Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R35/00—Flexible or turnable line connectors, i.e. the rotation angle being limited
  • H01R35/02—Flexible line connectors without frictional contact members
• • 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
  • 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
  • H01M10/482—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for several batteries or cells simultaneously or sequentially
• • 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
  • H01M50/505—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising a single busbar
• • 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
  • H01M50/521—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the material
  • H01M50/522—Inorganic material
• • 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

Definitions

• the subject matter disclosed herein relates to battery systems and, more particularly, to battery systems where the state of charge of each battery cells in a connected group of batteries is monitored, and more particularly to battery systems in electric or hybrid electric vehicles.
• Hybrid electric vehicles are vehicles that include both an internal combustion engine (ICE) and an electric motor. Such vehicles can, in some instances, provide greater fuel economy than a vehicle that includes only an ICE. Full electrical vehicles have only one or multiple electrical motors.
• the electric motor receives power from a battery unit.
• the battery unit typically includes two or more serially connected battery cells.
• the number of battery cells can be in the hundreds.
• each cell can be monitored individually. For instance, monitoring each cell during charging operations can increase safety.
• knowledge of the charge in the cells can be used to predict vehicle range or lifetime of the cells themselves.
• the cells are serially connected to one another to form the battery unit. Then, sensor wires are connected to the terminals of each cell. The sensor wires are then bundled together by a harness that is mounted on top of the cells. This approach, while effective, can be slow and prone to connection errors.
• a multilayer busbar for connecting a plurality of battery cells includes a cell connection layer including a plurality of conductor plates arranged to serially connect the plurality of battery cells and a flexible circuit layer including a substrate having a plurality of measurement lines formed on it.
• the measurement lines are arranged to connect to a positive and a negative connection location on at least two of the plurality of battery cells.
• a battery system for a vehicle includes a plurality of battery cells and a multilayer busbar for connecting the plurality of battery cells.
• the busbar includes a cell connection layer including a plurality of conductor plates arranged to serially connect the plurality of battery cells and a flexible circuit layer including a substrate having a plurality of measurement lines formed on it. The measurement lines are arranged to connect to a positive and a negative connection location on at least two of the plurality of battery cells.
• the busbar also includes an insulating layer disposed between the conductor plates and the flexible circuit layer.
• FIG. 1 is a top view of a battery compartment that includes a plurality of serially connected battery cells
• FIG. 2 is a line diagram illustrating a flexible circuit according to one embodiment.
• FIG. 3 illustrates an exploded view of a multilayer busbar according to one embodiment of the present invention.
• a battery enclosure 100 that contains a battery system 101.
• the battery enclosure 100 and battery system 101 can be located, for example, in a hybrid electric vehicle (HEV) or a full electric vehicle. In other instances, the battery enclosure 100 and/or the battery system 101 could be in any type of device that includes batteries such as, for example, a wind turbine.
• the battery system 101 includes a plurality of serially connected battery cells (cells) 102a- 102d. The cells will collectively be referred to as cells 102 from time to time herein. As illustrated, the battery system 101 includes four cells 102a-102d. Of course, the number of cells 102 in the system 101 can be any number greater than one. As illustrated, all the cells 102 are included in a single battery enclosure 100. In some instances, additional cells 102 could be located in different enclosures (not shown).
• the battery system 101 can provide an output voltage Vout- In some cases, V ou t can be provided to an electric motor in an HEV.
• Each illustrated cell 102a-102d includes a pair of positive terminals 104 and a pair of negative terminals 106.
• cell 102a includes a pair of positive terminals 104a and a pair of negative terminals 106a
• cell 102b includes a pair of positive terminals 104b and a pair of negative terminals 106b
• cell 102c includes a pair of positive terminals 104c and a pair of negative terminals 106c
• cell 102d includes a pair of positive terminals 104d and a pair of negative terminals 106d.
• each cell 102 need not a pair of either positive or negative terminals. That is, each cell could include any number of terminals as long as it provides at least one positive connection point and one negative connection point. As illustrated, the paired positive 104 and negative terminals 106 on each cell 102 are provided as redundant failsafe connections.
• FIG. 1 has each cell 102 arranged in an opposite orientation than at least one neighboring cell 102.
• the negative terminals 106a are arranged adjacent to the positive terminals 104b and the negative terminals 106b are arranged adjacent positive terminals 104c and so on.
• the terminals 104, 106 of one cell are connected to the terminals 104, 106 of an adjacent cell by one or more conductor plates 108.
• the negative terminals 106a of cell 102a are connected to the positive terminals 104b of cell 102b by conductor plate 108a-b
• the negative terminals 106b of cell 102b are connected to the positive terminals 104c of cell 102c by conductor plate 108b-c
• the negative terminals 106c of cell 102c are connected to the positive terminals 104d of cell 102d by conductor plate 108c-d.
• connection scheme provides for the serial connection of cells 102a- 102d and provides for output voltage V ou t between the positive terminals 104a of cells 102a and negative terminals 106d of cell 106d. While designated as V ou t it shall be understood the cells 102 can be charged by application of a voltage/current across the positive terminals 104a of cells 102a and negative terminals 106d of cell 106d.
• V ou t it shall be understood the output voltage V out can be presented as separate connection or can be included in a pin-connector or other type of connector element. In addition, the output voltage V out could be included in a connector element that includes other electrical connections.
• the conductor plates 108 can be made of different types of conductive metals, for example stainless steel, copper, aluminum, zinc, iron, transition metals, and alloys including at least one of the foregoing.
• the conductor plates 108 are formed of metal that is plated with tinplating or nickelplating.
• the thickness of the conductor plates 108 can have any thickness, shape, size or texture depending on the context.
• the conductor plates 108 can have any number of holes formed therein depending on the number and location of terminals 104, 106 on the cells 102. In one embodiment, the holes may include dishing and/or bushings disposed therein to level contact points between the conductor plates 108.
• some or all of the conductor plates 108 can be included in one of, or enclosed between, the layers of a multilayer busbar.
• wires were coupled to the terminals 104, 106 to allow for the charge in each cell 102 to be measured. These wires were then bundled together and, as such, took up space in the battery compartment.
• FIG. 2 illustrates measurement lines 202, 204, 206 and 208 that could be connected to different terminals of one or more cells 102.
• the cells 102 are not shown in FIG. 2 but it shall be understood that the cells could be configured as shown in FIG. 1, for example.
• each of the conductor plates 108a-b, 108b-c and 108c-d include holes 201 sized to allow cell terminals to pass through them.
• a flexible circuit 200 is provided that can be displaced either above or below the conductor plates 108 relative to the cells.
• the flexible circuit 200 includes measurement lines 202, 204, 206 and 208 formed thereon.
• the flexible circuit 200 can include a substrate layer 203.
• the measurement lines 202-208 can be formed on one or both sides of the substrate layer 203.
• the substrate layer 203 can be formed, for example, of polyesters such as certain liquid crystal polymers (LCP), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and the like; fluorinated polymers and copolymers such as polytetrafluoroethylene (PTFE), polyimide (PI), polyetherimide (PEI), and epoxy.
• LCP liquid crystal polymers
• PET polyethylene terephthalate
• PEN polyethylene naphthalate
• PTFE polytetrafluoroethylene
• PI polyimide
• PEI polyetherimide
• the required number of measurement lines can be formed and arranged such they include connection ends 230 that overlie where the holes 201 will exist when placed on top of battery cells.
• the other end of the measurement lines can be coupled to a connector 210 in one embodiment.
• the connector 210 can be formed in or coupled to the substrate 203 in one embodiment
• the measurement lines 202-208 provide a connection mechanism for a device (not shown) to monitor the charge or other parameter of the cells to which the lines are connected.
• the flexible circuit 200 is overlaid over cells arranged as in FIG. 1, the voltage in cell 102b can be measured between measurement lines 202 and 204 and the voltage in cell 102c can be measured between measurement lines 206 and 208.
• the flexible circuit can include other measurement lines that are configured to connect to other portions of a cell such as, for example, a sensor or other output.
• one or more of the measurement lines 202-208 can include a redundant path 202'- 208' that couples to the redundant terminal.
• the measurement lines 202-208 are formed on a substrate, all of the lines are contained in a thin layer, do not need separate bundling, and operator connection error can be reduced or eliminated. With a knowledge of how the cells in a battery compartment are to be arranged, the particular configuration of the measurement lines 202-208 can be determined. As such, it shall be understood that the measurement lines can be laid out in any configuration and the configuration shown in FIG. 2 is merely by way of example.
• the flexible circuit 200 is physically separated from the conductor plates such that none of the measurement lines 202- 208 physically contact the conductor plates 108.
• the measurement lines 202-208 can have any thickness but generally may be 12, 18, 35 or 70 micrometers thick and can be formed of a conductive metal such as copper.
• the copper is plated with tin, gold, or combinations or allows thereof such as Ni-Au.
• the flexible circuit 200 can include a layer of cover coat or other insulator disposed on some or all of one or both of the sides of it.
• FIG. 3 illustrates an exploded view of a multilayer busbar 300 according to one embodiment.
• the multilayer busbar 300 is arranged and configured such that it includes a plurality of access holes 312 placed such that can allow terminals 104, 106 of cells 102 to pass through them. Such passage allows electrical elements in the multilayer busbar 300 to form electrical contact with the terminals 104, 106. Such contact can provide for serially coupling the cells 102 and for monitoring the voltage on each cell 102, for example.
• all of the layers 302-308 of the multilayer busbar 300 are sandwiched together and form a flexible unit. It will be understood, however, that the cells 102 may not include terminals 104, 106 as illustrated in FIG. 3. In such a case, other means, such as compressive polymer, can be included in the multilayer busbar to urge the electrical elements (e.g., wires 316 and/or connection plates 108) into electrical communication with the electrical connection locations on the cells 102.
• the electrical elements e.g., wires
• the illustrated multilayer busbar 300 includes outer layers 302 and 310 which serve to seal and encase the other layers.
• the outer layers 302 and 310 can be formed of adhesive coated insulation based on polyethylene tereftalate (PET), polyimide (PI) or polyethylene naphtalate (PEN) films It shall be understood, however, that one or both of the outer layers 302, 310 could be omitted.
• a cell connection layer 304 is adjacent outer layer 302 and includes one or more conductor plates 108. While the connection layer 304 is illustrated as a physical element that carries conductor plates 108, it shall be understood the connection layer 304 could only include the conductor plates 108. It shall further be understood that one or both of the outer layers 302, 310 could include cavities or cut outs arranged to receive the conductor plates 108. The conductor plates 108 can be arranged such that a flex region 314 exists between them to allow the multilayer busbar 300 to flex.
• a flexible circuit layer 308 includes a flexible circuit that includes measurement lines 316 formed therein.
• the flexible circuit layer 308 could be formed, for example, as described above with respect to the flexible circuit 200 of FIG. 2.
• the relative order of the layers 304-308 can vary from that shown in FIG. 3.
• the cell connection layer 304 could be below the flexible circuit layer 308.
• an insulating layer 306 is disposed between the cell connection layer 304 and the flexible circuit layer 308 so that the conductor plates 108 do not short any of the measurement lines 316 to one another.
• the cell connection layer 304 and the flexible circuit layer 308 are not bonded to each other. Rather, these layers could each be laid over the batteries and held together, for example, by fasteners that couple them to terminals on the batteries.
• the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Landscapes

• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Electrochemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Inorganic Chemistry (AREA)
• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Connection Of Batteries Or Terminals (AREA)
• Secondary Cells (AREA)
• Primary Cells (AREA)

Priority Applications (3)

Applications Claiming Priority (2)

Publications (2)

Family

ID=47669201

Family Applications (1)

Country Status (4)

Cited By (5)

Families Citing this family (3)

Family Cites Families (9)

• 2012
  • 2012-08-08 JP JP2014525109A patent/JP2014525649A/ja active Pending
  • 2012-08-08 CN CN201280038246.7A patent/CN103718341A/zh active Pending
  • 2012-08-08 EP EP12822814.5A patent/EP2742554A4/en not_active Withdrawn
  • 2012-08-08 WO PCT/US2012/049944 patent/WO2013022938A2/en active Application Filing

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events