延伸部。通过以压缩和结构上更理想的关系将电化学电池保持在一起,引导延伸部也可使相关蓄电池模块更坚固。本说明书中的技术效果和技术问题为示例性的并且为非限制性的。应当指出的是,本说明书中所描述的实施例可具有其它技术效果,并且可解决其它技术问题。
虽然仅已示出并描述了某些特征和实施例,但是对本领域的技术人员而言可想起许多修改和变更(例如,尺寸、尺度、结构、各种元件的形状和比例、参数值(例如,温度、压力等)、安装布置、使用的材料、颜色、取向等等的改变),而在本质上并不脱离所公开主题的新颖性教导和优点。任何过程或方法步骤的次序或序列根据替代实施例可更改或重新排序。此外,为提供示例性实施例的简洁描述,未描述实际实施方式的所有特征。应当理解,在任何此类实际实施方式的开发中,如在任何工程或设计项目中,可做出许多实施方式具体决策。此类开发努力可谓复杂并且耗时的,然而对于受益于本公开的技术人员而言将为设计、制作和制造的例行任务而无需过度的实验。
Claims (35)
1.一种蓄电池模块,所述蓄电池模块包括:
电化学电池的电池组,所述电化学电池的所述电池组具有从所述电池组的所述电化学电池的端子端延伸的端子,其中所述电池组包括第一端和与所述第一端相对的第二端;以及
汇流条载体,所述汇流条载体设置于所述电化学电池的所述电池组上方,使得设置于所述汇流条载体上的汇流条与所述电化学电池的所述电池组的所述端子介接,其中所述汇流条载体包括沿着所述汇流条载体的周界延伸的相对的第一引导延伸部和第二引导延伸部,其中所述电化学电池的所述电池组设置于所述相对的第一引导延伸部和第二引导延伸部之间,其中所述第一引导延伸部包括第一内表面,所述第一内表面物理地接触第一最外侧电化学电池的第一侧面,其中所述第一侧面设置在所述电池组的所述第一端,其中所述第二引导延伸部包括第二内表面,所述第二内表面物理地接触第二最外侧电化学电池的第二侧面,其中所述第二侧面设置在所述电池组的所述第二端,并且其中所述第一引导延伸部和所述第二引导延伸部引导所述电化学电池的所述电池组的所述端子朝向所述汇流条载体上的适当的汇流条;
其中所述第一最外侧电化学电池的所述第一侧面和所述第二最外侧电化学电池的所述第二侧面分别横向于所述电池组的所述电化学电池的所述端子端延伸,其中所述第一引导延伸部和所述第二引导延伸部分别包括与所述第一内表面和所述第二内表面相对的第一外表面和第二外表面,并且其中所述第一内表面和所述第二内表面分别从所述第一引导延伸部和所述第二引导延伸部的近端到远端朝向所述第一外表面和所述第二外表面向外渐缩;并且
其中,在多个所述电化学电池中,仅所述第一最外侧电池与所述第一引导延伸部接触,并且仅所述第二最外侧电池与所述第二引导延伸部接触。
2.根据权利要求1所述的蓄电池模块,包括外壳和具有额外端子的电化学电池的额外电池组,其中所述外壳接纳所述电化学电池的所述电池组和所述电化学电池的所述额外电池组,其中所述电化学电池的所述额外电池组设置成相邻于所述电化学电池的所述电池组并且与之对准,其中所述汇流条载体包括相对的第三引导延伸部和第四引导延伸部,其中所述电化学电池的所述额外电池组设置于所述相对的第三引导延伸部和第四引导延伸部之间,并且其中所述相对的第三引导延伸部和第四引导延伸部分别物理地接触所述电化学电池的所述额外电池组的第三最外侧电化学电池和第四最外侧电化学电池,以将所述电化学电池的所述额外电池组的所述额外端子引导朝向设置于所述汇流条载体上的适当的汇流条。
3.根据权利要求1所述的蓄电池模块,其中所述电化学电池的所述电池组包括三个电化学电池。
4.根据权利要求1所述的蓄电池模块,其中所述电化学电池的所述电池组包括棱柱形锂离子(Li离子)电化学电池。
5.根据权利要求1所述的蓄电池模块,其中所述电化学电池的所述电池组的所述第一最外侧电化学电池和所述第二最外侧电化学电池的每一者均包括一对端子,并且所述汇流条载体的所述第一引导延伸部和所述第二引导延伸部分别在所述一对端子之间物理地接触所述第一最外侧电化学电池和所述第二最外侧电化学电池。
6.根据权利要求1所述的蓄电池模块,包括所述汇流条,其中所述汇流条固定至所述汇流条载体。
7.根据权利要求6所述的蓄电池模块,其中所述汇流条载体包括面向所述电化学电池的所述电池组的第一侧、与所述第一侧相对的第二侧,以及所述第一侧和所述第二侧之间的厚度,其中所述汇流条在所述汇流条载体的所述第二侧上固定至所述汇流条载体。
8.根据权利要求7所述的蓄电池模块,其中所述汇流条中的某些汇流条通过所述汇流条载体中的开口接触所述电化学电池的所述电池组的所述端子,其中所述汇流条中的某些汇流条延伸到所述汇流条载体的周界之外,以接触所述电化学电池的所述电池组的所述端子,或实现上述两者的组合。
9.根据权利要求6所述的蓄电池模块,其中所述汇流条载体包括卡扣特征,以接纳所述汇流条来将所述汇流条固定至所述汇流条载体。
10.根据权利要求1所述的蓄电池模块,其中所述第一引导延伸部的所述第一外表面和所述第二引导延伸部的所述第二外表面从所述第一引导延伸部和所述第二引导延伸部的所述近端至所述远端朝向所述第一引导延伸部和所述第二引导延伸部的所述第一内表面和所述第二内表面向内渐缩。
11.根据权利要求1所述的蓄电池模块,其中所述电化学电池的所述电池组的每个电化学电池均包括具有一对所述端子的端子端,其中每个端子端均包括第一长度,并且其中所述第一引导延伸部和所述第二引导延伸部中的每一者均包括第二长度,所述第二长度至少为所述第一长度的一半。
12.根据权利要求1所述的蓄电池模块,包括被配置成接收所述电化学电池的所述电池组的外壳,其中所述汇流条载体包括卡扣特征和/或开口,所述卡扣特征和/或开口配置成与所述外壳的对应开口和/或卡扣特征介接,以将所述汇流条载体在所述电化学电池的所述电池组上方联接至所述外壳。
13.根据权利要求1所述的蓄电池模块,包括传感器,所述传感器设置于所述汇流条上并且联接至所述汇流条载体。
14.根据权利要求1所述的蓄电池模块,包括传感器,所述传感器设置于所述汇流条上并且固定至所述汇流条载体。
15.根据权利要求1所述的蓄电池模块,包括多个隔板,其中所述多个隔板中的每一个隔板被设置在所述电化学电池的所述电池组的两个电化学电池之间。
16.一种蓄电池模块,所述蓄电池模块包括:
电化学电池,所述电化学电池以电池组方式设置,使得多个端子从邻近所述电池组的端子端的所述电化学电池的端子端延伸;
汇流条,所述汇流条配置成与所述多个端子介接;以及
汇流条载体,所述汇流条载体设置成相邻于所述电池组的所述端子端并且具有设置于其上的所述汇流条,其中所述汇流条载体包括沿着所述汇流条载体的周界延伸的第一引导延伸部,所述第一引导延伸部具有第一内表面,所述第一内表面物理地接触设置于所述电池组的第一侧上的第一电化学电池的第一侧面,其中所述汇流条载体包括沿着所述汇流条载体的所述周界延伸的第二引导延伸部,所述第二引导延伸部具有第二内表面,所述第二内表面物理地接触设置于所述电池组的与所述第一侧相对的第二侧上的第二电化学电池的第二侧面,并且其中所述第一引导延伸部和所述第二引导延伸部将所述电池组的所述电化学电池压缩在一起,使得所述多个端子与对应的所述汇流条对准;
其中所述第一电化学电池的所述第一侧面和所述第二电化学电池的所述第二侧面分别横向于所述电池组的所述端子端和所述电化学电池的所述端子端延伸,其中所述第一引导延伸部和所述第二引导延伸部分别包括与所述第一内表面和所述第二内表面相对的第一外表面和第二外表面,并且其中所述第一内表面和所述第二内表面分别从所述第一引导延伸部和所述第二引导延伸部的近端到远端朝向所述第一外表面和所述第二外表面向外渐缩。
17.根据权利要求16所述的蓄电池模块,其中所述第一引导延伸部和所述第二引导延伸部从所述汇流条载体的所述周界的相对两侧延伸出或在所述汇流条载体的所述周界的相对两侧的附近延伸出。
18.根据权利要求16所述的蓄电池模块,其中所述第一引导延伸部和所述第二引导延伸部的所述外表面从所述第一引导延伸部和所述第二引导延伸部的近端至远端朝向所述第一引导延伸部和所述第二引导延伸部的所述内表面向内渐缩。
19.根据权利要求16所述的蓄电池模块,包括外壳,所述外壳具有开放侧,所述开放侧配置成接纳所述电化学电池,使得所述电化学电池以所述电池组方式设置于所述外壳的内侧,其中所述汇流条载体设置于所述外壳的所述开放侧中,使得设置于所述汇流条载体上的所述汇流条与所述电化学电池的所述端子介接。
20.根据权利要求16所述的蓄电池模块,其中所述汇流条载体包括面向所述电化学电池的第一表面、与所述第一表面相对的第二表面,以及所述第一表面和所述第二表面之间的厚度,其中所述汇流条在所述汇流条载体的所述第二表面上设置于所述汇流条载体上。
21.一种蓄电池模块,所述蓄电池模块包括:
电化学电池的电池组,所述电化学电池的所述电池组具有从所述电池组的所述电化学电池的端子端延伸的端子,其中所述电池组包括第一端和与所述第一端相对的第二端;以及
汇流条载体,所述汇流条载体设置于所述电化学电池的所述电池组上方,使得设置于所述汇流条载体上的汇流条与所述电化学电池的所述电池组的所述端子介接,其中所述汇流条载体包括沿着所述汇流条载体的周界延伸的相对的第一引导延伸部和第二引导延伸部,其中所述电化学电池的所述电池组设置于所述相对的第一引导延伸部和第二引导延伸部之间,其中所述第一引导延伸部包括第一内表面,所述第一内表面物理地接触第一最外侧电化学电池的第一侧面,其中所述第一侧面设置在所述电池组的所述第一端,其中所述第二引导延伸部包括第二内表面,所述第二内表面物理地接触第二最外侧电化学电池的第二侧面,其中所述第二侧面设置在所述电池组的所述第二端,并且其中所述第一引导延伸部和所述第二引导延伸部引导所述电化学电池的所述电池组的所述端子朝向所述汇流条载体上的适当的汇流条;并且
其中,在多个所述电化学电池中,仅所述第一最外侧电池与所述第一引导延伸部接触,并且仅所述第二最外侧电池与所述第二引导延伸部接触。
22.一种蓄电池模块,所述蓄电池模块包括:
电化学电池的电池组,所述电化学电池的所述电池组具有从所述电池组的所述电化学电池的端子端延伸的端子,其中所述电池组包括第一端和与所述第一端相对的第二端;以及
汇流条载体,所述汇流条载体设置于所述电化学电池的所述电池组上方,使得设置于所述汇流条载体上的汇流条与所述电化学电池的所述电池组的所述端子介接,其中所述汇流条载体包括沿着所述汇流条载体的周界延伸的相对的第一引导延伸部和第二引导延伸部,其中所述电化学电池的所述电池组设置于所述相对的第一引导延伸部和第二引导延伸部之间,其中所述第一引导延伸部包括第一内表面,所述第一内表面暂时、短暂或永久物理地接触第一最外侧电化学电池的第一侧面,其中所述第一侧面设置在所述电池组的所述第一端,其中所述第二引导延伸部包括第二内表面,所述第二内表面暂时、短暂或永久物理地接触第二最外侧电化学电池的第二侧面,其中所述第二侧面设置在所述电池组的所述第二端,并且其中所述第一引导延伸部和所述第二引导延伸部将所述电化学电池的所述电池组的所述端子引导朝向设置于所述汇流条载体上的所述汇流条;
其中所述第一最外侧电化学电池的所述第一侧面和所述第二最外侧电化学电池的所述第二侧面分别横向于所述电池组的所述电化学电池的所述端子端延伸,其中所述第一引导延伸部和所述第二引导延伸部分别包括与所述第一内表面和所述第二内表面相对的第一外表面和第二外表面,并且其中所述第一内表面和所述第二内表面分别从所述第一引导延伸部和所述第二引导延伸部的近端到远端朝向所述第一外表面和所述第二外表面向外渐缩;并且
其中,在多个所述电化学电池中,仅所述第一最外侧电化学电池与所述第一引导延伸部接触,并且仅所述第二最外侧电化学电池与所述第二引导延伸部接触。
23.根据权利要求22所述的蓄电池模块,包括外壳和具有额外端子的电化学电池的额外电池组,其中所述外壳接纳所述电化学电池的所述电池组和所述电化学电池的所述额外电池组,其中所述电化学电池的所述额外电池组设置成相邻于所述电化学电池的所述电池组并且与之对准,其中所述汇流条载体包括相对的第三引导延伸部和第四引导延伸部,其中所述电化学电池的所述额外电池组设置于所述相对的第三引导延伸部和第四引导延伸部之间,并且其中所述相对的第三引导延伸部和第四引导延伸部分别暂时、短暂或永久物理地接触所述电化学电池的所述额外电池组的第三最外侧电化学电池和第四最外侧电化学电池,以将所述电化学电池的所述额外电池组的所述额外端子引导朝向设置于所述汇流条载体上的适当的所述汇流条。
24.根据权利要求22所述的蓄电池模块,其中所述电化学电池的所述电池组包括三个电化学电池。
25.根据权利要求22所述的蓄电池模块,其中所述电化学电池的所述电池组包括棱柱形锂离子(Li离子)电化学电池。
26.根据权利要求22所述的蓄电池模块,其中所述电化学电池的所述电池组的所述第一最外侧电化学电池和所述第二最外侧电化学电池的每一者均包括一对端子,并且所述汇流条载体的所述第一引导延伸部和所述第二引导延伸部分别在所述一对端子之间暂时、短暂或永久物理地接触所述第一最外侧电化学电池和所述第二最外侧电化学电池。
27.根据权利要求22所述的蓄电池模块,包括所述汇流条,其中所述汇流条固定至所述汇流条载体。
28.根据权利要求27所述的蓄电池模块,其中所述汇流条载体包括面向所述电化学电池的所述电池组的第一侧、与所述第一侧相对的第二侧,以及所述第一侧和所述第二侧之间的厚度,其中所述汇流条在所述汇流条载体的所述第二侧上固定至所述汇流条载体。
29.根据权利要求28所述的蓄电池模块,其中所述汇流条中的某些汇流条通过所述汇流条载体中的开口接触所述电化学电池的所述电池组的所述端子,其中所述汇流条中的某些汇流条延伸到所述汇流条载体的周界之外,以接触所述电化学电池的所述电池组的所述端子,或实现上述两者的组合。
30.根据权利要求27所述的蓄电池模块,其中所述汇流条载体包括卡扣特征,以接纳所述汇流条来将所述汇流条固定至所述汇流条载体。
31.根据权利要求22所述的蓄电池模块,其中所述第一引导延伸部的所述第一外表面和所述第二引导延伸部的所述第二外表面分别从所述第一引导延伸部和所述第二引导延伸部的所述近端至所述远端朝向所述第一引导延伸部的所述第一内表面和所述第二引导延伸部的所述第二内表面向内渐缩。
32.根据权利要求22所述的蓄电池模块,其中所述电化学电池的所述电池组的每个电化学电池均包括具有一对所述端子的端子端,其中每个端子端均包括第一长度,并且其中所述第一引导延伸部和所述第二引导延伸部中的每一者均包括第二长度,所述第二长度至少为所述第一长度的一半。
33.根据权利要求22所述的蓄电池模块,包括被配置为接纳所述电化学电池的所述电池组的外壳,其中所述汇流条载体包括卡扣特征和/或开口,所述卡扣特征和/或开口配置成与所述外壳的对应开口和/或卡扣特征介接,以将所述汇流条载体在所述电化学电池的所述电池组上方联接至所述外壳。
34.根据权利要求22所述的蓄电池模块,包括传感器,所述传感器设置于所述汇流条上并且联接至所述汇流条载体。
35.根据权利要求22所述的蓄电池模块,包括传感器,所述传感器设置于所述汇流条上并且固定至所述汇流条载体。
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