CN109037577B - 具有电池模块和提供内置电路保护的盖组件的电气系统 - Google Patents

具有电池模块和提供内置电路保护的盖组件的电气系统 Download PDF

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CN109037577B
CN109037577B CN201810557955.5A CN201810557955A CN109037577B CN 109037577 B CN109037577 B CN 109037577B CN 201810557955 A CN201810557955 A CN 201810557955A CN 109037577 B CN109037577 B CN 109037577B
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CN109037577A (zh
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C·S·沙瓦
范悦
P·奈克
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Abstract

一种电池模块，包括组部分和盖组件。组部分具有互连板、导电通道以及延伸穿过互连板的电池电芯。每个电池电芯包括接合到对应导电通道的电极电芯突片。盖组件可以连接到组部分，并且具有导电互连构件、电保险丝以及内置到盖板或与其集成的感测线。互连构件从盖板延伸，并且当将盖组件连接到组部分时在组部分的导电通道与保险丝和盖板的感测线之间形成电气电路的一部分。一种电气系统，其包括电池模块、DC电压母线，以及通过DC电压母线连接到电池模块的至少一个高电压部件。该电气系统可以是机动车辆的一部分。

Description

具有电池模块和提供内置电路保护的盖组件的电气系统
引言
电动动力传动系通常利用一个或多个电动机来选择性地给予变速器输入扭矩并在不同的动力传动系操作模式下生成产生电力。用来对电动机或其他高压部件供电的电能存储在可充电能量存储系统(RESS)即电池模块中并与接触器和保险丝相关联。电池模块继而可以包括设置在组或组部分内的多个互连的锂离子电池电芯。单独的电池电芯的电极伸出部接合至导电通道以在各个电池电芯和多个电池组之间提供串联和并联的电气连接。
控制器被用来调节电池模块的操作。就这一点而言，各个电池电芯的单独的电芯电压利用柔性电路或印刷电路板组件的单独的感测线来周期性地进行测量。电芯电压被报告给控制器，其随后利用所报告的电芯电压来控制流向RESS和从RESS流来的电能的量，以及监测电池组的整体健康并执行电芯电压平衡和热调节功能。作为预防，小型低电压感测线电阻丝被焊接到感测线内并永久封装于该感测线以帮助保护免受过电压或过电流状况影响。
感测线电阻丝通常具有高水平的串联可靠度。尽管如此，此类电阻丝通常非常小，例如，不超过6mm×3mm×3mm。此外，微小的保险丝被焊接到形成安装到电池模块的柔性电路板(“柔性电路”)或刚性印刷电路板组件(PCBA)中的导电迹线，该导电迹线继而被铆接到电池模块的刚性互连板。焊接的保险丝之后被永久封装到柔性电路或PCBA上的适当位置，例如，通过利用厚环氧树脂层。
发明内容
本文公开了一种电池模块，其可以在电气系统中使用。作为示例而并非限制，该电气系统可以是电池电动车、延程型电动车或混合动力电动车辆或者其他移动平台的一部分，或者用于固定的电气系统，比如发电站。电池模块包括盖组件，其为电池模块的给定组部分的各个电池电芯提供集成/内置感测线保护。
如以下参考各个附图所描述的，所公开的盖组件可以响应于感测线保险丝故障维护或更换，并且由此避免了更换电池模块或组部分的需要。本方法嵌入感测线保险丝和在盖组件的结构内跟踪，并且利用以上所述构造解决了其中单独的封装的保险丝不易更换或维护所存在的潜在问题。此类现有构造的一种可能结果是响应于保险丝故障其电池模块或组部分被拆除或更换。
相比而言，本方法作为替代提供了一种基于低电压保险丝的感测线电路保护集成方法，特别是在利用多电芯高压电池模块的电气系统中。在示例性实施例中的组部分包括多个电池电芯，其各自具有一组电极片。盖组件包括盖板和多个导电互连构件，以及感测线保险丝和形成以上所提到的单独的感测线的电路迹线。保险丝和感测线被内置到盖组件或者与其集成形成，而当盖组件连接到组部分时导电互连构件在导电通道、保险丝和感测线之间形成导电电路的一部分。
在一个特定实施例中，电池模块包括组部分和盖组件。组部分具有互连板、多个导电通道以及延伸穿过互连板的多个电池电芯。每个电池电芯包括至少一个电极电芯突片，其接合至导电通道中的对应一个。盖组件可以连接到组部分，并且具有盖板和导电互连构件、电保险丝以及内置到盖板或与其集成的感测线。导电互连构件从盖板延伸，并且当将盖组件连接到组部分时在组部分的导电通道与保险丝和盖板的感测线之间形成电气电路的一部分。
导电互连构件可以不同地体现为螺旋弹簧、片簧或者具有夹紧端和压接端的电连接器。
当体现为螺旋弹簧时，互连构件可以具有形成线圈环的远端，同时导电通道任选地限定了与线圈环对准并配合的表面特征件。
当体现为片簧时，互连构件可以包括当将盖组件连接到组部分时与导电通道的表面接触的表面特征件。
盖组件可以包括形成感测线终端的多针电连接器。
在一些实施例中，保险丝可以具有在约100毫安至5安范围内的额定电流。
还公开了一种电气系统，其包括电池模块、直流(DC)电压母线，以及通过DC电压母线连接到电池模块的至少一个高电压部件。高电压部件可以包括功率变换器模块，同时电气系统包括通过该功率变换器模块连接到电池模块的电动机。
电气系统可以连接至变速器，该变速器具有连接到电动机的输入构件和连接到负载的输出构件。例如，电气系统可以是具有作为负载的道路车轮的车辆的一部分，同时输出构件连接至该道路车轮。
当结合附图时，通过对用来实现本公开的最佳模式的以下详细描述，本公开的以上特征和优点以及其他特征和优点将是显而易见的。
附图说明
图1是具有如本文所公开的电池模块的示例性电气系统的示意图，该电池模块具有提供集成感测线电路保护的盖组件。
图2是可用作图1的电气系统的一部分的可维护盖组件和组部分的示意性平面图说明。
图3是图2的盖组件和组部分的示意性侧视图说明。
图4A至4D是可以和图2中所示的盖组件一起使用的替代性导电互连构件的示意性透视图说明。
本发明易于作出各种修改及替代形式，并且在附图中已经通过示例方式示出了一些代表性实施例且将在详细进行描述。然而，应当理解的是，本公开的新颖方面并不限于附图中所示的特定形式。而是，本公开将覆盖落入由所附权利要求书限定的本公开的精神和范围内的所有修改、等同形式、置换、组合、子组合以及替代形式。
具体实施方式
参考附图，其中在整个若干附图中相同的附图标记对应于类似的部件，图1中示意性示出了示例性车辆10和电气系统20。车辆10可以替代地配置为电池电动车辆、延程型电动车、混合动力电动车辆或者具有电动动力传动系的其他车辆10。尽管显示的是车辆应用，电气系统20可以用于其他移动平台、发电站或者具有配置为存储或提供电力的可充电电池模块12的固定系统。
电池模块12包括组部分22和配合的盖组件22C，同时盖组件22C为组部分22提供集成或内置电路保护，如以下具体参考图2所详细描述的。组部分22包括多个电池电芯13，例如，锂离子电池电芯或具有合适的电池化学性质的电池电芯。具有相同数目或不同数目电池电芯13的多个组部分22可以串联和/或并联连接在一起以共同提供约50伏DC(VDC)至450VDC的直流(DC)高电压电平，或者更高，取决于应用和功率需求。因此，本文所使用的术语“高电压”指的是超过典型的12至15VDC辅助电压电平的电压。
电池模块12可以电连接至高功率分配模块(HPDM)16，例如电接线盒，以将电力通过DC电压母线31从电池模块12分配到各种高电压部件 26A-E。在图1所示的非限制性示例构造中，高电压部件26A、26B和26C 可以分别包括辅助功率模块(APM)、客舱加热控制模块(CHCM)以及车载充电模块(OBCM)。如本领域所已知的，术语“APM”指的是一种配置为增大或减小电池模块12的DC电压输出的电压转换器。CHCM是一种可操作用于加热车辆10的乘客客舱的装置，而OBCM是一种通常用于当需要时对电池模块22充电的装置。高电压部件26D可以是空调控制模块(ACCM)，即，一种可操作用于冷却乘客客舱和/或车辆10的其他部件的装置。高电压部件26E可以体现为功率变换器模块(PIM)，如图所示，其在本领域中已知为可以操作用于将来自电池模块22的DC电压(VDC) 变换成AC电压(VAC)。
图1的车辆10在某些操作模式下可以仅利用由电池模块22提供的电能提供动力，此类操作模式被称为电动车辆或“EV”模式。就这一点而言，车辆10可以包括一个或多个电动机25(MA)，例如，通过马达输出轴25S 提供马达输出扭矩(箭头TM)的电动牵引马达。马达输出扭矩(箭头TM) 可以形成输入扭矩(箭头TI)的一些或全部，该输入扭矩被提供给变速器(T)28的输入构件15，例如，具有一个或多个行星齿轮组(未示出)的齿轮箱、直接传动或1:1传动比变速器或者无级变速器。
任选的内燃机(E)33可以用来选择性地通过曲轴11生成发动机扭矩 (箭头TE)。曲轴11可以通过输入离合器CI的接合选择性连接到输入构件15。变速器28的输出构件17最终将变速器输出扭矩(箭头TO)传送到一个或多个驱动轴21，并且由此在图1的非限制性车辆实施例中传送到一组道路车轮19，或者在非车辆实施例中传送到另一种负载。从而，在非限制性混合动力电动车辆实施例的一些模式下，发动机扭矩(箭头TE)和马达输出扭矩(箭头TM)可以组合以形成给变速器28的输入扭矩(箭头 TI)。
如以上提到的，图1的电池模块12包括组部分22和配置的盖组件 22C。在图2中的示意平面图中示出了组部分22和盖组件22C两者。盖组件22C通过结合保护性电气电路为组部分22提供集成/内置电路保护。所公开的结构允许拆下并修理或者废弃盖组件22C，以替代修理或更换组部分22或电池模块12，由此加快了修理操作并潜在地降低了电池模块12相关的修理成本。
具体地，组部分22包括互连板30和多个电池电芯13(参见图1)，同时电池电芯13设置在互连板30后面和下方。在某些实施例中互连板30 可以由实心平坦的模制塑料件构成，从而使互连板30为组部分22提供结构刚性。如本领域已知的，每个电池电芯13可以包括主电芯体(未示出)，其具有正集流体和负集流体，例如分别由铝和铜构成，由电介质溶液隔开，并封闭在箔袋或其他合适的构造中。集流体的一部分从主电芯体突出作为电极电芯突片13E，其正交延伸穿过互连板30。
单独的电芯突片13E可以超声焊接或以其他方式接合到导电通道14，例如细长的U形或L形铜汇流条，以电互连各个电池电芯13。尽管在图2 中以简化示意形式示出，当使用U形导电通道14时一组三个以上这样的电芯突片13E可以突出穿过导电通道14的相对侧，或者当使用L形导电通道14时如图所示在导电通道14的一侧上。
盖组件22C包括盖板40和多个互连构件50，以及相对应的多个感测线42和感测线保险丝46。保险丝46可以体现为小型电保险丝，额定为约 100毫安至5安，并且具有较小的包层，例如约50mm3或更小。例如利用二次成型工艺，或者通过将感测线42和保险丝46安装到盖板40的表面 40S，感测线42和保险丝46可以内置到盖板40的结构内或者与其集成。从表面40S向外延伸的互连构件50中的每一个对应于组部分22的导电通道14中的给定一个，使得当将盖组件22C连接到组部分22时，盖组件22C 和单独的电池电芯13一起形成电气电路的一部分。
感测线42可以电连接到多针电连接器35从而形成各个感测线42的终端。连接器35继而可以连接到外部控制器(C)80，例如电压电流温度模块(VITM)，其可操作用于监测组部分22、平衡充电和/或电池电芯13 的单独的电芯电压，以及调节到组22的功率流和来自组22的功率流。替代地，连接器35可以以执行VITM功能的集成电路或感测芯片替代，在这种情况下可以省略控制器80或者至少将其配置为执行更少的功能。
如图3中最佳示出的，导电互连构件50从盖板40的表面40S正交向外突出，使得当盖组件22C最终夹紧到组部分22时，使互连构件50进入与导电通道14中相对应的一个直接接触的状态。可以利用对准定位销(未示出)或者其他对准特征将互连构件50引导到适当位置，同时互连构件 50能够提供法向力以确保与对应的导电通道14的良好电连接。类似地，互连构件50可以配置有足够量的弹性，以便吸收盖组件22C和组部分22 的一定程度的相对移动。
通过示例而非限制，互连构件50可以体现为图3中所示的螺旋弹簧，从表面40S突出。表面40S继而沿与互连板30的表面30S的平面P2平行的平面P1进行设置。互连构件50可以各自具有远端51。当盖板40沿朝向组部分22的箭头A方向移动时，远端51开始与导电通道14及其表面特征件27(例如，凸台或导电通道14的其他突出部)或者导电通道14的凹陷表面部分直接接触，同时表面特征件27在螺旋弹簧实施例中可以用于与由远端51形成的线圈环对准并配合。这允许互连构件50吸收相对移动，同时互连构件50的弹簧力提供了期望的法向力以有助于维持盖组件 22C和组部分22之间的良好电接触。
图4A-图4D示出了图3的螺旋弹簧型互连构件50的替代实施例。在各个示例中，变型提供了互连构件50和导电通道14之间良好电接触所需的正法向力，与此同时吸收了盖组件22C的相对移动。图4A示出了从表面40S向外延伸的互连构件50A。互连构件50A可以具有从表面40S正交延伸的固定部分54和通过铰链52连接至固定部分54的铰接部分52。此处，当使盖组件22C与互连板30的表面30S接触时，铰接部分52的端部 53朝向固定部分54旋转，由此吸收了以上提到的相对运动。
图4B示出了其中互连构件50B被配置为片簧的实施例，例如具有从盖组件22C的表面40S向外延伸的V形突出部。同样，如图4C中所示的互连构件50C可以具有隔开距离D的相对支腿60和64，并且形成了图4B 的构造的替代性片簧。推动支腿60和64朝向彼此的压缩力吸收了盖组件 22C和组部分22的相对移动，当将盖组件22C夹紧到图1或图2的组部分22上合适位置时，以升高隆起物或定位高摩擦区域形式的滚花66提供了与导电通道14的良好电接触。
如图4D中所示的互连构件50D可以用作图4B和图4C的片簧实施例的替代方案。互连构件50D可以是电连接器，比如所示非限制性示例实施例。在所示实施例中，互连构件50D具有夹紧端70，其具有可对置的钳夹 74，该钳夹74夹紧到电芯图片13E上以确保良好的电接触。连接至盖板 40的导线(未示出)可以在压接端72处压接到互连构件50D和盖板40，可以焊接至该压接端72或者利用导电粘合剂连接在一起。与图4D的实施例一样，图4A至4C的其他螺旋弹簧和片簧实施例可以类似地在到导电通道14的界面处使用导电粘合剂。尽管图4D的实施例可能比图4A-C中所示的那些更少弹性且更为费力，特别是在相对易于与组部分22对准方面而言，但是互连构件50D是一种易于采购并适合于在当前盖组件22C中使用的实施例。
如本领域普通技术人员将易于理解的，电池组通常将电芯感测控制板铆接至刚性互连板，例如图2的互连板30。之后，单独的电芯突片13E被超声焊接至导电通道14。其结果是，太大或太小的振动能量和相关热量可能影响此类先前形成的铆钉以及周围结构的结构完整性，比如在焊接衬垫或给定电池电芯内的电芯突片13E。尽管如此，电芯感测结构被集成到盖组件22C内，由此在电芯突片13E的超声焊接期间所给予的力和热量对此类铆钉的结构完整性不产生影响。这和通过将电路保护部件集成到一次性或可替换盖组件22C实现的潜在成本益处一起，是以上所阐述的本公开的一些可能优点。
尽管已经详细描述了用于实现本公开的最佳模式，但是那些熟悉本公开所涉及领域的技术人员将能意识到用于在所附权利要求书范围内实践本公开的各种替代设计和实施例。

Claims (9)

1.一种电池模块，包括：
组部分，所述组部分具有互连板、多个导电通道，以及多个电池电芯，所述多个导电通道中的每一个形成细长的U形或L形汇流条，所述多个电池电芯中的每一个具有正交地延伸穿过所述互连板的至少一个电极电芯突片，所述电池电芯中的每一个设置在所述互连板的后面，所述至少一个电极电芯突片接合到所述导电通道中相对应的一个；以及
盖组件，所述盖组件可以连接至所述组部分，并且具有盖板和多个导电互连构件、多个电保险丝以及多个内置于所述盖板或者与所述盖板集成的感测线，所述导电互连构件从所述盖板正交向外突出并且当将所述盖组件连接至所述组部分时在所述组部分的所述导电通道与所述保险丝和所述盖板的感测线之间形成电气电路的一部分。
2.根据权利要求1所述的电池模块，其中所述导电互连构件为螺旋弹簧。
3.根据权利要求2所述的电池模块，其中所述螺旋弹簧具有形成线圈环的远端，所述导电通道形成所述细长的U形汇流条，其中底板在侧面与一对侧壁相接，该底板限定了与所述线圈环对准并配合的表面特征件，且所述至少一个电极电芯突片被超声焊接至该对侧壁中的一个。
4.根据权利要求1所述电池模块，其中所述导电互连构件为片簧。
5.根据权利要求4所述的电池模块，其中所述片簧包括当将所述盖组件连接到所述组部分时与所述导电通道的表面接触的表面特征件。
6.根据权利要求1所述的电池模块，其中所述导电互连构件包括具有可夹紧端和可卷曲端的电连接器。
7.根据权利要求1所述的电池模块，其中所述盖组件包括形成所述感测线的终端的多针电连接器。
8.根据权利要求1所述的电池模块，其中所述保险丝具有在约100毫安至5安范围内的额定电流。
9.一种电气系统，包括：
电池模块，所述电池模块具有组部分和连接至所述组部分的盖组件；
直流(DC)电压母线；以及
至少一个高电压部件，所述至少一个高电压部件通过所述直流电压母线连接至所述电池模块；
其中所述组部分包括互连板、多个导电通道，以及多个电池电芯，所述多个导电通道中的每一个形成细长的U形或L形汇流条，所述多个电池电芯中的每一个具有正交地延伸穿过所述互连板的至少一个电极电芯突片，所述电池电芯中的每一个设置在所述互连板的后面，所述至少一个电极电芯突片接合到所述导电通道中相对应的一个，并且其中所述盖组件包括盖板和多个导电互连构件、多个电保险丝以及多个内置于所述盖板或者与所述盖板集成的感测线，所述导电互连构件从所述盖板正交向外突出并且当将所述盖组件连接至所述组部分时在所述组部分的所述导电通道与所述保险丝和所述盖板的感测线之间形成电气电路的一部分。
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