Abstract:
Battery modules having interconnect members are provided. An interconnect member includes a first plate portion having a first thickness. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a first vibration dampening portion coupled to the first and second plate portions. The first vibration dampening portion has a third thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion to the second plate portion.

Description:
BACKGROUND 
     Battery modules have utilized interconnect members to electrically couple battery terminals together. However, when an interconnect member is ultrasonically welded to a battery terminal, the interconnect member may transmit vibrations therethrough which degrade prior weld joints on the interconnect member. 
     The inventors herein have recognized a need for an improved interconnect member that minimizes and/or eliminates the above-mentioned deficiency. 
     SUMMARY 
     An interconnect member for a battery module in accordance with an exemplary embodiment is provided. The interconnect member includes a first plate portion having a first thickness. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a first vibration dampening portion coupled to the first and second plate portions. The first vibration dampening portion has a third thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion to the second plate portion. 
     A battery module in accordance with another exemplary embodiment is provided. The battery module includes a first battery cell having at least a first terminal, and a second battery cell having at least a second terminal. The battery module further includes an interconnect member having a first plate portion having a first thickness that is welded to the first terminal. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness that is welded to the second terminal. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a first vibration dampening portion coupled to the first and second plate portions. The first vibration dampening portion has a third thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion to the second plate portion. 
     An interconnect member for a battery module in accordance with another exemplary embodiment is provided. The interconnect member includes a first plate portion having a first thickness. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a third plate portion having a third thickness equal to the first thickness. The third plate portion extends generally parallel to the second plate portion. The interconnect member further includes first and second first vibration dampening portions disposed generally perpendicular to the first, second, and third plate portions. The first vibration dampening portion is coupled to the first plate portion and the second vibration dampening portion. The second vibration dampening portion is coupled to the second plate portion and the third plate portion. The second vibration dampening portion has a fourth thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion and the second vibration dampening portion to the second plate portion. 
     A battery module in accordance with another exemplary embodiment is provided. The battery module includes a first battery cell having at least a first terminal. The battery module further includes a second battery cell having at least a second terminal. The battery module further includes a third battery cell having at least a third terminal. The battery module further includes an interconnect member having a first plate portion having a first thickness that is welded to the first terminal. The interconnect member further includes a second plate portion having a second thickness equal to the first thickness that is welded to the second terminal. The second plate portion extends generally parallel to the first plate portion. The interconnect member further includes a third plate portion having a third thickness equal to the first thickness that is welded to the third terminal. The third plate portion extends generally parallel to the second plate portion. The interconnect member further includes first and second first vibration dampening portions disposed generally perpendicular to the first, second, and third plate portions. The first vibration dampening portion is coupled to the first plate portion and the second vibration dampening portion. The second vibration dampening portion is coupled to the second plate portion and the third plate portion. The second vibration dampening portion has a fourth thickness greater than the first thickness, such that vibrations induced on the first plate portion are attenuated when a portion of the vibrations pass through the first vibration dampening portion and the second vibration dampening portion to the second plate portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic of a battery module having interconnect members in accordance with an exemplary embodiment; 
         FIG. 2  is a schematic of an interconnect member utilized in the battery module of  FIG. 1  in accordance with another exemplary embodiment; 
         FIGS. 3-12  are schematics of a plate member having plate portions that are folded to obtain the interconnect member of  FIG. 2 ; 
         FIG. 13  is a schematic of a portion of the interconnect member of  FIG. 2  illustrating vibration dampening portions; 
         FIG. 14  is a schematic of a welding horn and an anvil utilized to weld battery terminals to the interconnect member of  FIG. 2 ; 
         FIG. 15  is a schematic of another battery module having interconnect members in accordance with another exemplary embodiment; 
         FIG. 16  is a schematic of an interconnect member utilized in the battery module of  FIG. 15  in accordance with another exemplary embodiment; 
         FIGS. 17-24  are schematics of a plate assembly having plate portions that are folded to obtain the interconnect member of  FIG. 16 ; and 
         FIG. 25  is a schematic of a portion of the interconnect member of  FIG. 16  illustrating vibration dampening portions. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , a battery module  10  in accordance with an exemplary embodiment is illustrated. The battery module  10  includes battery cells  20 ,  22 ,  24 ,  26 ,  28 ,  30 ,  32 ,  34 , interconnect members  50 ,  52 ,  54 ,  56 ,  58 , and a housing  60 . An advantage of the battery module  10  is that the battery module  10  utilizes interconnect members that have vibration dampening portions to attenuate vibrations. As a result, when a battery terminal is ultrasonically welded to a region of the interconnect member, vibrations are attenuated in other regions of the interconnect member to reduce degradation of prior weld joints in other regions of the interconnect member. 
     Before describing the interconnect members in greater detail, a brief explanation of the battery cells  20 - 34  will be provided. The battery cells  20 - 34  have pouch shaped bodies (not shown) that are contained within the housing  60 . Each of the battery cells  20 - 34  further include a pair of terminals that are operably coupled to the pouch shaped bodies and extend out of the housing  60 . In particular, the battery cell  20  includes terminals  70 ,  72 , and the battery cell  22  includes terminals  74 ,  76 . Further, the battery cell  24  includes terminals  78 ,  80 , and the battery cell  26  includes terminals  82 ,  84 . Also, the battery cell  28  includes terminals  86 ,  88 , and the battery cell  30  includes terminals  90 ,  92 . Still further, the battery cell  32  includes terminals  94 ,  96 , and the battery cell  34  includes terminals  98 ,  100 . 
     The interconnect members  50 - 58  are provided to electrically couple the battery cells  20 - 34  in series with one another. In one exemplary embodiment, the interconnect members  50 - 58  are constructed of copper. Of course, in alternative embodiments, other bendable electrically-conductive materials known to those skilled in the art could be utilized to construct the interconnect members  50 - 58 . The interconnect member  50  is electrically coupled to terminals  70 ,  74 ,  78 ,  82  via weld joints; the interconnect member  52  is electrically coupled to terminals  86 ,  90 ,  94 ,  98  via weld joints; and the interconnect member  54  is electrically coupled to terminals  80 ,  84 ,  88 ,  92  via weld joints. Finally, the interconnect member  56  is electrically coupled to terminals  72 ,  76  via weld joints, and the interconnect member  58  is electrically coupled to terminals  96 ,  100  via weld joints. 
     The interconnect members  50 ,  52 ,  54  have a substantially similar structure in accordance with an exemplary embodiment. Accordingly, only the structure of the interconnect member  50  will be described in greater detail below. 
     Referring to  FIGS. 3-12 , a process of folding plate portions of a plate member  51  to construct the interconnect member  50  will be explained. 
     Referring to  FIG. 3 , the plate member  51  includes plate portions  120 ,  122 ,  124 ,  126 ,  128 ,  130 ,  132 ,  134 ,  136 ,  138  and bendable regions  140 ,  141 ,  142 ,  144 ,  145 ,  146 ,  148 ,  149 ,  150 . As shown, initially, the plate portions  120 - 138  are disposed substantially co-planar with one another. Each of the plate portions  120 - 138  have a same thickness. 
     Referring to  FIG. 4 , during a first bending step, a user bends the plate portion  120  about the bendable region  140  such that the plate portion  120  is disposed substantially perpendicular to the plate portion  122 , and the plate portion  120  extends in a first direction. 
     Referring to  FIG. 5 , during a second bending step, the user bends the plate portion  122  about the bendable region  141  such that the plate portion  122  contacts the plate portion  124 , and the plate portion  120  is disposed in a second direction opposite to the first direction. 
     Referring to  FIG. 6 , during a third bending step, the user bends the plate portion  124  about the bendable region  142  such that the plate portion  124  is disposed perpendicular to the plate portion  126 , and the plate portion  120  is disposed parallel to the plate portion  126 . 
     Referring to  FIG. 7 , during a fourth bending step, the user bends the plate portion  126  about the bendable region  144  such that the plate portion  126  is disposed perpendicular to the plate portion  128 . 
     Referring to  FIG. 8 , during a fifth bending step, the user bends the plate portion  130  about the bendable region  145  such that the plate portion  130  contacts the plate portion  128 . 
     Referring to  FIG. 9 , during a sixth bending step, the user bends the plate portion  138  about the bendable region  150  such that the plate portion  138  is disposed perpendicular to the plate portion  136 . 
     Referring to  FIGS. 8 and 10 , during a seventh bending step, the user bends the plate portion  136  about the bendable region  149  such that the plate portion  136  contacts the plate portion  134 . 
     Referring to  FIG. 11 , during an eighth bending step, the user bends the plate portion  136  about the bendable region  148  such that the plate portion  136  is perpendicular to the plate portion  132 . 
     Referring to  FIG. 12 , during a ninth bending step, the user bends the plate portion  132  about the bendable region  146  such that the plate portion  132  is disposed parallel to the plate portion  126 , to obtain the interconnect member  50 . 
     Referring to  FIGS. 12-14 , the interconnect member  50  has vibration dampening portions  160 ,  162 ,  164 . The vibration dampening portions  160 ,  162 ,  164  attenuate vibrations that can occur during ultrasonic welding of battery terminals to the plate portions  120 ,  126 ,  132 ,  138  utilizing the ultrasonic horn  180  and the anvil  182 . For example, when a battery terminal is ultrasonically welded to the plate portion  138 , the vibration dampening portion  164  attenuates the vibrations before the vibrations reach the plate portion  132 . The vibration dampening portion  162  further attenuates the vibrations before the vibrations reach the plate portion  126 . Further, the vibration dampening portion  160  further attenuates the vibrations before the vibrations reach the plate portion  120 . 
     The vibration dampening portion  160  comprises plate portions  122 , 124  disposed between and coupled to the plate portions  120 ,  126 . The vibration dampening portion  160  has a thickness that is twice as thick as a thickness of each of the plate portions  120 ,  126 . 
     The vibration dampening portion  162  comprises plate portions  128 ,  130  disposed between and coupled to the plate portions  126 ,  132 . The vibration dampening portion  162  has a thickness that is twice as thick as a thickness of each of the plate portions  126 ,  132 . 
     The vibration dampening portion  164  comprises plate portions  134 ,  136  disposed between and coupled to the plate portions  132 ,  138 . The vibration dampening portion  164  has a thickness that is twice as thick as a thickness of each of the plate portions  132 ,  138 . 
     Referring to  FIG. 15 , a battery module  210  in accordance with another exemplary embodiment is illustrated. The battery module  210  includes battery cells  220 ,  222 ,  224 ,  226 ,  228 ,  230 ,  232 ,  234 , interconnect members  250 ,  252 ,  254 ,  256 ,  258 , and a housing  260 . An advantage of the battery module  210  is that the battery module  210  utilizes interconnect members that have vibration dampening portions to attenuate vibrations. As a result, when a battery terminal is ultrasonically welded to a region of the interconnect member, vibrations are attenuated in other regions of the interconnect member to reduce degradation of prior weld joints in other regions of the interconnect member. 
     Before describing the interconnect members in greater detail, a brief explanation of the battery cells  220 - 234  will be provided. The battery cells  220 - 234  have pouch shaped bodies (not shown) that are contained within the housing  260 . Each of the battery cells  220 - 234  further include a pair of terminals that are operably coupled to the pouch shaped bodies and extend out of the housing  260 . In particular, the battery cell  220  includes terminals  270 ,  272 , and the battery cell  222  includes terminals  274 ,  276 . Further, the battery cell  224  includes terminals  278 ,  280 , and the battery cell  226  includes terminals  282 ,  284 . Also, the battery cell  228  includes terminals  286 ,  288 , and the battery cell  230  includes terminals  290 ,  292 . Still further, the battery cell  232  includes terminals  294 ,  296 , and the battery cell  234  includes terminals  298 ,  300 . 
     The interconnect members  250 - 258  are provided to electrically couple the battery cells  220 - 234  in series with one another. In one exemplary embodiment, the interconnect members  250 - 258  are constructed from copper. Of course, in alternative embodiments, other bendable electrically-conductive materials known to those skilled in the art could be utilized to construct the interconnect members  250 - 258 . The interconnect member  250  is electrically coupled to terminals  278 ,  282 ,  286 ,  290  via weld joints; and the interconnect member  252  is electrically coupled to the terminals  288 ,  292 ,  296 ,  300  via weld joints. The interconnect member  254  is electrically coupled to the terminals  272 ,  276 ,  280 ,  284  via weld joints; and the interconnect member  256  is electrically coupled to the terminals  270 ,  274  via weld joints. Further, the interconnect member  258  is electrically coupled to the terminals  294 ,  298  via weld joints. 
     The interconnect members  250 ,  252 ,  254  have a substantially similar structure in accordance with another exemplary embodiment. Accordingly, only the structure of the interconnect member  250  will be described in greater detail below. 
     Referring to  FIGS. 17-24 , a process of folding plate portions of a plate member  251  to construct the interconnect member  250  will be explained. 
     Referring to  FIG. 17 , the plate member  251  includes plate portions  420 ,  422 ,  424 ,  426 ,  428 ,  430 ,  432 ,  434  and bendable regions  440 ,  441 ,  442 ,  443 ,  444 ,  445 ,  446 . As shown, initially, the plate portions  420 - 434  are disposed substantially co-planar with one another. Each of the plate portions  420 - 434  have a same thickness. 
     Referring to  FIG. 18 , during a first bending step, a user bends the plate portion  420  about the bendable region  440  such that the plate portion  420  is disposed substantially perpendicular to the plate portion  422 , and the plate portion  120  extends in a first direction. 
     Referring to  FIG. 19 , during a second bending step, the user bends the plate portion  426  about the bendable region  442  such that the plate portion  426  is disposed substantially perpendicular to the plate portion  424 , and the plate portion  426  extends in a second direction. 
     Referring to  FIG. 20 , during a third bending step, the user bends the plate portion  430  about the bendable region  444  such that the plate portion  430  is disposed substantially perpendicular to the plate portion  428 , and the plate portion  430  extends in the first direction. 
     Referring to  FIG. 21 , during a fourth bending step, the user bends the plate portion  434  about the bendable region  446  such that the plate portion  434  is disposed substantially perpendicular to the plate portion  432 , and the plate portion  434  extends in the second direction. 
     Referring to  FIG. 22 , during a fifth bending step, the user bends the plate portion  432  about the bendable region  445  such that the plate portion  432  is disposed adjacent to and contacts the plate portion  428 . 
     Referring to  FIG. 23 , during a sixth bending step, the user bends the plate portion  422  about the bendable region  441  such that the plate portion  422  is disposed adjacent to the plate portion  424 , and the plate portion  420  is disposed substantially parallel to the plate portion  426 . 
     Referring to  FIGS. 21 and 24 , during a seventh bending step, the user bends the plate portion  424  about the bendable region  443  such that the plate portion  424  is disposed adjacent to and contacts the plate portion  432 , to obtain the interconnect member  250 . 
     Referring to  FIGS. 16, 24 and 25 , the interconnect member  250  has vibration dampening portions  460  and  480 . The vibration dampening portions  460  and  480  attenuate vibrations that can occur during ultrasonic welding of battery terminals to the plate portions  420 ,  426 ,  430 ,  434  utilizing the ultrasonic horn  180  and the anvil  182 . For example, when a battery terminal is ultrasonically welded to the plate portion  434 , the vibration dampening portion  460  attenuates the vibrations before the vibrations reach the plate portions  426 ,  420 . The vibration dampening portion  480  further attenuates the vibrations before the vibrations reach the plate portion  430 . 
     The vibration dampening portion  460  comprises plate portions  422 ,  424 ,  428 , and a portion of the plate portion  432  disposed between and coupled to the plate portions  426 ,  420 . The vibration dampening portion  460  has a thickness that is four times as thick as a thickness of each of the plate portions  420 ,  426 ,  430 ,  434 . 
     The vibration dampening portion  480  comprises plate portions  432 ,  428  disposed between and coupled to the plate portions  420 ,  430 . The vibration dampening portion  480  has a thickness that is twice as thick as a thickness of each of the plate portions  430 ,  420 . 
     The battery modules and interconnect members described herein provide a substantial advantage over other battery modules and interconnect members. In particular, the battery modules provide a technical effect of utilizing interconnect members with vibration dampening portions to attenuate vibrations in the interconnect member. As a result, when terminals are ultrasonically welded to the interconnect members, previously formed weld joints are less likely to be degraded. 
     While the claimed 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 claimed 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 claimed invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the claimed invention is not to be seen as limited by the foregoing description.