Patent Description:
<CIT> and <NUM> July <NUM> and was published on <NUM> September <NUM>. <CIT>discloses a multi-wire cable used to connect battery cells of a battery module to a connector assembly with terminals to which conductors of wires of the multi-wire planar cable are terminated. <CIT> discloses a similar arrangement in which the multi-wire cable comprises plural insulated wires interconnected by web extensions of insulation of the wires such that the multi-wire planar cable includes grooves in opposed surfaces thereof.

A need remains for battery modules that use low cost, flexible flat cables for termination of wires to components of the battery monitoring system.

According to the invention there is provided a connector assembly suitable for voltage monitoring of bus bars electrically connecting adjacent battery cells of a battery module, the connector assembly comprising: a connector having a plurality of terminals configured to be mated with a control module connector associated with the battery module; a multi-wire planar cable extending from the connector, the multi-wire planar cable having a plurality of wires terminated to corresponding terminals of the connector and a common jacket for the plurality of wires, the jacket having grooves between adjacent wires for controlled separation of the wires and surrounding jacket portions at a sensor end of the multi-wire planar cable to define separated planar cable segments, the separated planar cable segments being configured to be routed to different areas for termination to different voltage sensors associated with corresponding bus bars, wherein the wires include punch-out portions and dead portions downstream of the terminating portions, the punch-out portions defining a discontinuity along the wires such that the dead portions are no longer electrically connected to the corresponding terminating portions, and wherein the grooves are provided in only a top surface or only a bottom surface of the multi-wire planar cable.

<FIG> is a top perspective view of a battery system <NUM> formed in accordance with an exemplary embodiment. The battery system <NUM> includes one or more battery modules <NUM> with corresponding carrier assemblies <NUM> mounted to the battery module(s) <NUM>. The battery modules <NUM> may be stacked together as a battery pack used as part of the battery system <NUM>, such as a battery system in a vehicle, such as an electric vehicle or a hybrid electrical vehicle. The battery system <NUM> may be used in other applications in alternative embodiments. The battery modules <NUM> may be contained within a housing.

The battery system <NUM> includes a battery control module <NUM>, which may be mounted to the battery module(s) <NUM>. The battery control module <NUM> controls activities of the battery modules <NUM>. The battery control module <NUM> may include or communicate with a vehicle system controller to verify that the battery module <NUM> is operating within the parameters set for the current condition of the battery module <NUM>. The battery control module <NUM> may monitor the voltage of the cells of the battery module <NUM>. The battery control module <NUM> may monitor the temperature of the battery module <NUM>. The battery control module <NUM> may supply fault codes to the vehicle.

The battery system <NUM> includes one or more connector assemblies <NUM> coupled to the battery control module <NUM>, such as to corresponding control module connectors <NUM> of the battery control module <NUM>. The connector assemblies <NUM> are electrically coupled to voltage sensors, temperature sensors and the like within the battery module <NUM> and routed to the battery control module <NUM>.

<FIG> is a top perspective view of one of the battery modules <NUM>. The battery module <NUM> includes a plurality of battery cells <NUM>, such as prismatic battery cells. The battery cells <NUM> are arranged in a stacked configuration, side-by-side, to form the battery module <NUM>. Optional, the battery module <NUM> may include a case or other housing that holds the battery cells <NUM>. A battery cover may be provided over the tops of the battery cells <NUM>. The battery cover may cover each of the battery cells <NUM>.

Each battery module <NUM> includes a positive battery terminal and a negative battery terminal. The battery terminals are configured to be coupled to external power cables or alternatively may be bussed to battery terminals of another battery module <NUM>. Optionally, the battery terminals may be connected using quick-connection types of connectors.

The carrier assembly <NUM> is provided over the battery module <NUM>. The carrier assembly <NUM> holds the one or more connector assemblies <NUM>. The carrier assembly <NUM> includes one or more trays <NUM> holding a plurality of bus bars <NUM> (shown in <FIG>). The bus bars <NUM> have voltage sensors associated therewith. The connector assembly <NUM> is electrically connected to corresponding voltage sensors for monitoring the bus bars <NUM> and the battery cells <NUM>.

The connector assembly <NUM> includes a connector <NUM> and a multi-wire planar cable <NUM> terminated to corresponding terminals held in the connector <NUM>. The connector <NUM> is configured to be mated with the corresponding control module connector <NUM> (shown in <FIG>) of the battery control module <NUM> (shown in <FIG>). The connector assembly <NUM> is electrically connected to the bus bars <NUM> to monitor the voltage of the corresponding battery cells <NUM> of the battery module <NUM> by measuring the voltage across the buss bar <NUM> between the associated battery cells <NUM>. For example, the plurality of wires of the cable <NUM> may be electrically connected to corresponding bus bars <NUM>.

<FIG> is a top perspective view of one of the battery cells <NUM> formed in accordance with exemplary embodiment. The battery cell <NUM> includes a cell housing <NUM> having a top <NUM> and side walls <NUM>. In the illustrated embodiment, the cell housing <NUM> is boxed shaped having four side walls <NUM>.

The battery cell <NUM> includes a positive cell terminal <NUM> and a negative cell terminal <NUM>. In the illustrated embodiment, the terminals <NUM>, <NUM> include flat pads having upper surfaces that define connection interfaces for electrical connection to corresponding bus bars <NUM> (shown in <FIG>).

<FIG> is a top perspective view of one of the buss bars <NUM> formed in accordance with an exemplary embodiment. The buss bar <NUM> is used to electrically connect the cell terminals <NUM> or <NUM> (shown in <FIG>) of adjacent battery cells <NUM> (shown in <FIG>).

The buss bar <NUM> includes a positive plate <NUM> and a negative plate <NUM>. The positive plate <NUM> is configured to be terminated to a corresponding positive cell terminal <NUM> of one battery cell <NUM> and the negative plate <NUM> is configured to be terminated to a corresponding negative cell terminal <NUM> of the adjacent battery cell <NUM>.

The buss bar <NUM> includes a voltage sensor <NUM>. The voltage sensor <NUM> may extend from one of the plates, such as from the negative plate <NUM>. The voltage sensor <NUM> may be defined by one of the plates <NUM>, <NUM>. For example, the voltage sensor <NUM> may be a portion or surface of one of the plates <NUM>, <NUM>. In the illustrated embodiment, the voltage sensor <NUM> constitutes a weld tab configured to receive a wire <NUM> of the connector assembly <NUM> (shown in <FIG>). Welding provides a reliable connection with the wire <NUM> for accurate, reliable sensing. Other types of voltage sensors may be provided in alternative embodiments to connect to a corresponding component of the connector assembly <NUM>, such as a crimp barrel, an insulation displacement contact, a spring contact, a pin, a socket, a poke-in wire connection, and the like. The wire <NUM> may be affixed to the buss bar <NUM>, such as be crimping, welding, soldering, using conductive adhesive, and the like in other alternative embodiments. Optionally, the voltage sensor <NUM> may be stamped and formed with the bus bar <NUM>. In alternative embodiments, the voltage sensor <NUM> may be a separate component coupled to the bus bar <NUM>, such as by being soldered, welded, fastened or otherwise secured to the bus bar <NUM>.

<FIG> is a top view of an end <NUM> of the multi-wire planar cable <NUM> in accordance with an exemplary embodiment. <FIG> is a cross-sectional view of the cable <NUM>. The cable <NUM> extends between a connector end <NUM> and a sensor end <NUM>. The wires <NUM> at the connector end <NUM> are configured to be terminated to corresponding terminals of the connector <NUM> (shown in <FIG>). The wires <NUM> at the sensor end <NUM> are configured to be terminated to corresponding voltage sensors <NUM> (shown in <FIG>).

The cable <NUM> has a plurality of the wires <NUM> and a common jacket <NUM> for the plurality of wires <NUM>. The wires <NUM> are metal conductors. Optionally, the wires <NUM> may be flat wires having a rectangular cross-section. However, other types of wires may be provided in alternative embodiments, such as non-flat wires, rounded wires, and the like. In an exemplary embodiment, the cable <NUM> is flat or planar. The cable <NUM> is flexible. The cable <NUM> has the wires <NUM> arranged in a stacked arrangement with the wires <NUM> side-by-side. Each of the wires <NUM> are connected together as a unit by the common jacket <NUM> in a ribbon portion <NUM> (<FIG>) of the cable <NUM>.

The connector end <NUM> and/or the sensor end <NUM> of the cable <NUM> may have one or more of the wires <NUM> separated from each other for a length at a separation region <NUM> (<FIG>) of the cable <NUM> (any or all of the wires <NUM> may be separated from each other at the separation region <NUM>). For example, the separated portions may be torn or cut to separate portions of the wires <NUM>. The separated portions may be referred to as separated planar cable segments <NUM> of the cable <NUM>. Each separated planar cable segment <NUM> has one or more of the wires <NUM> and the corresponding portion of the material of the jacket <NUM>. The separated planar cable segments <NUM> extend from the ribbon portion <NUM> of the cable <NUM>, where the wires <NUM> remain intact and coupled together as a unit. The separated planar cable segments <NUM> are independently movable relative to each other, such as for termination to the terminals and/or for independent loading into the connector <NUM>. Each separated planar cable segment <NUM> includes at least one wire <NUM> and corresponding jacket portion. Optionally, the separated planar cable segments <NUM> may have multiple wires <NUM> and associated jacket portions with such jacket portions remaining intact and coupled together as a unit to the distal end of the cable <NUM>. Optionally, the separated planar cable segments <NUM> may have a ribbon segment along a portion thereof where the separated planar cable segment <NUM> is separated from other segment(s) <NUM> but where the jacket portions of the particular separated planar cable segment are not separated from each other, and then where one or more of the wires <NUM> may be separated downstream of the ribbon segment to the distal end.

In an exemplary embodiment, the separated planar cable segments <NUM> are separated at grooves <NUM> in the jacket <NUM>. The grooves <NUM> may be centered between adjacent wires <NUM>. The grooves <NUM> may be V-shaped to force separation at the point of the groove <NUM>, such as along the bisector line between the grooves <NUM>. The grooves <NUM> define boundaries between the wires <NUM> and force separation to occur along the grooves <NUM>. Without the grooves, tearing or cutting may wander away from one wire <NUM> and toward another wire <NUM> leading to some wires <NUM> have more jacketing material and other wires <NUM> having less jacketing material. Without controlled separation, portions of the wires <NUM> may be exposed by the tearing or cutting.

The jacket <NUM> is insulative and made from a dielectric material, such as polyurethane, polyvinylchloride, chlorinated polyethylene, thermoplastic elastomer, rubber, and the like. The jacket <NUM> has a top surface <NUM> and a bottom surface <NUM> opposite the top surface <NUM>. The top and bottom surfaces <NUM>, <NUM> are generally planar. A cable plane <NUM> (<FIG>) of the cable <NUM> is defined between the top and bottom surfaces <NUM>, <NUM>. The jacket <NUM> has a thickness between the top and bottom surfaces <NUM>, <NUM>. The thickness is relatively small compared to a length and a width of the cable <NUM>. The thickness may be reduced at the grooves <NUM>. For example, the thickness may be reduced by approximately <NUM>%, by approximately <NUM>%, by approximately <NUM>%, or more at the grooves <NUM>. The grooves <NUM> are provided on only the top surface <NUM> or the bottom surface <NUM>.

At the separation region <NUM>, the separated planar cable segments <NUM> have jacket portions <NUM> surrounding the wires <NUM> that define insulating sleeves and may be referred to hereinafter as insulating sleeves <NUM>. The insulating sleeves <NUM> extend a length of the wires <NUM> to the ribbon portion <NUM>. In an exemplary embodiment, terminating portions <NUM>, <NUM> of the wires <NUM> may be exposed beyond the insulating sleeves <NUM> at distal ends of the wires <NUM> for termination to the terminals of the connector <NUM> or to the voltage sensor <NUM>, respectively (for example, shown at the connector end <NUM> and on the top half of the wires <NUM> at the sensor end <NUM>). The terminating portion <NUM> is configured to be electrically connected to the bus bar <NUM> by the corresponding voltage sensor <NUM>.

Alternatively, rather than exposing the terminating portions <NUM>, <NUM> beyond the insulating sleeves <NUM>, the terminating portions <NUM>, <NUM> may be exposed through the insulating sleeve <NUM>, such as from the top surface <NUM> and/or the bottom surface <NUM>. For example, a portion of the jacket <NUM> may be removed to define a window <NUM> exposing the wire <NUM>. The exposed portion of the wire <NUM> may be electrically connected to the terminal or the voltage sensor <NUM>. In an exemplary embodiment, the wires <NUM> include punch-out portions <NUM> and dead portions <NUM> downstream of the terminating portions <NUM>. The punch-out portions <NUM> are formed by punching through the cable <NUM> to remove a length of the wire <NUM>. The punch-out portion <NUM> defines a discontinuity along the wire <NUM> such that the corresponding dead portion <NUM> is no longer electrically connected to the corresponding terminating portion <NUM>. The electrical signal on the wire <NUM> is only able to be transmitted upstream of the punch-out portion <NUM> to the connector end <NUM> and is unable to be transmitted along the dead portion <NUM>, which may reduce the risk of cross-talk or interference with other adjacent wires <NUM>. <FIG> illustrates a terminating portion <NUM>, a punch-out portion <NUM> and a dead portion <NUM> in cross-section for reference. The exposed terminating portions <NUM> define take-out points <NUM> for the wires <NUM> where the electrical signals are transferred to the wires <NUM>. The take-out points <NUM> may be at the distal ends of the wires <NUM> or may be upstream from the distal ends, such as at the terminating portions <NUM> upstream of the punch-out portions <NUM>.

In other various embodiments, the wire <NUM> may be electrically connected to the terminal or the voltage sensor <NUM> by the terminal or the voltage sensor <NUM> piercing the jacket <NUM>. For example, the terminal or voltage sensor <NUM> may be terminated by a pierce crimp. The point of the pierce crimp defines the take-out point <NUM> for the particular wire <NUM>.

The wires <NUM> have an upper flat side <NUM>, a lower flat side <NUM> and opposite first and second edges <NUM>, <NUM> between the flat sides <NUM>, <NUM>. In an exemplary embodiment, the insulating sleeves <NUM> surround the sides <NUM>, <NUM> and the edges <NUM>, <NUM> to ensure that no portion of the wires <NUM> are exposed, which could lead to a short circuit or arcing.

<FIG> is a perspective view of a portion of the connector assembly <NUM>. The connector assembly <NUM> includes the connector <NUM> provided at the connector end <NUM> of the multi-wire planar cable <NUM>. The cable <NUM> includes a plurality of the wires <NUM>, which are connected to corresponding voltage sensors <NUM> (shown in <FIG>) and to corresponding terminals of the connector <NUM>.

The connector <NUM> includes a housing holding the terminals (not shown). The housing extends between a front <NUM> and a rear <NUM>. The front <NUM> defines a mating end of the connector <NUM> configured for mating with the control module connector <NUM> (shown in <FIG>).

<FIG> is a front perspective view of the carrier assembly <NUM> including a plurality of the connector assemblies <NUM>. <FIG> is a rear perspective view of the carrier assembly <NUM> including a plurality of the connector assemblies <NUM>. <FIG> illustrates a portion of the carrier assembly <NUM>, showing the connector assemblies <NUM> and the bus bars <NUM> with the tray <NUM> removed for clarity.

The carrier assembly <NUM> includes the tray <NUM> holding the bus bars <NUM>. The tray <NUM> includes a top <NUM> and a bottom <NUM>. The bottom <NUM> is configured to be mounted to the battery module <NUM>. The tray <NUM> includes a front <NUM> and a rear <NUM> with sides <NUM> therebetween. A cover (shown in <FIG>) may be coupled to the tray <NUM> at the top <NUM>, such as being coupled to the front <NUM>, the rear <NUM> and/or the sides <NUM>.

The tray <NUM> includes pockets <NUM> receiving corresponding bus bars <NUM>. Optionally, the pockets <NUM> may be positioned generally along the front <NUM> and the rear <NUM>. The tray <NUM> includes channels <NUM> extending between various pockets <NUM>. The cables <NUM> may be routed in the channels <NUM> to interface with the corresponding bus bars <NUM>. In an exemplary embodiment, the tray <NUM> includes a central beam <NUM> extending between the sides <NUM> and being approximately centered between the front <NUM> and the rear <NUM>. The channels <NUM> may be provided on opposing sides of the central beam <NUM> between the central beam <NUM> and the pockets <NUM>. The channels <NUM> may be provided on top of the pockets <NUM>. The cables <NUM> may extend between the channels <NUM> across the central beam <NUM>.

In an exemplary embodiment, the sensor ends <NUM> of the cables <NUM> are separated into the various separated planar cable segments <NUM> and routed to different areas of the tray <NUM> for termination to different voltage sensors <NUM> associated with corresponding bus bars <NUM>. Optionally, the separated planar cable segments <NUM> may have different lengths to extend to the different areas for termination to different voltage sensors <NUM>. The separated planar cable segments <NUM> are branched in multiple directions including in opposite directions.

In an exemplary embodiment, the connectors <NUM> and connector ends <NUM> of the cables <NUM> are generally centrally located between the opposite sides <NUM> of the tray <NUM>. The separated planar cable segments <NUM> may then be branched outward from the center toward the sides <NUM>. The separated planar cable segments <NUM> may be branched to extend across the central beam <NUM> from one channel <NUM> to another channel <NUM>.

Various separated planar cable segments <NUM> may include a single wire <NUM> (shown in <FIG>) and associated surrounding jacket portion <NUM>. Other separated planar cable segments <NUM> may include multiple wires <NUM> and associated surrounding jacket portions <NUM>, which extend in a different direction than other separated planar cable segments <NUM> of the same cable <NUM>.

In an exemplary embodiment, the cables <NUM> may be stacked in a cable stack <NUM> to route the cables <NUM> to the various areas of the tray <NUM>. Some cables <NUM> may be stacked on other cables <NUM>. Some cables <NUM> may be stacked on themselves. For example, the cables <NUM> may be folded over at a folded section <NUM> to change a routing direction of the multi-wire planar cable <NUM>. For example, the folded section <NUM> of the cable <NUM> may allow the cable to be turned approximately <NUM>° to route from one channel <NUM> to the other channel <NUM>. The wires <NUM> overlap each other in the folded section <NUM>. The folded section <NUM> includes a folded edge <NUM>, which may be oriented at approximately a <NUM>° angle to achieve an approximate <NUM>° change in routing direction of the cable <NUM>. The wires <NUM> are generally co-planar along any particular section of the separated planar cable segments <NUM>. For example, upstream of the folded section <NUM> the wires <NUM> of a particular cable <NUM> are generally co-planar and downstream of the folded section <NUM> the wires <NUM> of a particular cable <NUM> are generally co-planar. However, at the folded section <NUM>, such as at the folded edge <NUM>, the wires transition.

Optionally, some cables <NUM> may be routed to similar areas and are thus routed within the cable stack <NUM> to a common area and then branched in appropriate directions for termination to targeted voltage sensors <NUM> or another sensor, such as a temperature sensor <NUM>. Optionally, the separated planar cable segments <NUM> of a particular cable <NUM> (for example, a first cable <NUM>) may be stacked with the separated planar cable segments <NUM> of a different cable <NUM> (for example, a second cable <NUM>), while other separated planar cable segments <NUM> of the first cable <NUM> may be routed in a different cable stack <NUM> with separated planar cable segments <NUM> of another cable <NUM> (for example, the second cable <NUM> or a third cable <NUM>). Portions of the separated planar cable segments <NUM> (for example, the portions closest to the sensor ends <NUM>) branch out from the cable stack <NUM> and are routed to different areas of the tray <NUM> for termination to different voltage sensors <NUM> than portions of the separated planar cable segments <NUM> of the other multi-wire planar cable(s) <NUM>.

<FIG> illustrates a portion of the carrier assembly <NUM> showing cables <NUM> of the connector assemblies <NUM>. <FIG> illustrates a portion of the carrier assembly <NUM> showing one of the cables <NUM> of one of the connector assemblies <NUM>. <FIG> shows the cable stack <NUM> showing multiple cables <NUM> stacked on top of each other within the channels <NUM>. <FIG> and <FIG> show the separated planar cable segments <NUM> extending in different directions to corresponding bus bars <NUM>. <FIG> illustrates a plurality of take-out points <NUM> where the separated planar cable segments <NUM> intersect with the bus bars <NUM>. Optionally, each separated planar cable segment <NUM> may include multiple take-out points <NUM>, one for each wire <NUM> (shown in <FIG>).

Claim 1:
A connector assembly (<NUM>) suitable for voltage monitoring of bus bars (<NUM>) electrically connecting adjacent battery cells (<NUM>) of a battery module (<NUM>), the connector assembly comprising:
a connector (<NUM>) having a plurality of terminals configured to be mated with a control module connector (<NUM>) associated with the battery module;
a multi-wire planar cable (<NUM>) extending from the connector, the multi-wire planar cable having a plurality of wires (<NUM>) terminated to corresponding terminals of the connector (<NUM>) and a common jacket (<NUM>) for the plurality of wires, the jacket having grooves (<NUM>) between adjacent wires for controlled separation of the wires and surrounding jacket portions at a sensor end (<NUM>) of the multi-wire planar cable to define separated planar cable segments (<NUM>), the separated planar cable segments configured to be routed to different areas for termination to different voltage sensors (<NUM>) associated with corresponding bus bars,
wherein the wires (<NUM>) include punch-out portions (<NUM>) and dead portions (<NUM>) downstream of the terminating portions (<NUM>, <NUM>), the punch-out portions defining a discontinuity along the wires such that the dead portions are no longer electrically connected to the corresponding terminating portions,
and wherein the grooves (<NUM>) are provided in only a top surface (<NUM>) or only a bottom surface (<NUM>) of the multi-wire planar cable (<NUM>).