Patent ID: 12230829

It should be understood that the drawings are not necessarily to scale. 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. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that 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.

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, the battery module may include a support member (e.g., lid) that is disposed within a housing of the battery module that includes one or more mounting clips for securing a printed circuit board (PCB) within the battery housing. The clips are configured to be more robust to tolerance stack ups. In particular, the clips are more robust with regard to part variation (e.g., parts associated with the PCB). Each clip includes a recess that receives and holds the PCB while enabling the PCB to slightly move within the recess (e.g., during expansion of components of the PCB) to dampen loading. The recess also provides flexibility with regard to the location and/or height of the PCB relative to the housing and busbars of the battery module. The clips may reduce manufacturing equipment and steps needed to install the PCB into the housing. Avoiding additional components to secure the PCB into the housing reduces cost. In addition, the clips take up less space on the PCB, thus, maximizing the usable space on the PCB. In addition, since the clips take up less space on the PCB, it enables more direct connections between components of the PCB (e.g., traces).

To help illustrate,FIG.1is a perspective view of an embodiment of a vehicle10, 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 system12to be largely compatible with traditional vehicle designs. Accordingly, the battery system12may be placed in a location in the vehicle10that would have housed a traditional battery system. For example, as illustrated, the vehicle10may include the battery system12positioned similarly to a lead-acid battery of a typical combustion-engine vehicle (e.g., under the hood of the vehicle10). Furthermore, as will be described in more detail below, the battery system12may be positioned to facilitate managing temperature of the battery system12. For example, in some embodiments, positioning a battery system12under the hood of the vehicle10may enable an air duct to channel airflow over the battery system12and cool the battery system12.

A more detailed view of the battery system12is described inFIG.2. As depicted, the battery system12includes an energy storage component13coupled to an ignition system14, an alternator15, a vehicle console16, and optionally to an electric motor17. Generally, the energy storage component13may capture/store electrical energy generated in the vehicle10and output electrical energy to power electrical devices in the vehicle10.

In other words, the battery system12may 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 component13supplies power to the vehicle console16and the ignition system14, which may be used to start (e.g., crank) the internal combustion engine18.

Additionally, the energy storage component13may capture electrical energy generated by the alternator15and/or the electric motor17. In some embodiments, the alternator15may generate electrical energy while the internal combustion engine18is running. More specifically, the alternator15may convert the mechanical energy produced by the rotation of the internal combustion engine18into electrical energy. Additionally or alternatively, when the vehicle10includes an electric motor17, the electric motor17may generate electrical energy by converting mechanical energy produced by the movement of the vehicle10(e.g., rotation of the wheels) into electrical energy. Thus, in some embodiments, the energy storage component13may capture electrical energy generated by the alternator15and/or the electric motor17during regenerative braking. As such, the alternator15and/or the electric motor17are generally referred to herein as a regenerative braking system.

To facilitate capturing and supplying electric energy, the energy storage component13may be electrically coupled to the vehicle's electric system via a bus19. For example, the bus19may enable the energy storage component13to receive electrical energy generated by the alternator15and/or the electric motor17. Additionally, the bus19may enable the energy storage component13to output electrical energy to the ignition system14and/or the vehicle console16. For example, when a 12-volt battery system12is used, the bus19may carry electrical power typically as a non-limiting example between 8-18 volts.

Additionally, as depicted, the energy storage component13may include multiple battery modules. For example, in the depicted embodiment, the energy storage component13includes a lithium ion (e.g., a first) battery module20and a lead-acid (e.g., a second) battery module22, which each includes one or more battery cells. In other embodiments, the energy storage component13may include any number of battery modules. Additionally, although the lithium ion battery module20and lead-acid battery module22are depicted adjacent to one another, they may be positioned in different areas around the vehicle. For example, the lead-acid battery module22may be positioned in or about the interior of the vehicle10while the lithium ion battery module20may be positioned under the hood of the vehicle10.

In some embodiments, the energy storage component13may include multiple battery modules to utilize multiple different battery chemistries. For example, when the lithium ion battery module20is used, performance of the battery system12may 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 system12may be improved.

To facilitate controlling the capturing and storing of electrical energy, the battery system12may additionally include a control module24. More specifically, the control module24may control operations of components in the battery system12, such as relays (e.g., switches) within energy storage component13, the alternator15, and/or the electric motor17. For example, the control module24may regulate amount of electrical energy captured/supplied by each battery module20or22(e.g., to de-rate and re-rate the battery system12), perform load balancing between the battery modules20and22, determine a state of charge of each battery module20or22, determine temperature of each battery module20or22, control voltage output by the alternator15and/or the electric motor17, and the like.

Accordingly, the control unit24may include one or more processor26and one or more memory28. More specifically, the one or more processor26may 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 memory28may 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 unit24may include portions of a vehicle control unit (VCU) and/or a separate battery control module.

FIGS.3and4show perspectives of an exploded side view of an embodiment of the battery module20for use in the vehicle10ofFIG.1. For simplicity, not all components of the battery module20are illustrated (e.g., terminals, bus bars, sensors, etc.). The battery module20(e.g., lithium-ion (Li-ion) battery module) includes a housing30(e.g., plastic housing), a support member32(e.g., lid), a PCB34, and a cover36. A plurality of electrochemical cells38(e.g., Li-ion electrochemical cells) are disposed within the housing30. In certain embodiments, the battery module20may include any number of electrochemical cells38(e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or more electrochemical cells), any type of electrochemical cell38(e.g., Li-ion, lithium polymer, lead-acid, nickel cadmium, or nickel metal hydride, prismatic, and/or cylindrical), and any arrangement of the electrochemical cells38(e.g., stacked, separated, or compartmentalized).

The housing30includes an opening40on one side42(upper side or face) to receive the electrochemical cells38. The support member32is disposed within the opening40above the electrochemical cells38. The support member32includes one or more clips44(e.g., mounting clips) disposed on a side46of the support member32opposite the electrochemical cells38. The number of clips44may vary (e.g., 1, 2, 3, 4, 5, 6, or more clips44). The clips44may be molded as part of the support member32. In certain embodiments, the clips44may be coupled or adhered to the support member32. The clips44secure the PCB34to the support member32to secure the PCB34within the housing30. In certain embodiments, the PCB34receives signals from sensors and processes the signals to provide useful information relating to the operating conditions of the battery module20. The cover36is disposed over the opening40to enclose the components within the battery module20.

As discussed in greater detail below, the clips44are configured to be more robust to tolerance stack ups. In particular, the clips44are more robust with regard to part variation (e.g., parts associated with the PCB). Each clip44includes a recess78that receives and holds the PCB34while enabling the PCB34to slightly move within the recess78(e.g., during expansion of components of the PCB34) to dampen loading. The recess78also provides flexibility with regard to the location and/or height of the PCB34relative to the housing30and busbars of the battery module20. In certain embodiments, the clips44include components (e.g., cross member48) that act as a vibration dampener. In certain embodiments, displacement of the clip44, when the PCB34is inserted, is spread out over multiple locations of the clip44(e.g., due to self-opposing features of the clip44).

FIGS.5-8are different views of an embodiment of the mounting clip44for securing the PCB34. The mounting clip44includes a cross member48located at a top portion50of the clip44, a structure52(e.g., support structure), a pair of flanking support members54, and a pair of foot members56(e.g., stops) located at a bottom portion58of the clip44. The cross member48extends crosswise to a longitudinal axis60of the structure52. The cross member48acts as a vibrational dampener. The flanking support members54are coupled to respective longitudinal ends62,64of the cross member48. The support members54extend in a vertical direction66(e.g., crosswise to a longitudinal axis68of the cross member48) from the top portion50to the bottom portion58of the clip44. Each flanking support member54has a longitudinal length70greater than a longitudinal length72of the structure52. This enables the structure52to be suspended in the vertical direction66(e.g., crosswise to longitudinal axis68). The flanking support members54flank the structure52.

The clip44includes a front side74(e.g., that interfaces with the PCB34) and a back side76. The structure52includes a recess78that extends partially into structure52in a direction80from the front side74toward the back side76. The recess78also extends parallel to the longitudinal axis68of the cross member48(as well as crosswise to the longitudinal axis60of the structure52). The recess78is configured to receive and hold the PCB34. The PCB34may vary in thickness (e.g., tolerance or functional stackup). The shape of the recess78may vary. As depicted, the recess78has a wedge shape (e.g., narrows or tapers in the direction80). The recess78is configured to enable the PCB34to slightly move within the recess78(e.g., during thermal expansion of the PCB34) to dampen loading. In addition, the recess78is sized to enable the PCB34to expand within the recess78. A portion82of the structure52defining the recess78includes an upper region or portion84and a lower region or portion86. The lower region86extends further away from the structure52(e.g., in a direction toward the PCB34) than the upper region84. The surface defining the upper portion of the recess78is acutely angled relative to the surface defining the lower portion of the recess78to keep the PCB34from slipping out of the recess during vibrations or shock.

As depicted, the recess78is located in a lower portion88of the structure52(e.g., adjacent the bottom portion58of the clip44). The structure52includes an upper portion90located above the recess78. The upper portion90tapers or narrows from adjacent the recess78to the cross member48(e.g., adjacent the top portion50of the clip44). The upper portion90includes an inclined face92located on the front side74of the clip44(e.g., the same side as the recess78). The inclined face92is angled at an acute angle relative to the longitudinal axis60of the structure52. The angle of the inclined face92may vary (e.g., approximately 5, 10, 15, 20, 25 degrees, or any other acute angle). The inclined face92enables the clip44to receive PCB34in the vertical direction66.

The upper portion90(along with the rest of the structure52) is configured to flex (e.g., deflect) in the direction66to enable the PCB34to be moved from above the clip44into the recess78. In addition, the flanking support members54are also configured to flex or deflect. Thus, the self-opposing arrangement of the clip44enables displacement of the clip44(with the PCB34in place) to occur to be distributed across multiple areas (e.g., the flanking support members54and the structure52).

As depicted inFIGS.5-7, a respective foot member56(e.g., stop) is disposed adjacent to and contacts a respective flanking support member54at the bottom portion58of the clip44. Each foot member56includes a top surface94located beneath the recess78. The foot members56are configured to keep the PCB34from being pressed too far into the mounting clip in the direction66. In other words, the PCB34cannot be pressed in the direction66past the foot members56. In certain embodiments, the foot members56are disposed adjacent to but spaced apart from the flanking support members54as depicted inFIG.8.

The configuration of the clip44may be robust to material choice. In certain embodiments, the clip44may be made of plastic. For example, the clip44may be made of unfilled polypropylene or glass filled polypropylene.

FIGS.9A and9Bare overhead perspective views of various embodiments of a plurality of the mounting clips44ofFIG.4coupled to the PCB34. As noted above, the clips44may be molded as part of the support member32(e.g. lid) or coupled (e.g., adhered or fastened) to the support member32. As depicted, four clips44couple the PCB34to the support member32. As noted above, the number of clips44to secure the PCB34may vary. As depicted, the clips44may be spaced apart. In certain embodiments, the clips44may be located adjacent each other. In certain embodiments, protrusions96(e.g., guides) may extend (e.g., vertically) from the support member32to act as guides during the coupling of the PCB34to the clips44.

FIGS.10-13are different views of an embodiment of the mounting clip44(e.g., having C-shaped region defining recess) for securing the PCB34. In certain embodiments, the clip44may be made of plastic. For example, the clip44may be made of a glass filled polypropylene (for example, but not limited to, 30 percent glass filled). The mounting clip44includes a structure98(for example, but not limited to, support structure) having a top portion100and a bottom portion102. The clip44includes a front side104(for example, which may interface with the PCB34) and a back side106. The structure52includes a recess108that extends partially into structure98in a direction110from the front side104toward the back side106. The recess108also extends crosswise to a longitudinal axis112of the structure98. The recess108is configured to receive and hold the PCB34. The shape of the recess108may vary. As depicted, the recess108slightly narrows or tapers in the direction110. The recess108is configured to enable the PCB34to slightly move within the recess108(e.g., during expansion of the PCB34) to dampen loading. In addition, the recess108is sized to enable the PCB34to expand within the recess108. A portion114of the structure98defining the recess108includes an upper region or portion116and a lower region or portion118. The lower region116extends further away from the structure98(e.g., in a direction toward the PCB34) than the upper region116.

As depicted, the recess108is located centrally between the top portion100and the bottom portion102of the clip44. The structure98includes an upper portion120located above the recess108. The upper portion120tapers or narrows from adjacent the recess108to the top portion100of the clip44. The upper portion120includes an inclined face122located on the front side104of the clip44(e.g., the same side as the recess108). The inclined face122is angled at an acute angle relative to the longitudinal axis112of the structure98. The angle of the inclined face122may vary (e.g., approximately 5, 10, 15, 20, 25 degrees, or any other acute angle). The inclined face122enables the clip44to receive PCB34in the vertical direction124. The upper portion120is configured to flex (e.g., deflect) in the direction110to enable the PCB34to be moved from above the clip44into the recess108.

FIG.13is an overhead perspective view of an embodiment of a plurality of the mounting clips44ofFIG.10coupled to the PCB34. As noted above, the clips44may be molded as part of the support member32(e.g. lid) or coupled (e.g., adhered or fastened) to the support member32. As depicted, four clips44are coupling the PCB34to the support member32. As noted above, the number of clips44to secure the PCB34may vary. As depicted, the clips44may be spaced apart. In certain embodiments, the clips44may be located adjacent each other. In certain embodiments, protrusions126(e.g., guides) may extend (e.g., vertically) from the support member32to act as guides during the coupling of the PCB34to the clips44.

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. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention. 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.

While specific examples are shown, one of skill in the art will recognize that these are examples only and variations thereon may be made without departing from the overall scope of the present invention.

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 and claimed are considered to be within the scope of the invention as recited in the appended claims.

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.) without materially departing from the novel teachings and advantages of the subject matter recited. 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. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the various examples of embodiments without departing from the spirit or scope of the present inventions.

While this invention has been described in conjunction with the examples of embodiments outlined above, various alternatives, modifications, variations, improvements and/or substantial equivalents, whether known or that are or may be presently foreseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the examples of embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit or scope of the invention. Therefore, the invention is intended to embrace all known or earlier developed alternatives, modifications, variations, improvements and/or substantial equivalents.

The technical effects and technical problems in the specification are exemplary and are not limiting. It should be noted that the embodiments described in the specification may have other technical effects and can solve other technical problems.