GB2612806A - Harness for battery module - Google Patents

Harness for battery module Download PDF

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Publication number
GB2612806A
GB2612806A GB2116295.3A GB202116295A GB2612806A GB 2612806 A GB2612806 A GB 2612806A GB 202116295 A GB202116295 A GB 202116295A GB 2612806 A GB2612806 A GB 2612806A
Authority
GB
United Kingdom
Prior art keywords
harness
cluster
battery module
electrical
longitudinal axis
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
GB2116295.3A
Other versions
GB202116295D0 (en
Inventor
Jones Steve
Symes Matthew
Foster Jaimie
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Jaguar Land Rover Ltd
Original Assignee
Jaguar Land Rover Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jaguar Land Rover Ltd filed Critical Jaguar Land Rover Ltd
Priority to GB2116295.3A priority Critical patent/GB2612806A/en
Publication of GB202116295D0 publication Critical patent/GB202116295D0/en
Publication of GB2612806A publication Critical patent/GB2612806A/en
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/269—Mechanical means for varying the arrangement of batteries or cells for different uses, e.g. for changing the number of batteries or for switching between series and parallel wiring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/262—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks
    • H01M50/264—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks for cells or batteries, e.g. straps, tie rods or peripheral frames
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/284—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with incorporated circuit boards, e.g. printed circuit boards [PCB]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/298—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the wiring of battery packs
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/507—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/514—Methods for interconnecting adjacent batteries or cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/519—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising printed circuit boards [PCB]
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/569—Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Abstract

A harness (400) for a vehicle battery module (200) having a first cluster (203-A) of electrical cells and a second cluster (203-B) of electrical cells (100) disposed on either side of a longitudinal axis extending between a first end (310) of the vehicle battery module and a second end (320) of the vehicle battery module. The harness (400) comprises a first fastening portion (410) configured to retain the harness to the first end (310) of the vehicle battery module; a second fastening portion (420) configured to retain the harness to the second end (320) of the vehicle battery module; and a harness body (430) extending between the first fastening portion (410) and the second fastening portion (420) along the longitudinal axis. The harness body (430) comprises a configurable connector portion (440) disposed to bridge the longitudinal axis. The configurable connector portion (440) is arranged to receive, in a first configuration, an electrical connector (446) for connecting the first cluster (203-A) and the second cluster (203-B) in parallel across the longitudinal axis, and in a second configuration, insulate the first cluster (203-A) from the second cluster (203-B) at the longitudinal axis. This allows battery packs of differing voltages to be manufactured.

Description

HARNESS FOR BATTERY MODULE
TECHNICAL FIELD
The present disclosure relates to a harness for a battery module. Aspects of the invention relate to a harness, to a vehicle battery module, to a vehicle, and to a method of manufacturing a vehicle battery module.
BACKGROUND
Vehicle traction battery modules comprise a plurality of electrical cells connected to provide power to an electric motor of an electric vehicle (EV). Within the module, electrical cells may be mechanically joined together to form a cluster of cells connected in parallel, and a battery module may comprise one or more of such clusters of cells electrically connected together in series. It can be desired to provide battery modules having different voltage outputs, for example to form part of either a 400V or an 800V battery pack. The clusters may be differently arranged within the module depending on the target voltage output for the battery module. However, making extensive structural modifications to the battery module depending on the voltage output can be burdensome and increase the cost of manufacture.
It is an aim of the present invention to address one or more of the disadvantages associated
with the prior art.
SUMMARY OF THE INVENTION
Aspects and embodiments of the invention provide a harness, a vehicle battery module, a vehicle and a method as claimed in the appended claims.
According to a first aspect there is provided a harness for a vehicle battery module having a first cluster of electrical cells and a second cluster of electrical cells disposed on either side of a longitudinal axis extending between a first end of the vehicle battery module and a second end of the vehicle battery module. The harness comprises a first fastening portion configured to retain the harness to the first end of the vehicle battery module; a second fastening portion configured to retain the harness to the second end of the vehicle battery module; and a harness body extending between the first fastening portion and the second fastening portion along the longitudinal axis. The harness body comprises a configurable connector portion disposed to bridge the longitudinal axis; wherein the configurable connector portion is arranged to receive, in a first configuration, an electrical connector for connecting the first cluster and the second cluster in parallel across the longitudinal axis, and in a second configuration, insulate the first cluster from the second cluster at the longitudinal axis. Advantageously, the arrangement of the harness facilitates easy adaptation of the battery module between a first voltage output and a second voltage output by configuring the connector portion in the first configuration or second configuration. Thus, a vehicle battery can be tailored to provide a first voltage or a second voltage without changing the size or number of battery modules.
The battery module may comprise two rows of cell clusters, i.e. one row of cell cluster pairs.
The rows extend between the first end and second end of the battery module. The harness may comprise a configurable connector portion for each cell cluster pair, thus providing a mechanism by which the voltage output of the battery module can be readily doubled. The first end of the battery module may comprise a first terminal face and the second end of the battery module may comprise a second terminal face. The longitudinal axis can be considered to extend between a midpoint of the first terminal face and a midpoint of the second terminal face. That is, the harness may be disposed centrally along the vehicle battery module. Advantageously, disposing the harness centrally between two rows of cells enables the harness to be thin and thus not extend across a majority of the width of the module perpendicular to the longitudinal axis.
The first fastening portion and the second fastening portion may each comprise a retention clip to facilitate ease of construction and removal for servicing.
Optionally, the configurable connector portion comprises a first conducting tab arranged to be in electrical contact with a cell of the first cluster and a second conducting tab arranged to be in electrical contact with a cell of the second cluster. The electrical connector, in the first configuration, may comprises a voltmeter in contact with the first conducting tab and the second conducting tab configured to measure a voltage of the first cluster and the second cluster. Thus, the configurable connector may advantageously also be used to monitor the voltage of the connected clusters. The configurable connector portion may be arranged to receive, in the second configuration, a first voltmeter in contact with the first conducting tab configured to measure a voltage of the first cluster and a second voltmeter in contact with the second conducting tab configured to measuring a voltage of the second cluster. Thus, the voltage of each cell cluster may be separately measured when the cell clusters are not connected by the electrical connector.
The harness may comprise one or more sensing elements disposed on the harness body for monitoring the vehicle battery module. The sensing elements may comprise one or both of: a voltmeter for measuring the voltage of the first cluster or second cluster; and a thermistor for measuring a temperature of the first cluster or second cluster. The harness may comprise a connector at the first fastening portion or the second fastening portion and one or more electrical tracks along a length of the harness body for connecting the one or more sensing elements to a battery supervisory circuit. In some embodiments, the harness may be provided with the connector and tracks without the sensing elements, to facilitate connection of the sensing elements at a later time. The harness body may comprise a flexible printed circuit board (PCB) comprising the plurality of electrical tracks and an insulating support layer between the electrical tracks and the vehicle battery module.
Optionally, the harness body comprises a thermistor housing portion configured to retain a thermistor for measuring a temperature of the first cluster or the second cluster. The thermistor housing portion may comprise a pocket bonded to the harness body and the harness may comprise electrical tracks connected to the thermistor housing portion for connecting the thermistor housing portion to a cell supervisory circuit. In some embodiments, a thermistor is disposed in the thermistor housing portion.
Optionally, the harness body is configured to lie coplanar and adjacent to a face of the vehicle battery module extending between the first end and the second end. Thus, the harness body may add minimal height to the battery module, facilitating space efficient packing.
The harness body may comprise one or more gaps arranged to expose an end of one or more of the electrical cells. The one or more gaps may be larger than a cross-sectional area of the cells of the battery module. Advantageously, providing such gaps facilitates venting of the cells. In some embodiments, the harness body may comprise an anti-thermal propagation compound in the one or more gaps.
According to another aspect, there is provided vehicle battery module, comprising a first end, a second end and a module housing extending between the first end and the second end; a first cluster of electrical cells connected in parallel and disposed in the module housing on a first side of a longitudinal axis extending between the first end and the second end; a second cluster of electrical cells connected in parallel and disposed in the module housing on a second side of the longitudinal axis; and a harness according to the aspect above.
According to another aspect, there is provided a vehicle comprising a harness or a vehicle battery module according to the aspects above.
According to another aspect, there is provided a method of manufacturing a vehicle battery module. The method comprises providing a battery module body comprising a first end, a second end and a module housing extending between the first end and the second end, a first cluster of electrical cells connected in parallel by a first internal busbar and disposed in the module housing on a first side of a longitudinal axis extending between the first end and the second end, and a second cluster of electrical cells connected in parallel by a second internal busbar and disposed in the module housing on a second side of the longitudinal axis; providing a harness according to the aspect above; fixing a first conducting tab and a second conducting tab to the harness body; and laser welding the first conducting tab to the first internal busbar; and laser welding the second conducting tab to the second internal busbar.
Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a cylindrical electrical cell for a battery module; Figure 2 shows an exploded view of a battery module; Figure 3A shows a battery module from above; Figure 3B shows an underside of the battery module; Figure 4A shows a harness for a battery module in a first configuration; Figure 4B shows the harness in use on a battery module; Figure 40 shows an arrangement of module terminals in the first configuration; Figure 4D shoes a circuit diagram of the module in the first configuration; Figure 5A shows a harness for a battery module in a second configuration; Figure 5B shows the harness in use on a battery module; Figure 50 shows an arrangement of module terminals in the second configuration; Figure 5D shoes a circuit diagram of the module in the second configuration; Figure 6 illustrates a vehicle; and Figure 7 shows a flow chart to illustrate a method according to the invention.
DETAILED DESCRIPTION
The present invention relates to a traction battery module for use in a vehicle. A traction battery module comprises a plurality of electrical cells connected to provide power to an electric motor of an electric vehicle (EV), for example a battery electric vehicle (BEV) or hybrid electric vehicle (HEV).
Figure 1 illustrates a conventional cylindrical cell 100 for use in a traction battery for a vehicle. The cell 100 comprises a positive terminal 100P and a negative terminal 100N. In this example, the positive terminal is provided by a steel end cap 106 in a central region of a first end 104 of the cell, and the negative terminal is provided by a steel cylindrical case 108.
The steel cylindrical case 108 covers a second end 102, the entire cylindrical surface between the first and second ends, and a peripheral region of the first end surface 104. In commercially-available cells, it is sometimes the case that the end cap that defines the positive terminal 100P on the first end surface 104 protrudes beyond the peripheral region of the first end surface 104, although this is not shown in the cell shown in Figure 1. This allows a substantially planar connector to be connected to the positive terminal and not the negative terminal. It is important to avoid direct electrical connections between the positive and negative terminals 100P, 100N, as such connections create a short circuit which may damage the cell.
Cells 100 may be grouped together within a housing and electrically connected together by a busbar assembly to create a battery module. Furthermore, as will become apparent from the following description, in some embodiments a plurality of cells 100 may be mechanically joined together to form a cluster of cells, and a battery module may comprise one or more of such clusters of cells.
Figure 2 shows an exploded view of a battery module 200 according to an embodiment of the present invention. The battery module 200 comprises a plurality of electrical cells 202.
The electrical cells 202 may be the cylindrical cells 100 as shown in Figure 1. However, it will be appreciated that other types of electrical cell may also be implemented such as pouches, prismatic cells, capacitors or supercapacitors. In the embodiment shown in Figure 2, the cells 202 are cylindrical cells arranged with their positive terminals (i.e. first ends) directed downwards, and second ends directed upwards. The cells 202 are arranged into two rows of eleven cell clusters 203, so that 22 cell clusters are provided in total. However, it will be appreciated that in other embodiments alternative numbers and arrangements of cell clusters 203 may be provided. The cell cluster 203 comprises a plurality of the cylindrical cells 100 mechanically joined together via an adhesive on the cylindrical surfaces of the cells 100. In the embodiment of Figure 2 the cluster comprises thirty cylindrical cells though it will be appreciated by the skilled person that other numbers of cells may be useful. The adhesive preferably has a thickness of 0.5mm or less, in order to reduce a packaging size of the cell cluster 300. At its narrowest point, the adhesive has a thickness of between Omm and 0.5mm, preferably between 0.2mm and 0.4mm. In the illustrated embodiment, the thickness of the adhesive is approximately 0.3mm. It will be understood that the diameter of the cells 100 may not be controlled to a very high dimensional tolerance. Accordingly, the thickness of the layer of adhesive between adjacent cells 100 may vary depending upon the actual dimensions of the cells, and this allowable variation may help to mitigate the effects of the dimensional tolerance of the cells 100 on the overall dimensional tolerance of the cell cluster 300. Some of the cells 100 in the cluster may thus have a point of contact, i.e. be touching. Each cell cluster 203 is wrapped with an electrically-insulating material 218, to help to ensure that unwanted electrical connections between the negative terminals of cells in adjacent clusters do not occur.
A cell carrier component 205 is provided to locate each cell cluster 203 within a housing (not shown), and to provide the required spacing between adjacent cell clusters 203.
Alternatively, the cell clusters 203 may be located within the housing to achieve a particular spacing with use of a jig apparatus. In this case, the component 205 may comprise an adhesive to bond the cell clusters 203 once spaced. The cell carrier component 205 may in some embodiments also locate at least part of a single-sided internal busbar 216 adjacent to the first end surfaces of the cells 202. In other embodiments, the single-sided busbar 216 may be located adjacent to the first end surfaces of the cells 202 by a jig apparatus and welded or otherwise secured in position. The internal busbar 216 may be so named to distinguish it from module-connecting busbars arranged to electrically connect a plurality of battery modules within a pack. Although various configurations of single-sided busbar are possible, the internal busbar 216 shown comprises a positive collection plate having a plurality of tabs connected to the positive terminals of each of the cells 202, and a negative collection plate contacting the negative terminals of each of the cells 202. As shown, the cells 202 of a cell cluster 203 are all connected in parallel by the internal busbar 216. Each cell cluster 203 may then be connected in series with its neighbouring cell clusters 203 by connecting a negative collection plate connected to one cell cluster 203 to a positive collection plate connected to an adjacent cell cluster 203 (not shown).
A support component 222 is provided to support the battery module 200 within the housing. The support component 222 comprises a plurality of apertures 223, each aperture being positioned so as to be aligned with and adjacent to the first end of a respective cell 202 in the assembled battery module 200, so as to allow gases to pass through the support component 222 should a cell undergo a venting event. Although the housing is not visible in Figure 2, it will be understood that the support component 222 is configured to maintain a predetermined spacing between the cells 202 and the lower inside surface of the housing, such that a vent volume is provided underneath the cells. An exhaust port is also provided in the housing to allow gases to escape from the vent volume. The vent volume provides a volume in which vent gases can expand and cool, thereby reducing the risk that a venting event in an individual cell will damage other cells and potentially cause them to also undergo venting events. Although not illustrated in Figure 2, it will be understood that in some embodiments the assembled battery module 200 may also include one or more protective layers located in each of the apertures 223 in the support component 222. The protective layers may be arranged to rupture when the cell they are attached to undergoes a venting event but remain intact when a neighbouring cell undergoes a venting event. In this way the protective layers may prevent vent gases from entering the space between the cells 202. The protective layers may comprise one or more layers of an electrically insulating material such as mica or a mica-based material sheet or film. Other electrically insulating materials may also be used.
Cooling of the cells 202 is provided by cooling plate 260, which is arranged in the battery module 200 to be in contact with the second ends of the cells 202 (i.e. the end of the cells opposite the positive terminal) via a layer of thermal interface material 214. The cooling plate 260 comprises a plurality of channels through which a liquid coolant may flow, thereby cooling the cells 202. In some embodiments, the cooling plate 260 provides an upper surface of the housing. Structural members 215 may be provided to ensure that the cooling plate 260 has the required stiffness to form part of the housing.
A plurality of battery modules, such as the battery module 200, may be connected together to form a battery pack. Module terminals (not shown) may be disposed on the module housing to provide an electrical connection to the cell clusters 203. Battery modules 200 may then be electrically connected in series or parallel within a battery pack by connecting the module terminals of adjacent battery modules 200 with module connecting busbars.
With reference to Figures 3A and 3B, there is shown a battery module 200 according to the present invention in conjunction with its module housing 300. Figure 3A illustrates the battery module 200 from an angle above the cooling plate 260 of Figure 2. Figure 3B illustrates an end portion from the underside of the battery module 200 from an angle below the support component 222 of Figure 2.
The module housing 300 comprises a frame within which the components of Figure 2 are located. The module housing 300 comprises a first end 310, a second end 320, and a module housing body extending between the first end 310 and the second end 320. An upper surface of the housing body may be provided by the cooling plate 260, as shown. For reference, a longitudinal axis L of the battery module 200 extends between the first end 310 and second end 320. The module housing 300 contains the electrical cells 202 arranged in a plurality of cell clusters 203 as discussed in relation to Figure 2. A respective row of eleven cell clusters 203 lies on either side of the longitudinal axis L. A first end connector portion 330 is disposed at the first end 310 of the module housing 300 and a second end connector portion 340 (only partially visible) is disposed at the second end 340 of the module housing 300. One or both of the first end connector portion 330 and the second end connector portion may be configured to receive a module connecting busbar for electrically connecting the battery module 200 within a pack. A positive terminal for the battery module and a negative terminal for the battery module may each be situated at one of the first end connector portion 330 and second end connector portion 340. The positive terminal may be defined by an electrical connection to the positive collection plate of an internal busbar 216, and the negative terminal may be defined by an electrical connection to the negative collection plate of an internal busbar 216. The location of each terminal will be dependent on the internal configuration of the battery module 200, as will be explained.
A harness 400 for the module 200 is provided along a surface of the battery module adjacent to the internal busbars 216. The harness 400 extends between the first end 310 and the second end 320 of the module 200 along the longitudinal axis L and provides configurable circuitry for selectively connecting and monitoring predetermined cell clusters 203, as will be explained with reference to Figures 4 and 5.
Figure 4A illustrates a harness 400 for the battery module 200 in a first configuration. The harness 400 has been shortened in this figure for ease of illustration in comparison to the battery module 200 illustrated in Figure 2. The harness 400 may be adapted to fit battery modules 200 of different dimensions.
The harness 400 comprises a first fastening portion 410 configured to retain the harness 400 to the first end 310 of the battery module 200 and a second fastening portion 420 configured to retain the harness 400 to the second end 320 of the battery module 200. Each of the first fastening portion 410 and the second fastening portion 420 may comprise a retention clip for clipping to the first end connector portion 330 and second end connector portion 340 respectively. Alternative fastening mechanisms may be provided; however, a clip-on connection facilitates ease of construction of the battery module 200 and removal for servicing. A harness body 430 extends between the first fastening portion 410 and the second fastening portion 420. When the harness 400 is attached to the battery module 200, the harness body 430 is configured to extend along the longitudinal axis L of the battery module 200.
Figure 4B illustrates the harness 400 in use with a portion of a battery module 200. The harness body 430 lies coplanar and adjacent to a lower face of the vehicle battery module 200 extending between the first end 310 and the second end 320. The battery module 200 comprises a first cluster 203-A of electrical cells and a second cluster 203-B of electrical cells disposed on either side of the longitudinal axis L of the battery module 200. The first cluster 203-A is connected in parallel by a first internal busbar 216 (not shown) and the second cluster 203-B is connected in parallel by a second internal busbar 216 (not shown). Although the battery module 200 may comprise further cell clusters 203 as shown in Figure 2, only four are shown in Figure 4B to illustrate the arrangement of the harness 400. The further cell clusters 203 may be analogously arranged in pairs, such that each pair lie adjacent to each other at the longitudinal axis L. In the example shown, the longitudinal axis L extends between a midpoint of the first end 310 and a midpoint of the second end 320. Thus, the harness 400 is disposed centrally along the vehicle battery module 200.
The harness body 430 comprises a configurable connector portion 440 disposed to bridge the longitudinal axis L between the first cell cluster 203-A and the second cell cluster 203-B.
The configurable connector portion 440 may be configurable for tailoring the battery module to provide a given voltage, by selectively providing an electrical connection between the first cluster 203-A and the second cluster 203-B. The configurable connector portion 440 comprises a first conducting tab 442 arranged to be in electrical contact with the first cluster 203-A, and a second conducting tab 444 arranged to be in electrical contact with the second cluster 203-B. The conducting tabs 442, 444 may not be arranged directly in contact with a cell, but rather can be electrically connected to the cells indirectly via the positive or negative collection plate of the respective internal busbar 216. The conducting tab 442, 444 may be welded or otherwise secured to the positive or negative collection plate of the respective internal busbar 216. As each cell in a given cluster 203 is connected in parallel by the internal busbar 216, the conducting tab 442, 444 can thus be configured to be electrically connected to all cells in the respective cluster. Each conducting tab 442, 444 may be made of any suitably conducting material, such as copper. The conducting tabs 442, 444 may be arranged to be in electrical contact either with the positive terminals 100P of the cells via the positive collection plate or the negative terminals 100N of the cells via the negative collection plate. If the conducting tabs 442, 444 are each arranged to be in contact with the same terminal type, i.e. both positive or both negative, a parallel connection between the cell clusters 203-A, 203-B can be facilitated as will be explained.
In the first configuration shown in Figures 4A and 4B, the configurable connector portion 440 receives an electrical connector 446 providing a conducting path between the first conducting tab 442 and the second conducting tab 444, and thus electrically connecting the first cluster 203-A and the second cluster 203-B across the longitudinal axis in parallel. That is, by providing the electrical connector 446 on the configurable connector portion 440, the configurable connector portion 440 acts as a busbar electrically joining the first cluster 203-A and second cluster 203-B. When the first cluster 203-A and the second cluster 203-B are joined in parallel, they function as a single cell cluster 203.
With reference to Figures 4C and 4D, the electrical connections internal to the battery module 200 when arranged in the first configuration are illustrated. Figure 4C illustrates the resultant terminal arrangement of the battery module 200 in the first configuration, and Figure 4D illustrates a circuit diagram for the module 200 in the first configuration. As shown, the battery module comprises a first row of first clusters 203-A and a second row of second clusters 203-B disposed on either side of the longitudinal axis, arranged in pairs across the longitudinal axis as has been explained. The first row and the second row are symmetrically arranged about the longitudinal axis, and each row is connected in series through the internal busbars 216. The electrical connectors 446 provide a conducting path between the internal busbars 216 to connect each pair of a first cluster 203-A and a second cluster 203-B in parallel. A positive terminal 330-P for the battery module is provided on the first end connector portion 330 and a negative terminal 330-N for the battery module is provided on the second end connector portion 340. The positive collection plate of the internal busbar 216 of a first cluster 203-A and a second cluster 203-B are each connected to the first end connector portion 330 to provide a positive terminal 330-P. At the second end 320 of the module, the negative collection plate of an internal busbar 216 of a first cluster 203-A and a second cluster 203-B is connected to the second end connector portion 340 to provide a negative module terminal 340-N. The circuit diagram of Figure 4D (and also Figure 5D) show each cluster 203-A, 203-B comprising 4 cells in parallel for illustration purposes, though thirty cells ('x30') may be present in an embodiment. Other numbers of cells are useful. For example there may be more cells in a cluster if the energy capacity of each cell is relatively small, or fewer cells in each cluster if the energy capacity of each cell is relatively large. Pouch or prismatic cells tend to have higher energy capacity than cylindrical cells.
The configurable connector portion 440 can be arranged in a second configuration as illustrated in Figures 5A and 5B. In the second configuration, the electrical connector 446 is absent from the configurable connector portion 440. In the second configuration, the configurable connector portion 440 is thus arranged such that the first cluster 203-A is insulated from the second cluster 203-B at the longitudinal axis L. That is, the configurable connector portion 440 provides no electrical connection between the first cluster 203-A and the second cluster 203-B.
A configurable connector portion 440 can be provided on the harness body 430 at each location on the longitudinal axis L wherein a pair of cell clusters 203 lie adjacent, thus providing a configurable connection between each respective pair.
Therefore, the configurable connector portions 440 provide a resource efficient manner by which the voltage output of a battery module 200 can be adjusted during manufacture. By selectively including or omitting the electrical connector 446 for each pair of cell clusters 203-A, 203-B, a parallel connection between adjacent cell clusters 203-A, 203-B can be selectively made or prevented. If the cell clusters 203 of the module 200 are connected in series by the internal busbars 216, then including the electrical connector 446 for each pair of cell clusters 203 effectively halves the number of cell clusters 203 in the module, and halves the voltage output from the module. In this way, a battery pack may be flexibly switched from a first voltage output (e.g. 400V) to a second voltage output (e.g. 800V) by removing the electrical connectors 446 from the harness 400 of each battery module 200, without necessitating any change to the number or size of the battery modules 200.
Thus, a battery module can be readily adapted to provide a different voltage output with only a minor adjustment in the configurable connector portions 440 of the harness 400, and an adjustment to the orientation of the electrical connections within the battery module 200 as will be explained.
With reference to Figures 5C and 5D, the electrical connections internal to the battery module 200 when arranged in the second configuration are shown. Figure 50 illustrates the resultant terminal arrangement of the battery module 200 in the second configuration, and Figure 5D illustrates a circuit diagram for the module 200 in the second configuration. In the second configuration, a positive terminal for the battery module and a negative terminal for the battery module are each provided at the same end of the battery module, as illustrated here on the second end connector portion 340. The second end connector portion is thus divided into two sub-portions 340-P and 340-N, which are electrically insulated from each other to prevent short circuiting of the module. A first sub-portion 340-P defines the positive terminal of the battery module 200 and is electrically connected to a positive connection plate of an internal busbar 216 of a first cluster 203-A in the first row. A second sub-portion 340-N defines the negative terminal of the battery module 200 and is electrically connected to a negative connection plate of an internal busbar 216 of a second cluster 203-B in the second row.
As shown, in the second configuration the internal busbars 216 are arranged to provide a continuous series connection from the positive terminal 340-P along the first row of clusters 203-A and back along the second row of clusters 203-B to the negative terminal 340-N. An additional internal busbar 502 is situated at the first end 310 of the battery module 200 to connect the first row of clusters 203-A and the second row of clusters 203-B in series.
The electrical configuration of the first row of clusters 203-A is reversed in comparison to the second row of clusters 203-B, as shown. That is, the orientation of the positive and negative collection plates of the internal busbars 216 of the first row of clusters 203-A is opposite to that of the second row of clusters 203-B in order to provide the continuous series connection. As will be appreciated, the arrangement of the second configuration as shown in Figures 50 and 5D provides double the voltage output across the module terminals than that provided by the arrangement of the first configuration as shown in Figures 40 and 4D.
Thus, it will be appreciated that to switch from the first configuration to the second configuration, in addition to removing the electrical connectors 446, the orientation of the first clusters 203-A in the first row should be reversed, and an additional busbar 502 should be provided at the first end 310 of the module 200 to facilitate a series connection between the rows.
It can be advantageous to monitor module parameters throughout the battery module 200, to ensure the module parameters throughout the battery module 200 are within safe operating limits. The module parameters may include a temperature or an electrical parameter, such as a voltage. The module parameters may vary spatially throughout the battery module 200 and so measurements may be taken at predetermined locations throughout the battery module 200, for example measurements may be taken for each cell cluster 203. Sensing elements may thus be provided adjacent to each cell cluster 203 and transmit electrical signals indicative of the measurements taken to a battery module controller. The battery module controller may be called a cell supervision circuit (CSC) in some examples. In some examples the CSC may perform some computation in dependence on the received signals, for example to determine whether the module parameter indicated by is within a safe operating range.
The harness 400 is configured to integrate one or more sensing elements on the harness body 430 to facilitate the monitoring of the battery module 200. The harness body 430 is provided with electrical tracks (not shown) extending between the sensing elements along the length of the harness body 430. The harness body 430 may comprise a flexible printed circuit board (PCB) to mount the electrical tracks and provide an insulating support layer between the electrical tracks and the other elements of the battery module 200. A connector is provided at the terminus of the tracks at the first or second fastening portion 410, 420 and is configured to provide a connection to the CSC and provide electrical signals indicative of measurements taken by the sensing elements to the CSC.
The sensing elements may comprise a voltmeter for measuring the voltage of one or more of the cell clusters 203. The arrangement of the voltmeter on the harness may vary between the first configuration and the second configuration. In the first configuration, as the electrical connector 446 provides a parallel connection between the first cluster 203-A and the second cluster 203-B, only one voltage measurement needs to be taken to effectively monitor the voltage of each cluster 203-A, 203-B. Thus, a voltmeter may be integrated with or otherwise in contact with the electrical connector 446 of each configurable connector portion 400, and thereby be configured to measure a common voltage of the first cluster 203-A and second cluster 203-B.
With reference to Figures 5A and 5B, in the second configuration, the first cluster 203-A and second cluster 203-B may have different voltages and thus a separate voltage measurement may be taken for each cluster. A first voltmeter may be provided on the first conducting tab 442 to measure a voltage of the first cluster 203-A and a second voltmeter may be provided on the second conducting tab 444 to measure a voltage of the second cluster 203-B. Each voltmeter is electrically connected to the tracks of the harness body 430 in order to transmit signals to the CSC.
The sensing elements may comprise a thermistor for measuring the temperature of one or more of the cell clusters 203. The harness body 430 may comprises a plurality of thermistor housing portions 450 along the length of the harness 400. Each thermistor housing portion 450 is configured to retain a thermistor and may comprise a pocket bonded to the harness body 430. The pocket may be bonded on an interior face of the harness body 430, i.e. the face of the harness body 430 adjoining the cell clusters 203. Each housing portion 450 is arranged such that when a thermistor is housed therein, the thermistor may be electrically connected to the tracks of the harness body 430 for transmitting an electrical signal to the CSC. A thermistor may then be disposed in at least one of the thermistor housing portions 450 to measure a temperature of a cell cluster 203.
As shown in Figures 4 and 5, the harness body 430 comprises gaps 460. The gaps 460 are arranged to expose an end of one or more of the electrical cells 202 of the battery module 200 to facilitate venting. Furthermore, the gaps 460 may facilitate the potting of an anti-thermal propagation compound over the ends of the cells 100. The size and shape of the gaps 460 may vary to facilitate the mounting of the electrical tracks, configurable connector portions 440 and thermistor housing portions 450. At least some of the gaps 460 may be larger than a cross-sectional area of a cylindrical cell 100. It can be beneficial to provide large gaps 460 to improve ventilation and also to reduce the weight of the battery module 200 by keeping the harness 400 as compact and light as possible. For the same reason, the alignment of the harness along the longitudinal axis L bridging the two rows of cell clusters 203 facilitates the harness body 430 being kept narrow, i.e. the harness 400 does not need to extend substantially across the lower face of the housing 300.
A vehicle 600 in accordance with an embodiment of the present invention is illustrated in Figure 6. The battery module 200 may be provided in the vehicle 600.
With reference to Figure 7, there is provided a method 700 of manufacturing a vehicle battery module 200. The method 700 comprises a block 710 of providing a battery module body 200. The battery module body 200 may be that described with reference to Figures 2 and 3, comprising a first end 310, a second end 320 and a module housing 300 extending between the first end 310 and the second end 320. The battery module body 200 comprises a first cluster of electrical cells 203-A connected in parallel by a first internal busbar and disposed in the module housing 300 on a first side of the longitudinal axis L, and a second cluster of electrical cells 203-B connected in parallel by a second internal busbar and disposed in the module housing on a second side of the longitudinal axis L. The method 700 comprises a block 720 of providing a harness 400. The harness 400 may be the harness 400 described with reference to Figures 4A and 5A and comprise a harness body 430 extending between a first fastening portion 410 and a second fastening portion. The method 700 comprises a block 730 fixing the first conducting tab 442 and the second conducting tab 444 to the harness body. The first conducting tab 442 and the second conducting tab 444 may be bonded to the harness body 430 at predefined locations and may be connected to the electrical tracks of the harness body 430, to provide signals from a voltmeter as discussed. The block 730 may further comprise extending the harness body 430 across the module housing 300 and securing the first fastening portion 410 to the first end 310 of the module housing and securing the second fastening portion 420 to the second end 320 of the module housing. The method 700 comprises a block 740 of laser welding the first conducting tab 442 to the module 200 to provide an electrical connection to the first cell cluster 203-A.
The first conducting tab 442 may be welded to a collection plate of the first internal busbar 216 associated with the cell cluster 203-A thus providing an indirect electrical connection to the first cell cluster 203-A. The method 700 comprises a block 750 of laser welding the second conducting tab 444 to the module 200 to provide an electrical connection to the second cell cluster 203-B. The second conducting tab 444 may be welded to a collection plate of the second internal busbar 216 associated with the cell cluster 203-B thus providing an indirect electrical connection to the second cell cluster 203-B. Laser welding the conducting tabs 442, 444 is beneficial for the joint because it is precise and is suitable for fast automated processes. However, alternative joining to laser welding may also be used, such as wire bonding, ultrasonic welding or soldering.
It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims (16)

  1. CLAIMS1. A harness for a vehicle battery module having a first cluster of electrical cells and a second cluster of electrical cells disposed on either side of a longitudinal axis extending between a first end of the vehicle battery module and a second end of the vehicle battery module, the harness comprising: a first fastening portion configured to retain the harness to the first end of the vehicle battery module; a second fastening portion configured to retain the harness to the second end of the vehicle battery module; a harness body extending between the first fastening portion and the second fastening portion along the longitudinal axis; the harness body comprising a configurable connector portion disposed to bridge the longitudinal axis; wherein the configurable connector portion is arranged to receive, in a first configuration, an electrical connector for connecting the first cluster and the second cluster in parallel across the longitudinal axis, and in a second configuration, insulate the first cluster from the second cluster at the longitudinal axis.
  2. 2. The harness of claim 1, wherein the configurable connector portion comprises a first conducting tab arranged to be in electrical contact with the first cluster and a second conducting tab arranged to be in electrical contact with the second cluster.
  3. 3. The harness of claim 2, wherein the electrical connector comprises a voltmeter in contact with the first conducting tab and the second conducting tab configured to measure a voltage of the first cluster and the second cluster.
  4. 4. The harness of claim 2 or 3, wherein the configurable connector portion is arranged to receive, in the second configuration, a first voltmeter in contact with the first conducting tab configured to measure a voltage of the first cluster and a second voltmeter in contact with the second conducting tab configured to measuring a voltage of the second cluster.
  5. 5. The harness of any preceding claim, wherein the harness comprises one or more sensing elements disposed on the harness body for monitoring the vehicle battery module.
  6. 6. The harness of claim 5, wherein the sensing elements comprise one or both of: a voltmeter for measuring the voltage of the first cluster or second cluster; or a thermistor for measuring a temperature of the first cluster or second cluster.
  7. 7. The harness of claim 5 or 6, wherein the harness comprises a connector at the first fastening portion or the second fastening portion and one or more electrical tracks along a length of the harness body for connecting the one or more sensing elements to a battery supervisory circuit.
  8. 8. The harness of claim 7, wherein the harness body comprises a flexible printed circuit board comprising the plurality of electrical tracks and an insulating support layer between the electrical tracks and the vehicle battery module.
  9. 9. The harness of any preceding claim, wherein the harness body comprises a thermistor housing portion configured to retain a thermistor for measuring a temperature of the first cluster or the second cluster.
  10. 10. The harness of claim 9, comprising a thermistor disposed in the thermistor housing portion.
  11. 11. The harness of any preceding claim, wherein the harness body is configured to lie coplanar and adjacent to a face of the vehicle battery module extending between the first end and the second end.
  12. 12. The harness of any preceding claim, wherein the harness body comprises one or more gaps arranged to expose an end of one or more of the electrical cells.
  13. 13. The harness of claim 12, wherein the harness body comprises an anti-thermal propagation compound in the one or more gaps. 30
  14. 14. A vehicle battery module, comprising a first end, a second end and a module housing extending between the first end and the second end; a first cluster of electrical cells connected in parallel and disposed in the module housing on a first side of a longitudinal axis extending between the first end and the second end; a second cluster of electrical cells connected in parallel and disposed in the module housing on a second side of the longitudinal axis; and a harness according to any of claims 1 to 13.
  15. 15. A vehicle comprising a harness according to any of claims 1 to 13 or a vehicle battery module according to claim 14.
  16. 16. A method of manufacturing a vehicle battery module according to claim 14, comprising: providing a battery module body comprising a first end, a second end and a module housing extending between the first end and the second end, a first cluster of electrical cells connected in parallel by a first internal busbar and disposed in the module housing on a first side of a longitudinal axis extending between the first end and the second end, and a second cluster of electrical cells connected in parallel by a second internal busbar and disposed in the module housing on a second side of the longitudinal axis; providing a harness according to any of claims 1 to 13; fixing a first conducting tab and a second conducting tab to the harness body; and laser welding the first conducting tab to the first internal busbar; and laser welding the second conducting tab to the second internal busbar.
GB2116295.3A 2021-11-12 2021-11-12 Harness for battery module Pending GB2612806A (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013180158A1 (en) * 2012-05-29 2013-12-05 株式会社オートネットワーク技術研究所 Battery wiring module
US20190283611A1 (en) * 2018-03-14 2019-09-19 GM Global Technology Operations LLC Modular battery pack system with series and parallel charging and propulsion modes
WO2020001806A1 (en) * 2018-06-27 2020-01-02 Ihi Charging Systems International Gmbh Control device for an exhaust-gas-conducting section of a turbocharger

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2013180158A1 (en) * 2012-05-29 2013-12-05 株式会社オートネットワーク技術研究所 Battery wiring module
US20190283611A1 (en) * 2018-03-14 2019-09-19 GM Global Technology Operations LLC Modular battery pack system with series and parallel charging and propulsion modes
WO2020001806A1 (en) * 2018-06-27 2020-01-02 Ihi Charging Systems International Gmbh Control device for an exhaust-gas-conducting section of a turbocharger

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