Abstract:
A battery array according to an exemplary aspect of the present disclosure includes, among other things, a circuit connector assembly and a cover that partially covers the circuit connector assembly. The cover includes a groove. A sense-line wire is received within the groove.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to a circuit connector assembly cover that includes a groove sized to receive sense-line wiring. The cover functions to both cover portions of the circuit connector assembly of the battery array, and retains and routes sense-line wiring of the battery array. 
       BACKGROUND 
       [0002]    Electrified vehicles, such as hybrid electric vehicles (HEV&#39;s), plug-in hybrid electric vehicles (PHEV&#39;s), battery electric vehicles (BEV&#39;s), or fuel cell vehicles differ from conventional motor vehicles because they are powered by electric machines (i.e., electric motors and/or generators) instead of or in addition to an internal combustion engine. High voltage current for powering the electric machines is typically supplied by high voltage battery assemblies. 
         [0003]    A battery assembly may be equipped with one or more battery arrays. Each battery array includes a plurality of battery cells that are supported relative to one another. The battery cells must be reliably connected to one another in order to achieve the necessary voltage and power levels for operating the electrified vehicle. Numerous parts, including but not limited to bus bars, individual sense-line wiring, multiple wiring retainers for routing the sense-line wiring, and sensors are typically required to electrically connect the battery cells. 
       SUMMARY 
       [0004]    A battery array according to an exemplary aspect of the present disclosure includes, among other things, a circuit connector assembly and a cover that partially covers the circuit connector assembly. The cover includes a groove. A sense-line wire is received within the groove. 
         [0005]    In a further non-limiting embodiment of the foregoing battery array, the cover includes an external face, the groove extending longitudinally across the external face. 
         [0006]    In a further non-limiting embodiment of either of the foregoing battery arrays, the groove is positioned at a first distance from an end wall of the cover and a battery terminal of the battery array is positioned at a second distance from the end wall. 
         [0007]    In a further non-limiting embodiment of any of the foregoing battery arrays, the first distance is a greater distance than the second distance. 
         [0008]    In a further non-limiting embodiment of any of the foregoing battery arrays, the first distance is a smaller distance than the second distance. 
         [0009]    In a further non-limiting embodiment of any of the foregoing battery arrays, the groove is positioned at a first distance from an end wall of the cover, the first distance disposed between a second distance of a first battery terminal from the end wall and a third distance of a second battery terminal from the end wall. 
         [0010]    In a further non-limiting embodiment of any of the foregoing battery arrays, the groove is positioned between a bus bar and a sensor of the circuit connector assembly. 
         [0011]    In a further non-limiting embodiment of any of the foregoing battery arrays, a secondary groove is connected to the groove. 
         [0012]    In a further non-limiting embodiment of any of the foregoing battery arrays, a wiring branch extends within the secondary groove between the sense-line wire and a sensor. 
         [0013]    In a further non-limiting embodiment of any of the foregoing battery arrays, the sensor is a voltage sensor. 
         [0014]    In a further non-limiting embodiment of any of the foregoing battery arrays, the secondary groove is perpendicular to the groove. 
         [0015]    In a further non-limiting embodiment of any of the foregoing battery arrays, the sense-line wire connects to a control module. 
         [0016]    A battery array according to another exemplary aspect of the present disclosure includes, among other things, a battery cell including a terminal, a bus bar connected to the terminal, an integrated circuit board electrically connected to the bus bar, an integrated circuit board cover at least partially covering the bus bar, the integrated circuit board cover including a groove and sense-line wiring retained within the groove. 
         [0017]    In a further non-limiting embodiment of the foregoing battery array, the integrated circuit board cover completely conceals the terminal and the bus bar. 
         [0018]    In a further non-limiting embodiment of either of the foregoing battery arrays, the integrated circuit board cover is positioned on a side of the battery cell. 
         [0019]    In a further non-limiting embodiment of any of the foregoing battery arrays, the integrated circuit board cover is positioned over top of the battery cell. 
         [0020]    In a further non-limiting embodiment of any of the foregoing battery arrays, the groove extends longitudinally across an external face of the integrated circuit board cover. 
         [0021]    A method according to another exemplary aspect of the present disclosure includes, among other things, covering portions of a circuit connector assembly of a battery array with a cover, and retaining and routing sense-line wiring of the battery array in a groove of the cover. 
         [0022]    In a further non-limiting embodiment of the foregoing method, the covering step includes completely concealing at least a bus bar of the circuit connector assembly. 
         [0023]    In a further non-limiting embodiment of either of the foregoing methods, the method includes pressing the sense-line wiring into the groove and pressing wiring branches that extend from the sense-line wiring into secondary grooves. 
         [0024]    The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible. 
         [0025]    The various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]      FIG. 1  schematically illustrates a powertrain of an electrified vehicle. 
           [0027]      FIG. 2  illustrates a battery array of an electrified vehicle. 
           [0028]      FIG. 3  illustrates the battery array of  FIG. 2  with a housing of the battery array shown in phantom. 
           [0029]      FIG. 4  illustrates a cross-sectional view of a battery array according to a first embodiment of this disclosure. 
           [0030]      FIG. 5  illustrates a cross-sectional view of a battery array according to a second embodiment of this disclosure. 
           [0031]      FIG. 6  illustrates a cross-sectional view of a battery array according to yet another embodiment of this disclosure. 
           [0032]      FIG. 7  illustrates another exemplary battery array. 
           [0033]      FIG. 8  illustrates a cross-sectional view of a battery array according to another embodiment of this disclosure. 
           [0034]      FIG. 9  illustrates a cross-sectional view of a battery array according to another embodiment of this disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0035]    This disclosure relates to a circuit connector assembly cover for a battery array. The cover functions to cover portions of the circuit connector assembly of the battery array, and to retain and route sense-line wiring of the battery array. The cover includes a groove sized to accommodate the sense-line wiring. The sense-line wiring may be routed along a side or top of the battery array via the groove to reduce the packaging space required by the battery array. These and other features are discussed in greater detail in the following paragraphs. 
         [0036]      FIG. 1  schematically illustrates a powertrain  10  for an electrified vehicle  12 . Although depicted as a HEV, it should be understood that the concepts described herein are not limited to HEV&#39;s and could extend to other electrified vehicles, including, but not limited to, PHEV&#39;s and BEV&#39;s. 
         [0037]    In one non-limiting embodiment, the powertrain  10  is a power-split powertrain system that employs a first drive system and a second drive system. The first drive system includes a combination of an engine  14  and a generator  18  (i.e., a first electric machine). The second drive system includes at least a motor  22  (i.e., a second electric machine), the generator  18 , and a battery assembly  24 . In this example, the second drive system is considered an electric drive system of the powertrain  10 . The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels  28  of the electrified vehicle  12 . 
         [0038]    The engine  14 , which may include an internal combustion engine, and the generator  18  may be connected through a power transfer unit  30 , such as a planetary gear set. Of course, other types of power transfer units, including other gear sets and transmissions, may be used to connect the engine  14  to the generator  18 . In one non-limiting embodiment, the power transfer unit  30  is a planetary gear set that includes a ring gear  32 , a sun gear  34 , and a carrier assembly  36 . 
         [0039]    The generator  18  can be driven by the engine  14  through the power transfer unit  30  to convert kinetic energy to electrical energy. The generator  18  can alternatively function as a motor to convert electrical energy into kinetic energy, thereby outputting torque to a shaft  38  connected to the power transfer unit  30 . Because the generator  18  is operatively connected to the engine  14 , the speed of the engine  14  can be controlled by the generator  18 . 
         [0040]    The ring gear  32  of the power transfer unit  30  may be connected to a shaft  40 , which is connected to vehicle drive wheels  28  through a second power transfer unit  44 . The second power transfer unit  44  may include a gear set having a plurality of gears  46 . Other power transfer units may also be suitable. The gears  46  transfer torque from the engine  14  to a differential  48  to ultimately provide traction to the vehicle drive wheels  28 . The differential  48  may include a plurality of gears that enable the transfer of torque to the vehicle drive wheels  28 . In one embodiment, the second power transfer unit  44  is mechanically coupled to an axle  50  through the differential  48  to distribute torque to the vehicle drive wheels  28 . 
         [0041]    The motor  22  can also be employed to drive the vehicle drive wheels  28  by outputting torque to a shaft  52  that is also connected to the second power transfer unit  44 . In one embodiment, the motor  22  and the generator  18  cooperate as part of a regenerative braking system in which both the motor  22  and the generator  18  can be employed as motors to output torque. For example, the motor  22  and the generator  18  can each output electrical power to the battery assembly  24 . 
         [0042]    The battery assembly  24  is an exemplary type of electrified vehicle battery assembly. The battery assembly  24  may include a high voltage battery pack having one or more battery arrays that are capable of outputting electrical power to operate the motor  22  and the generator  18 . Other types of energy storage devices and/or output devices can also be used to electrically power the electrified vehicle  12 . 
         [0043]      FIGS. 2 and 3  illustrate a battery array  60  that can be incorporated into an electrified vehicle, such as the electrified vehicle  12  of  FIG. 1 . For example, the battery array  60  may be part of the battery assembly  24  shown in  FIG. 1 . The battery assembly  24  could include a plurality of battery arrays similar to the battery array  60  that are stacked or decked relative to one another. However, this disclosure is not limited to a battery assembly having a specific number of battery arrays. 
         [0044]    The battery array  60  may include a plurality of battery cells  62  that are housed within a housing  64 . The housing  64  is shown in solid lines in  FIG. 2  such that the battery cells  62  are not visible. The battery cells  62  are best illustrated in  FIG. 3 , which illustrates the housing  64  in phantom lines. The battery array  60  may include any number of battery cells, and this disclosure is not limited to the specific number of cells depicted by  FIG. 3 . 
         [0045]    The battery cells  62  are arranged, or stacked horizontally, along a longitudinal axis A between opposing walls  66  of the housing  64 . The housing  64  may include a plurality of walls  66  that surround the battery cells  62  of the battery array  60 . Although not shown, spacers or separates can be disposed between the adjacent battery cells  62  inside of the housing  64 . 
         [0046]    The battery cells  62  may be pouch type cells. In one embodiment, the battery cells  62  are lithium ion cells. However, other electrochemical battery cell types are also contemplated. 
         [0047]    In one embodiment, one of the walls  66  that form the housing  64  includes a cover  68  (see  FIG. 2 ), which may also be referred to as an ICB cover. The cover  68  may be attached to one or more of the walls  66 . In another embodiment, the cover  68  itself establishes one of the walls  66  of the housing  64 . The cover  68  could be attached in numerous ways to one or more of the walls  66 . For example, the cover  68  could be bolted, snapped-on, or connected to a tray of the battery assembly rather than to the battery array  60 . 
         [0048]    The cover  68  is adapted to provide the dual functions of both covering portions of a circuit connector assembly  70  that electrically connects the battery cells  62  of the battery array  60 , and retaining sense-line wiring  72  that connects the circuit connector assembly  70  of the battery array  60  to a control module  82 . For example, the cover  68  may at least partially cover, surround and/or conceal an integrated circuit board (ICB)  74  and/or one or more bus bars  76  (see  FIG. 4 ) of the circuit connector assembly  70 . The circuit connector assembly  70  may be made up of any combination of components that provide a circuit connection within the battery array  60 . 
         [0049]    In addition to covering portions of the battery array  60 , and in particular portions of the circuit connector assembly  70 , the cover  68  may also retain the sense-line wiring  72  of the battery array  60  and route the sense-line wiring  72  to the control module  82 . In one embodiment, the cover  68  includes a groove  84  formed on an external face  86  of the cover  68 . The sense-line wiring  72  may be press fit or snapped into the groove  84 . The groove  84  may extend longitudinally across an entire length L of the external face  86 , and may extend in parallel to the longitudinal axis A. In one embodiment, the external face  86  faces away from an interior of the housing  64 . In other words, the external face  86  faces away from the battery cells  62 . 
         [0050]    The cover  68  may additionally include secondary grooves  81  that connect to the groove  84 . In one embodiment, the secondary grooves  81  are perpendicular to the groove  84 . The secondary grooves  81  may receive wiring branches  83  of the sense line wiring  72 . The wiring branches  83  connect to sensors  80  of the circuit connector assembly  70 . Information collected by the sensors  80  can be communicated to and monitored by the control module  82  through the wiring branches  83  and the sense-line wiring  72 . 
         [0051]    The cover  68  may include cut-outs  78  for accommodating the sensors  80  of the circuit connector assembly  70 . In other words, the sensors  80  may be partially exposed by the cover  68  for connecting the sensors  80  to the sense-line wiring  72  after the cover  68  is in place. The sense-line wiring  72  connects to the control module  82  for monitoring the functionality of the battery array  60 . In one non-limiting embodiment, the control module  82  is a battery electronic control module. 
         [0052]      FIG. 4 , with continued reference to  FIGS. 2 and 3 , illustrates a cross-sectional view of portions of the battery array  60 . This view better illustrates some features of the cover  68 , the components of the circuit connector assembly  70 , and the relationship of the cover  68  relative to the circuit connector assembly  70 . 
         [0053]    In one embodiment, the circuit connector assembly  70  includes the ICB  74 , bus bars  76  (only one shown in  FIG. 4 ), sense-line wiring  72 , and the sensors  80  (only one shown in  FIG. 4 ). The circuit connector assembly  70  provides an integrated circuit for electrically connecting the battery cells  62  of the battery array  60 . The circuit connector assembly  70  may connect the battery cells  62  in a series string or a parallel string. 
         [0054]    The ICB  74  is electrically connected to a terminal  90  of each battery cell  62 . Each battery cell  62  may include terminals  90  having both positive and negative polarities. In this embodiment, the positive and negative terminals  90  are disposed on opposite sides of the battery cell  62  such that only one terminal  90  of each battery cell  62  is connected to the ICB  74 . The ICB  74  may include openings  92  for receiving the terminals  90 . In this way, the terminals  90  support the ICB  74  relative to the battery cells  62 . 
         [0055]    The ICB  74  also establishes a mounting platform for the sensors  80 . The ICB  74  may include openings  94  for accommodating the sensors  80 . In one embodiment, the sensors  80  are voltage sensors. In another embodiment, the sensors  80  are temperature sensors. Other sensors are also contemplated as within the scope of this disclosure. 
         [0056]    Wiring branches  83  extend within the secondary grooves  81  from the sensors  80  to the sense-line wiring  72 . The sense-line wiring  72  transfers measurement signals from the sensors  80  and/or the ICB  74  to the control module  82  (see  FIG. 2 ). The control module  82  may be programmed to monitor the measurement signals received from the sensors  80  and/or ICB  74 , such as to prevent overcharging of the battery cells  62 . The control module  82  could additionally be programmed to perform multiple other functions related to the battery array  60 . 
         [0057]    The bus bar  76  is also connected to the terminal  90 . The bus bar  76  electrically connects the terminal  90  to an adjacent terminal of an adjacent battery cell, which in  FIG. 4  is directly behind the battery cell  62 . In one embodiment, the bus bars  76  connect adjacent terminals that have opposite polarities (i.e., negative to positive or positive to negative). The bus bars  76  are also electrically connected to the ICB  74 . 
         [0058]    In one embodiment, the bus bars  76  are stamped, relatively thin strips of metal that are configured to conduct power generated by the battery cells  62 . Example bus bar materials include copper, brass or aluminum, although other materials having conductive properties may also be suitable. In one embodiment, the bus bars  76  are high current bus bars having relatively high amperage capacities. 
         [0059]    In one embodiment, the cover  68  completely conceals the bus bars  76  and the terminals  90  and at least partially conceals the ICB  74 . The cover  68  may be positioned on a side of the battery cells  62  of the battery array  60 . In another embodiment, the cover  68  may be positioned on top of the battery cells  62  (see  FIG. 5 ). The actual placement and positioning of the cover  68  will depend on the battery assembly design, packaging considerations, and other factors. 
         [0060]    In one embodiment, the groove  84  of the cover  68  is positioned at a first distance D 1  from an end wall  99  of the cover  68  that is a larger distance than a second distance D 2  between the end wall  99  and the terminal  90 . In another embodiment, the groove  84  is disposed at a first distance D 1  from the end wall  99  of the cover  68  that is a smaller distance than a second distance D 2  between the end wall  99  and the terminal  90  (see  FIG. 6 ). Other locations for the groove  84  are also contemplated. 
         [0061]      FIG. 7  illustrates another embodiment of a battery array  160 . In this disclosure, like reference numbers designate like elements where appropriate and reference numerals with the addition of  100  or multiples thereof designate modified elements that are understood to incorporate the same features and benefits of the corresponding original elements. 
         [0062]    In this embodiment, both the positive and negative terminals  190  of the battery cells  162  are disposed on the same side of the battery cells  162 . The cover  168  may cover or conceal the bus bars  176 , the terminals  190 , and portions of the ICB  174 . The cover  168  includes a groove  184  for routing sense-line wiring  172 . In this non-limiting embodiment, the groove  184  is positioned at a first distance D 1  from an end wall  199  of the cover  168  that is a greater distance than distances D 2 , D 3  that extend between the end wall  199  and the terminals  190 . The first distance D 1  could alternatively be a smaller distance than distances D 2 , D 3  (see  FIG. 8 ). In yet another embodiment, the first distance D 1  is a distance between the distances D 2  and D 3  (see  FIG. 9 ). 
         [0063]    It should be understood that the various embodiments shown in  FIGS. 2-9  are not necessarily drawn to scale and are for illustrative purposes only. The exemplary grooved covers of this disclosure may reduce the number of wiring retainers required to route sense-line wiring, increase packaging space of the battery assembly, and simplify battery array assembly. 
         [0064]    Although the different non-limiting embodiments are illustrated as having specific components or steps, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. 
         [0065]    It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure. 
         [0066]    The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.