Patent Description:
The present disclosure relates generally to the field of batteries and battery modules. More specifically, the present disclosure relates to a sensor for use with a battery module.

A vehicle that uses one or more battery systems for providing all or a portion of the motive power for the vehicle can be referred to as an xEV, where the term "xEV" is defined herein to include all of the following vehicles, or any variations or combinations thereof, that use electric power for all or a portion of their vehicular motive force. For example, xEVs include electric vehicles (EVs) that utilize electric power for all motive force. As will be appreciated by those skilled in the art, hybrid electric vehicles (HEVs), also considered xEVs, combine an internal combustion engine propulsion system and a battery-powered electric propulsion system, such as <NUM> Volt (V) or 130V systems. The term HEV may include any variation of a hybrid electric vehicle. For example, full hybrid systems (FHEVs) may provide motive and other electrical power to the vehicle using one or more electric motors, using only an internal combustion engine, or using both. In contrast, mild hybrid systems (MHEVs) disable the internal combustion engine when the vehicle is idling and utilize a battery system to continue powering the air conditioning unit, radio, or other electronics, as well as to restart the engine when propulsion is desired. The mild hybrid system may also apply some level of power assist, during acceleration for example, to supplement the internal combustion engine. Mild hybrids are typically 96V to 130V and recover braking energy through a belt or crank integrated starter generator. Further, a micro-hybrid electric vehicle (mHEV) also uses a "Stop-Start" system similar to the mild hybrids, but the micro-hybrid systems of a mHEV may or may not supply power assist to the internal combustion engine and operates at a voltage below 60V. For the purposes of the present discussion, it should be noted that mHEVs typically do not technically use electric power provided directly to the crankshaft or transmission for any portion of the motive force of the vehicle, but an mHEV may still be considered as an xEV since it does use electric power to supplement a vehicle's power needs when the vehicle is idling with internal combustion engine disabled and recovers braking energy through an integrated starter generator. In addition, a plug-in electric vehicle (PEV) is any vehicle that can be charged from an external source of electricity, such as wall sockets, and the energy stored in the rechargeable battery packs drives or contributes to drive the wheels. PEVs are a subcategory of EVs that include all-electric or battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and electric vehicle conversions of hybrid electric vehicles and conventional internal combustion engine vehicles.

xEVs as described above may provide a number of advantages as compared to more traditional gas-powered vehicles using only internal combustion engines and traditional electrical systems, which are typically 12V systems powered by a lead acid battery. For example, xEVs may produce fewer undesirable emission products and may exhibit greater fuel efficiency as compared to traditional internal combustion vehicles and, in some cases, such xEVs may eliminate the use of gasoline entirely, as is the case of certain types of EVs or PEVs.

As technology continues to evolve, there is a need to provide improved power sources, particularly battery modules, for such vehicles. For example, in traditional battery module configurations, temperature sensing components may be coupled to a processor of the traditional battery module, such that the processor receives or determines data indicative of a temperature of various portions of the traditional battery module.

Unfortunately, integrating traditional temperature sensing components in traditional battery modules may be cumbersome and expensive, and may lead to undesirable affects, such as inaccurate temperature measurements. Accordingly, improved temperature sensors and integration features are desired.

For example, <CIT> relates to a conventional battery module comprising a plurality of battery cells provided in a housing, a transverse distribution plastic frame dispose at a top of the battery module, a plurality of busbars connected around the plastic frame, and a collection system on the plastic frame, the collection system provided with a temperature sensor, first collections terminal and second collection terminal.

<CIT> , provides a simple battery connection module for connecting a plurality of side-by-side batteries including an insulating frame disposed on the plurality of batteries, a plurality of bus bar connectors assembled on the insulating frame, a circuit board and a sensor assembly disposed on the insulating frame, each of the bus connecting members including an electrode connector and a circuit board connector, the electrode connector electrically connecting electrodes of at least two adjacent ones of the plurality of batteries.

These and other features and advantages of devices, systems, and methods are described in, or are apparent from, the following detailed descriptions and drawings of various examples of embodiments.

In certain instances, details that are not necessary to the understanding of the invention or render other details difficult to perceive may have been omitted. For ease of understanding and simplicity, common numbering of elements within the numerous illustrations is utilized when the element is the same in different Figures. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

The battery systems described herein may be used to provide power to various types of electric vehicles (xEVs) and other high voltage energy storage/expending applications (e.g., electrical grid power storage systems). Such battery systems may include one or more battery modules, each battery module having a number of battery cells (e.g., lithium-ion (Li-ion) electrochemical cells) arranged and electrically interconnected to provide particular voltages and/or currents useful to power, for example, one or more components of an xEV. As another example, battery modules in accordance with present embodiments may be incorporated with or provide power to stationary power systems (e.g., non-automotive systems).

In accordance with embodiments of the present disclosure, a battery module (e.g., a lithium-ion {Li-ion] battery module) may include a housing in which electrochemical cells (e.g., Li-ion electrochemical cells) are disposed, and in which a bus bar carrier is disposed. The bus bar carrier my include bus bars, among other components, disposed thereon, and the bus bar carrier may be configured to enable alignment of the bus bars with appropriate terminals of the electrochemical cells. A circuit which may be a flex circuit may be disposed on the bus bar carrier and include features configured to interface with the bus bars and/or with the electrochemical cells. The flex circuit may include a flexible base material, such as polyamide. However, components having non-polyamide (or non- flexible) materials, such as metallic or other components, may be integrated with the flexible (e.g., polyamide) material of the flex circuit.

In accordance with present embodiments, a sensor tab may be integrated within a circuit for use with the disclosed battery module. In various embodiments, the sensor tab may be one component integrated with the flexible material (e.g., polyamide) of the flex circuit. For example, the sensor tab may be a temperature sensor welding tab which may be integrated with the flex circuit via a hot-melt adhesive, a different adhesive, overmolding, or via other coupling techniques. The flex circuit may be disposed along an upper surface of the bus bar carrier, and the temperature sensor welding tab of the flex circuit may be disposed on the flex circuit in a location of the bus bar carrier that enables the temperature sensor welding tab to extend through an opening, or window, in the bus bar carrier. The window may enable the temperature sensor welding tab of the flex circuitry to physically access one of the electrochemical cells disposed in the housing and adjacent an underside surface of the bus bar carrier. The temperature sensor welding tab may extend through the window and may be welded or otherwise adhered to a surface (e.g., a terminal end) of the electrochemical cell.

The sensor tab, which may be referred to herein as a temperature sensor welding tab, may also include thermistors, or may be disposed adjacent an area of the flex circuit which includes the thermistors. When the temperature sensor welding tab is adhered (e.g., welded) to the surface of the electrochemical cell, the welded connection may bring the thermistors into close proximity to, or in contact with, the surface of the electrochemical cell. The thermistors may be communicatively coupled with the processor of the battery module via electrical wires embedded in the flex circuitry and extending toward an electrical contact with the processor. Thus, upon welding the temperature sensor welding tab to the surface of the electrochemical cell, the thermistors and corresponding signals may be utilized by the processor to determine a temperature of the surface of the electrochemical cell. Features of the flex circuit, such as notches in the flex circuit disposed adjacent the temperature sensor welding tab, may facilitate improved coupling of the temperature sensor welding tab to the electrochemical cell, which may enable improved temperature detection over traditional embodiments. These and other features will be described in detail below with reference to the drawings.

To help illustrate, <FIG> is a perspective view of an embodiment of a vehicle <NUM><NUM>, which may utilize a regenerative braking system. Although the following discussion is presented in relation to vehicles with regenerative braking systems, the techniques described herein are adaptable to other vehicles that capture/store electrical energy with a battery, which may include electric-powered and gas-powered vehicles.

As discussed above, it would be desirable for a battery system <NUM> to be largely compatible with traditional vehicle designs. Accordingly, the battery system <NUM> may be placed in a location in the vehicle <NUM> that would have housed a traditional battery system.

For example, as illustrated, the vehicle <NUM> may include the battery system <NUM> positioned similarly to a lead-acid battery of a typical combustion-engine vehicle (e.g., under the hood of the vehicle <NUM>). Furthermore, as will be described in more detail below, the battery system <NUM> may be positioned to facilitate managing temperature of the battery system <NUM>. For example, in some embodiments, positioning a battery system <NUM> under the hood of the vehicle <NUM> may enable an air duct to channel airflow over the battery system <NUM> and cool the battery system <NUM>.

In other words, the battery system <NUM> may supply power to components of the vehicle's electrical system, which may include radiator cooling fans, climate control systems, electric power steering systems, active suspension systems, auto park systems, electric oil pumps, electric super/turbochargers, electric water pumps, heated windscreen/defrosters, window lift motors, vanity lights, tire pressure monitoring systems, sunroof motor controls, power seats, alarm systems, infotainment systems, navigation features, lane departure warning systems, electric parking brakes, external lights, or any combination thereof. Illustratively, in the depicted embodiment, the energy storage component <NUM> supplies power to the vehicle console <NUM> and the ignition system <NUM>, which may be used to start (e.g., crank) the internal combustion engine <NUM>.

Additionally, the energy storage component <NUM> may capture electrical energy generated by the alternator <NUM> and/or the electric motor <NUM>. In some embodiments, the alternator <NUM> may generate electrical energy while the internal combustion engine <NUM> is running. More specifically, the alternator <NUM> may convert the mechanical energy produced by the rotation of the internal combustion engine <NUM> into electrical energy.

Additionally or alternatively, when the vehicle <NUM> includes an electric motor <NUM>, the electric motor <NUM> may generate electrical energy by converting mechanical energy produced by the movement of the vehicle <NUM> (e.g., rotation of the wheels) into electrical energy. Thus, in some embodiments, the energy storage component <NUM> may capture electrical energy generated by the alternator <NUM> and/or the electric motor <NUM> during regenerative braking. As such, the alternator <NUM> and/or the electric motor <NUM> are generally referred to herein as a regenerative braking system.

To facilitate capturing and supplying electric energy, the energy storage component <NUM> may be electrically coupled to the vehicle's electric system via a bus <NUM>. For example, the bus <NUM> may enable the energy storage component <NUM> to receive electrical energy generated by the alternator <NUM> and/or the electric motor <NUM>. Additionally, the bus <NUM> may enable the energy storage component <NUM> to output electrical energy to the ignition system <NUM> and/or the vehicle console <NUM>. Accordingly, when a <NUM>-volt battery system <NUM> is used, the bus <NUM> may carry electrical power typically between <NUM>-<NUM> volts.

Additionally, as depicted, the energy storage component <NUM> may include multiple battery modules. For example, in the depicted embodiment, the energy storage component <NUM> includes a lithium ion (e.g., a first) battery module <NUM> and a lead-acid (e.g., a second) battery module <NUM>. , which each includes one or more battery cells. In other embodiments, the energy storage component <NUM> may include any number of battery modules. Additionally, although the lithium ion battery module <NUM> and lead-acid battery module <NUM> are depicted adjacent to one another, they may be positioned in different areas around the vehicle. For example, the lead-acid battery module <NUM> may be positioned in or about the interior of the vehicle <NUM> while the lithium ion battery module <NUM> may be positioned under the hood of the vehicle <NUM>.

In some embodiments, the energy storage component <NUM> may include multiple battery modules to utilize multiple different battery chemistries. For example, when the lithium ion battery module <NUM> is used, performance of the battery system <NUM> may be improved since the lithium ion battery chemistry generally has a higher coulombic efficiency and/or a higher power charge acceptance rate (e.g., higher maximum charge current or charge voltage) than the lead-acid battery chemistry. As such, the capture, storage, and/or distribution efficiency of the battery system <NUM> may be improved.

To facilitate controlling the capturing and storing of electrical energy, the battery system <NUM> may additionally include a control module <NUM>. More specifically, the control module <NUM> may control operations of components in the battery system <NUM>, such as relays (e.g., switches) within energy storage component <NUM>, the alternator <NUM>, and/or the electric motor <NUM>. For example, the control module <NUM> may regulate an amount of electrical energy captured/supplied by each battery module <NUM> or <NUM> (e.g., to do-rate and re-rate the battery system <NUM>), perform load balancing between the battery modules <NUM> and <NUM>, determine a state of charge of each battery module <NUM> or <NUM>, determine temperature of each battery module <NUM> or <NUM>, control voltage output by the alternator <NUM> and/or the electric motor <NUM>, and the like.

Accordingly, the control unit <NUM> may include one or more processor <NUM> and one or more memory <NUM>. More specifically, the one or more processor <NUM> may include one or more application specific integrated circuits (ASICs), one or more field programmable gate arrays (FPGAs), one or more general purpose processors, or any combination thereof. Additionally, the one or more memory <NUM> may include volatile memory, such as random-access memory (RAM), and/or non-volatile memory, such as read-only memory (ROM), optical drives, hard disc drives, or solid-state drives. In some embodiments, the control unit <NUM> may include portions of a vehicle control unit (VCU) and/or a separate battery control module.

<FIG> is an exploded side view of an embodiment of the battery module <NUM> for use in the vehicle <NUM> of <FIG>, For simplicity, not all components of the battery module <NUM> are illustrated (e.g., terminals, bus bars, sensors, etc.). The battery module <NUM> (e.g., lithium-ion (Li-ion) battery module) includes a housing <NUM> (e.g., plastic housing), a bus bar carrier <NUM>, a flex circuit <NUM>, and a cover <NUM>. A plurality of electrochemical cells <NUM> (e.g., Li-ion electrochemical cells) are disposed within the housing <NUM>, and are shown via dashed lines in the illustrated embodiment to indicate that they are within the illustrated housing <NUM> (i.e., behind a wall of the housing <NUM> in the illustrated perspective). In certain embodiments, the battery module <NUM> may include any number of electrochemical cells <NUM> (e.g., <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or more electrochemical cells), any type of electrochemical cell <NUM> (e.g., Li-ion, lithium polymer, lead-acid, nickel cadmium, or nickel metal hydride, prismatic, and/or cylindrical), and any arrangement of the electrochemical cells <NUM> (e.g., stacked, separated, or compartmentalized).

The housing <NUM> includes an opening <NUM> on one side <NUM> (upper side or face) to receive the electrochemical cells <NUM>. The bus bar carrier <NUM> may be disposed within the opening <NUM> and above the electrochemical cells <NUM> and may include bus bars disposed thereon configured to interface with terminals <NUM> extending from terminal ends <NUM> of the electrochemical cells <NUM>. That is, although the bus bars are not shown in the illustrated embodiment, the bus bars may be disposed in locations of the bus bar carrier <NUM> suitable for coupling the bus bars to the terminals <NUM> of the electrochemical cells <NUM>, The bus bar carrier <NUM> may also include the circuit (for example, flex circuit) <NUM> disposed thereon. For example, the bus bar carrier <NUM> may be disposed on an upper side <NUM> of the bus bar carrier <NUM> opposing an underside <NUM> of the bus bar carrier <NUM>. The flex circuit <NUM> in the illustrated embodiment is coupled to the upper side <NUM> of the bus bar carrier <NUM>. The flex circuitry <NUM> may include a flexible material, such as a polyamide material, within which (and from which) electrical components extend. The electrical components of the flex circuit <NUM> may be configured to interface with the bus bars and/or with the terminal ends <NUM> of the electrochemical cells <NUM>. For example, as will be appreciated in view of further discussion below, the flex circuit <NUM> may include voltage sensing tabs configured to contact bus bars of the battery module <NUM>, and temperature sensor welding tabs <NUM> configured to contact the terminal ends <NUM> of certain ones of the electrochemical cells <NUM>. Each temperature sensor welding tab <NUM> may include a metal material, such as aluminum, and may be configured to be welded (e.g., from overhead) to the terminal end <NUM> of one of the electrochemical cells <NUM>. The flex circuit <NUM> may also include electrical contacts <NUM> extending toward other features disposed in the housing <NUM>, such as a processor of the battery module <NUM> or an electrical path to the processor.

The voltage sensing tabs and the sensor tabs (for example, temperature sensor welding tabs) <NUM> may be strategically positioned on the flex circuit <NUM>, and the flex circuit <NUM> may be strategically positioned on the bus bar carrier <NUM>, to enable coupling of the voltage sensing tabs and the temperature sensor welding tabs <NUM> of the flex circuit <NUM> with the appropriate features of the battery module <NUM>. Aspects of the temperature sensor welding tabs <NUM> will be described in detail below with reference to later drawings.

<FIG> is a perspective view of the bus bar carrier <NUM> having the flex circuit <NUM> illustrated in the battery module <NUM> of <FIG>. As previously described, the flex circuit <NUM> may include a thin layer of flexible material, such as polyamide. The flex circuit <NUM> may include various electrical components disposed in and/or extending from the polyamide material of the flex circuit <NUM>. For example, electrical wiring may be embedded within the polyamide material of the flex circuit <NUM> and may extend between various electrical components of the flex circuit <NUM>. in the illustrated embodiment, the flex circuit <NUM> includes, for example, two temperature sensor welding tabs <NUM> extending from edges of the flex circuit <NUM>, among other electrical components.

The temperature sensor welding tabs <NUM> are disposed on portions of the flex circuit <NUM> that, when the flex circuit <NUM> is disposed on the bus bar carrier <NUM>, cause the temperature sensor welding tabs <NUM> to extend through openings, or windows <NUM>, in the bus bar carrier <NUM>. The windows <NUM> may extend, for example, from the upper side <NUM> of the bus bar carrier <NUM> to the underside <NUM> of the bus bar carrier <NUM>. That is, the windows <NUM> extend entirely through a thickness of the bus bar carrier <NUM>. The windows <NUM> enable the temperature sensor welding tabs <NUM> to extend from the flex circuit <NUM> disposed on the upper side <NUM> of the bus bar carrier <NUM> into contact with features (e.g., terminal ends of electrochemical cells) disposed adjacent (e.g., under) the underside <NUM> of the bus bar carrier <NUM>. The windows <NUM> also enable an unobstructed view of the temperature sensor welding tabs <NUM> from above the bus bar carrier <NUM>. For example, <FIG> is a top view of the bus bar carrier <NUM> and the flex circuit <NUM> of <FIG>. As shown, each temperature sensor welding tab <NUM> includes a welding region <NUM> that is unobstructed from view. The welding region <NUM> may be welded or otherwise adhered to, for example, a terminal end of an electrochemical cell disposed underneath the bus bar carrier <NUM>.

<FIG> are perspective views of a portion of the bus bar carrier <NUM> and flex circuit <NUM>. For example, <FIG> is an overhead perspective view of the portion of the bus bar carrier <NUM> and the flex circuit <NUM>, and <FIG> is a bottom perspective view of the portion of the bus bar carrier <NUM> and the flex circuit <NUM>. In <FIG>, the flex circuit <NUM> is illustrated as disposed on the upper side <NUM> of the bus bar carrier <NUM>. The bus bar carrier <NUM> includes the window <NUM> through which the temperature sensor welding tab <NUM> extends. As shown in <FIG>, the flex circuit <NUM> includes a notch <NUM> between two adjacent extensions <NUM>, <NUM> of the flex circuit <NUM>, where the temperature sensor welding tab <NUM> is disposed on the first extension <NUM> of the two extensions <NUM>, <NUM>. A notch <NUM> may also be disposed on an opposing side of the first extension <NUM>. That is, the first extension <NUM> may be defined by the two notches <NUM>, <NUM>, and may include a rectangular shape or other suitable shape.

By disposing the temperature sensor welding tab <NUM> on the first extension <NUM>, the first extension <NUM> may flex downwardly when the temperature sensor welding tab <NUM> is welded or otherwise adhered to the terminal end of the electrochemical cell. For example, as shown, the temperature sensor welding tab <NUM> includes a circuit engagement region <NUM>, the welding region <NUM>, and a transverse region <NUM> extending transversely between the circuit engagement region <NUM> and the welding region <NUM>. That is, the temperature sensor welding tab <NUM> includes a bent plate, where the transverse region <NUM> is bent relative to the circuit engagement region <NUM>, and the welding region <NUM> is bent relative to the transverse region <NUM>. In other words, the transverse region <NUM> extends at a non-right angle relative to the circuit engagement region <NUM> and the welding region <NUM> to enable passage of the temperature sensor welding tab <NUM> from the flex circuit <NUM> on the upper side <NUM> of the bus bar carrier <NUM>, through the window <NUM>, and adjacent the underside <NUM> (see <FIG>) of the bus bar carrier <NUM>. Further, the bend of the temperature sensor welding tab <NUM> (e.g., between the transverse region <NUM> and the circuit engagement region <NUM>, and between the transverse region <NUM> and the welding region <NUM>) enforces a gap between the terminal end of the electrochemical cell and other components (e.g., thermistors) of, or on, the flex circuit <NUM>.

In <FIG>, the temperature sensor welding tab <NUM> is illustrated as extending through the window <NUM> and being disposed adjacent the underside <NUM> of the bus bar carrier <NUM>. That is, the welding region <NUM> is disposed adjacent the underside <NUM> of the bus bar carrier <NUM> and may be configured to be welded to the terminal end of an electrochemical cell. Further, in <FIG>, thermistors <NUM> are disposed on the flex circuit <NUM> adjacent to the temperature sensor welding tab <NUM>. For example, the thermistors <NUM> are disposed on an underside <NUM> of the first extension <NUM> of the flex circuit <NUM>. The temperature sensor welding tab <NUM> may be used, via the coupling (e.g., weld) to the terminal end of the electrochemical cell, to bring the thermistors <NUM> in close proximity to the terminal end of the electrochemical cell. For example, when the temperature sensor welding tab <NUM> is coupled to the terminal end of the electrochemical cell, the connection may cause the first extension <NUM> of the flex circuit <NUM> to be pulled downwardly, and the thermistors <NUM> may be disposed on the underside <NUM> of the first extension <NUM> of the flex circuit <NUM>. Thus, the thermistors <NUM> may be pulled toward, or held in close proximity to, the terminal end of the electrochemical cell via the coupling of the temperature sensor welding tab <NUM> to the terminal end of the electrochemical cell,.

In some embodiments, the thermistors <NUM> may be decoupled from the temperature sensor welding tab <NUM> but disposed in close proximity to the temperature sensor welding tab <NUM> (i.e., on the underside <NUM> of the first extension <NUM> of the flex circuit <NUM>) to enable the above-described effects. In other embodiments, the thermistors <NUM> may be electrically coupled to the temperature sensor welding tab <NUM>. Further, the thermistors <NUM> may be electrically coupled to electrical wiring encapsulated by the polyamide material of the flex circuit <NUM>, and/or running along an underside of the flex circuit <NUM> between the flex circuit <NUM> and the bus bar carrier <NUM>. The electrical wiring may then couple to electrical contacts <NUM> (see <FIG>), which may be coupled to a processor or other feature of a printed circuit board or battery module control and/or monitoring assembly.

<FIG> is a schematic cross-sectional side view of an embodiment of a coupling between the terminal end <NUM> of an electrochemical cell <NUM> and the temperature sensor welding tab <NUM> of the present disclosure. As previously described, the temperature sensor welding tab <NUM> may include the circuit engagement region <NUM>, the welding region <NUM>, and the transverse region <NUM> extending between the circuit engagement region <NUM> and the welding region <NUM>. The transverse region <NUM> may be bent to form an angle with the welding region <NUM>, and the circuit engagement region <NUM> may be bent relative to the transverse region <NUM> to form another angle with the transverse region. By including the transverse region <NUM> extending at angles relative to the welding region <NUM> and the circuit engagement region <NUM>, the welding region <NUM> may fall flat on the terminal end <NUM> of the electrochemical cell <NUM>. The welding region <NUM> may be coupled to the terminal end <NUM> of the electrochemical cell <NUM> such that at least the transverse region <NUM> of the temperature sensor welding tab <NUM> is disposed in the window <NUM> of the bus bar carrier <NUM>. As shown, a portion (e.g., the first segment <NUM>) of the polyamide material of the flex circuit <NUM> may also extend into (e.g., overlap with) the window <NUM> of the bus bar carrier <NUM>, and the thermistors <NUM> may be disposed on the first segment <NUM> of the polyamide material of the flex circuit <NUM>. Thus, the temperature sensor welding tab <NUM>, when coupled to the terminal end <NUM> of the electrochemical cell <NUM>, may cause the first segment <NUM> of the polyamide material of the flex circuit <NUM>, and the thermistors <NUM> coupled to the first segment <NUM>, to be drawn toward the terminal end <NUM> of the electrochemical cell <NUM>. However, in other embodiments, the welding region <NUM> may fall flat against the terminal end <NUM> of the electrochemical cell <NUM> without substantial bending of the first segment <NUM> of the polyamide material of the flex circuit <NUM>.

Further, the bend of the temperature sensor welding tab <NUM> (e.g., between the transverse region <NUM> and the circuit engagement region <NUM>, and between the transverse region <NUM> and the welding region <NUM>) enforces a gap between the terminal end <NUM> of the electrochemical cell <NUM> and other components (e.g., thermistors <NUM>) of, or on, the flex circuit <NUM>. The gap blocks an interference of the electrochemical cell <NUM> upon the thermistors <NUM> and/or other components.

The disclosed features of the bus bar carrier <NUM>, the flex circuit <NUM>, the temperature sensor welding tabs <NUM>, and the thermistors <NUM> may enable improved assembly of the battery module, may reduce a cost of the battery module, and may improve temperature measurements determined by the battery module.

<FIG> is another side view of the bus bar carrier <NUM> and the flex circuit <NUM> according to various examples of embodiments. As shown, the sensor tab or temperature sensor welding tab <NUM> includes a welding region <NUM>. The welding region <NUM> may be welded or otherwise adhered to, for example, a terminal end of an electrochemical cell <NUM>-<NUM> disposed underneath the bus bar carrier <NUM>. Between a first region or circuit engagement region <NUM> to a second region or welding region <NUM> is a third region or transverse region <NUM>. Thus, the first region or circuit engagement region <NUM> may be relatively above the second region or welding region <NUM> when the battery is positioned such that bus bar carrier <NUM> is above battery cell <NUM>-<NUM>. It should be understood second region or welding region <NUM> is coupled or welded to battery module <NUM> in various examples of embodiments, which may be understood to allow for sufficient electrical connection to measure battery cell temperature. In various embodiments, the sensor tab <NUM> may be relatively thin. For example, the tab may be less than <NUM> thick, between. <NUM> thick, between. <NUM> thick, and more particularly approximately. <NUM> thick.

The disclosed sensor welding tab, for example but not limited to a temperature sensor welding tab, and battery module may have various advantages, particularly to manufacturability. In various embodiments, the disclosed may allow for ease of assembly and connection of the sensors to the battery modules. As another non-limiting example, the thickness of the tab may have advantages to heat conduction for measurement of temperature, as well as advantages to assembly.

While only certain features and embodiments of the invention have been illustrated and described, many modifications and changes may occur to those skilled in the art (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters (e.g., temperatures, pressures, etc.), mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described (i.e., those unrelated to the presently contemplated best mode of carrying out the invention, or those unrelated to enabling the claimed invention). It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.

As utilized herein, the terms "approximately," "about," "substantially", and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described.

It should be noted that references to relative positions (e.g., "top" and "bottom") in this description are merely used to identify various elements as are oriented in the Figures. It should be recognized that the orientation of particular components may vary greatly depending on the application in which they are used.

For the purpose of this disclosure, the term "coupled" means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.

It is also important to note that the construction and arrangement of the system, methods, and devices as shown in the various examples of embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) as long as falling under the subject-matter recited in the appended claims. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied (e.g. by variations in the number of engagement slots or size of the engagement slots or type of engagement). The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. The invention is solely defined by the appended claims.

Claim 1:
A battery module (<NUM>), comprising:
- an electrochemical cell (<NUM>);
- a bus bar carrier (<NUM>) having a window (<NUM>);
- a circuit (<NUM>) disposed on the bus bar carrier (<NUM>); and
- a sensor welding tab (<NUM>) comprising a circuit engagement region (<NUM>) coupled to the circuit (<NUM>), a welding region (<NUM>) coupled to the electrochemical cell (<NUM>), and a transverse region (<NUM>) extending through the window (<NUM>) of the bus bar carrier (<NUM>) and between the circuit engagement region (<NUM>) and the welding region (<NUM>),
wherein the sensor welding tab (<NUM>) is a temperature sensor welding tab (<NUM>).