Patent ID: 12237546

DETAILED DESCRIPTION

Embodiments are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale. Some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art.

Various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

Due to cell count increases on some electric vehicle battery packs, multiple corresponding battery pack sensing modules, instead of a single battery pack sensing module, may be required. It may be desirable, however, to reduce battery pack sensing module counts.

Some battery pack sensing modules use a single board-to-board connection system mounted on a particular type of board, and the mating side on a board stiffener on the array side. This arrangement may require an individual battery pack sensing module for each array stack, potentially multiple per array. If a larger battery pack sensing module were made, it may need to connect to multiple arrays. Connecting multiple arrays together in such a configuration may require robust tolerance design for sense lead connector placement variation.

Higher battery pack series cell counts could thus be handled by using a single larger battery pack sensing module. Such a battery pack sensing module may have multiple battery monitoring integrated circuits and bridge across two arrays or cell stacks. Due to this bridge design, large arrays designed with multiple cell stacks can have a single battery pack sensing module mounting strategy. A single battery pack sensing module could simplify the design architecture with the corresponding arrays and meet packaging requirements while minimizing resistance values. A single battery back sensing module could also eliminate at least one pack interface connector and relax requirements for tight tolerances to ensure a seamless array assembly process.

In some examples, the battery pack sensing module assembly would have one pack interface connector and two sense lead connectors linked to the battery pack sensing module board by flexible printed circuit board allowing more flexibility for assembly and requiring less precise tolerances.

Mounting the proposed battery pack sensing modules to corresponding hardware could introduce blind operations for connector insertion. These battery back sensing modules could also be subject to tolerance stack-up issues, stress on soldered connectors, and vibration. An internal array bridge bracket may thus also be introduced.

The bridge bracket, in certain examples, is a molded plastic assembly that sits on top of both battery assemblies (one per sub-array), and can provide a mounting surface for the individual flexible printed circuit boards and connector stiffener boards that originate from each sub-array. The bridge bracket may have integrated studs and locating pins that protrude through the array cover to guide the battery pack sensing module alignment. It may also have downward-facing pegs that engage with the center wall between the sub-arrays to align components during array assembly. The bridge bracket thus enables direct alignment from the array internal components to the battery pack sensing module assembly.

Referring toFIG.1, a traction battery assembly10includes a battery pack sensing module12and a pair of battery arrays14,16that are adjacent to each other. The battery pack sensing module12includes, among other things, a case18and a pair of sense lead connectors20,22rigidly connected at opposite ends of the battery pack sensing module12. The battery array14includes a plurality of battery cells24each having a voltage sense lead26extending therefrom, a receiving connector28recessed within a case of the battery array14, and flexible printed circuit board30electrically connecting the voltage sense leads26and the receiving connector28. The battery array16includes a plurality of battery cells32each having a voltage sense lead34extending therefrom, a receiving connector36recessed within a case of the battery array16, and flexible printed circuit board38electrically connecting the voltage sense leads34and the receiving connector36.

The battery pack sensing module12is carried by and spans between the battery arrays14,16such that the sense lead connector20engages the receiving connector28, and the sense lead connector22engages the receiving connector36.

Referring toFIG.2, a battery pack sensing module40includes, among other things, a case42, a pair of sense lead connectors44,46at opposite ends of the battery pack sensing module40, and a flexible printed circuit board48. The sense lead connector44is rigidly connected at an end of the battery pack sensing module40. The sense lead connector46is flexibly connected at another end of the battery pack sensing module40via the flexible printed circuit board48.

Referring toFIG.3A, a battery pack sensing module50includes, among other things, a case52, a pair of sense lead connectors54,56at opposite ends of the battery pack sensing module50, and a flexible printed circuit boards58,60flexibly connected at opposite ends of the battery pack sensing module50via the flexible printed circuit boards58,60.

Referring toFIG.3B, a traction battery assembly62includes the battery pack sensing module50and a pair of battery arrays64,66that are adjacent to each other. The battery array64includes a plurality of battery cells68each having a voltage sense lead70extending therefrom, a receiving connector72(FIG.3A) recessed within a case of the battery array14, and flexible printed circuit board74electrically connecting the voltage sense leads70and the receiving connector72. The battery array66includes a plurality of battery cells76each having a voltage sense lead78extending therefrom, a receiving connector80recessed within a case of the battery array66, and flexible printed circuit board82electrically connecting the voltage sense leads78and the receiving connector82.

The battery pack sensing module50is carried by and spans between the battery arrays64,66such that the sense lead connector54engages the receiving connector72, and the sense lead connector56engages the receiving connector80. The battery pack sensing module50further includes a rigid printed circuit board84carried by and bridging between the battery arrays64,66, a plurality of integrated circuits86mounted on the printed circuit board84and electrically connected with the flexible printed circuit boards58,60, and a single pack interface connector88electrically connected with the integrated circuits86.

Referring toFIG.4, the battery arrays64,66have disposed between them a center wall90that defines a plurality of cavities92therein, and have thereon a bracket94that spans between them. The bracket94includes a plurality of locating pins96that project away from the battery arrays64,66and toward the battery pack sensing module50, and a plurality of additional pins98that project toward the center wall90. The locating pins94are on opposite ends of the bracket94and provide features that cooperate with the case52to locate the battery pack sensing module50relative to the battery arrays64,66. The additional pins98engage the cavities92to prevent the bracket94from rotating relative to the battery arrays64,66.

Referring toFIG.5, the traction battery assembly62further includes a cap98that covers the battery arrays64,66and center wall90, and the case52defines a plurality of holes100around a perimeter thereof. The cavity defined by the case52contains the sense lead connectors54,56, flexible printed circuit boards58,60, rigid printed circuit board84, integrated circuits86, and pack interface connector88. The locating pins96extend through and away from the cap96and engage the holes100.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. In the illustrated examples for example, the sense lead connectors extend away from the battery pack sensing module and the receiving connectors are recessed within the cases of the battery arrays. In other examples, the sense lead connectors may be recessed within a case of the battery sensing module and the receiving connectors may extend away from the battery arrays. The bracketry in the illustrated examples is relatively planar in construction. It may, however, resemble a scaffold or other support structure, etc.

The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of these disclosed materials.

As previously described, the features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes may include, but are not limited to strength, durability, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.