Patent Application
20250118870
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 C.F.R. § 1.57.
This application is directed to bus bars that facilitate electrical connection of battery cells in a battery module.
Typical battery modules use bus bars that connect a number of battery cells within the module. In larger assemblies of batteries more than one module may be provided. This can result in complexities in connecting the battery modules together within a larger battery assembly.
There is a need for an improved bus bar, e.g., one that allows battery cells in more than one longitudinally aligned row to be coupled to a single bus bar. Also, there is a need for enhanced flexibility in a manner of connecting more than one battery module in a larger battery assembly.
In one embodiment, a battery module has a width and a length. The battery module comprises a plurality of battery cells and a plurality of bus bars. The plurality of battery cells are arranged in a plurality of physical rows along the length of the battery module. The plurality of bus bars are located along the length of the battery module and defining a plurality of electrical rows of battery cells. Each bus bar is electrically coupled to battery cells of more than one of the physical rows. The battery cells of each electrical row are connected in parallel and the electrical rows are connected in series.
In some embodiments, at least one of the battery cells of each physical row is not connected in parallel with an adjacent battery cell in the physical row. In some embodiments each bus bar is electrically coupled to battery cells in three physical rows. In some embodiments, each bus bar of the plurality of bus bars connects a number of battery cells that exceeds the number of battery cells in one of the physical rows. In some embodiments, the battery cells in a first physical row are positioned offset the battery cells in a second physical row adjacent to the first physical row. In some embodiments, the battery modules further comprise a top plate positioned on top of the plurality of battery cells, the top plate comprising a plurality of openings configured to expose a positive terminal and a negative terminal of each battery cell.
In one embodiment, a battery assembly comprises a housing and a battery module enclosed by the housing. The battery module comprises a plurality of battery cells and a plurality of bus bars. The plurality of battery cells are positioned in a plurality of physical rows. Each bus bar of the plurality of bus bars is coupled to a subset of battery cells of the plurality of battery cells disposed in more than one physical row. The bus bar and the subset of batteries coupled thereto forming electrical rows of the battery. The battery cells of each electrical row are connected in parallel and the electrical rows are connected in series.
In some embodiments, the battery module is a first battery module. The battery assembly further comprising a second battery module. The first battery module and the second battery module configured to have opposite polarities. In some embodiments, the battery assembly is coupled to a vehicle. In some embodiments, at least one of the battery cells of each physical row is not connected in parallel with an adjacent battery cell of the physical row. In some embodiments, each bus bar is electrically coupled to battery cells in three physical rows. In some embodiments, the battery assembly further comprises a top plate positioned on top of the plurality of battery cells, the top plate comprising a plurality of openings configured to expose a positive and a negative terminal of each battery cell of the plurality of battery cells.
In one embodiment, a battery module comprises a plurality of battery cells and a plurality of bus bars. The plurality of battery cells are arranged in a plurality of linear rows. A first end of each of the plurality of battery cells is coupled to a bottom plate. The plurality of bus bars are coupled to a top plate. The top plate is positioned above a second end of each of the plurality of battery cells. The top plate comprises a plurality of openings configured to expose a positive terminal and a negative terminal of each battery cell. At least one bus bar of the plurality of bus bars has a non-linear shape whereby a first portion of the at least one bus bar is coupled with one or more battery cells in a select linear row of the plurality of linear rows and a second portion of the at least one bus bar is coupled with one or more cells not in the select linear row of the plurality of linear rows.
In some embodiments, the battery cells of electrical rows formed by each bus bar and the battery cells coupled thereto are connected in parallel and the electrical rows are connected in series. In some embodiments, at least one of the battery cells of each linear row is not connected in parallel with other battery cells of the linear rows whereby the linear rows are not connected in series. In some embodiments, each bus bar is electrically coupled to battery cells in three linear rows. In some embodiments, each bus bar connects a number of battery cells that exceeds the number of battery cells in each of at least one of the linear rows. In some embodiments, the battery cells in a first linear row are positioned offset the battery cells in a second linear row adjacent to the first linear row.
Features of the invention can be better understood from the following detailed description when read in conjunction with the accompanying schematic drawings, which are for illustrative purposes only. The drawings include the following figures:
While the present description sets forth specific details of various embodiments, it will be appreciated that the description is illustrative only and should not be construed in any way as limiting. Furthermore, various applications of such embodiments and modifications thereto, which may occur to those who are skilled in the art, are also encompassed by the general concepts described herein. Each and every feature described herein, and each and every combination of two or more of such features, is included within the scope of the present invention provided that the features included in such a combination are not mutually inconsistent.
This application discloses battery modules, in particular bus bars that facilitate electrical connection of battery cells within a battery module. While the term bus bar is primarily used herein, the bus bar(s) can also be referred to as a current collectors or battery interconnects. The battery modules can have physical rows of battery cells running along a length of the battery module and electrical rows of batteries that are defined by the shape and/or path of the bus bars. Electrical rows can correspond to a physical row in one or more segments or portions and can deviate from a physical row in one or more segments or portions. In some cases, adjacent bus bars can collect current from battery cells in a same or common physical row. In some cases, a bus bar can collect current from cells in three adjacent physical rows and can collect current from battery of a primary row and from battery cells in two adjacent rows. In some aspects, a bus bar can collect current from a first adjacent physical row shared with a first adjacent bus bar and from a second adjacent physical row shared with a second adjacent bus bar.
In
At least one mounting system 240 can be provided in a recess 212 between the central portion 206 and the first lateral portion 204. The recess 212 can include a bight formed by the housing 200. The bight can be formed in a concave periphery on the top side of the housing 200. The bight can include a more complex shape such as two U-shaped or concave portions on opposite sides of a central vertical plan of the housing 200. The mounting system 240 can include a first member 242 fixed to a wall of the housing 200 (e.g., to a wall of the second lateral portion 208) that is facing the beam 160 and a second member or component 244 for connecting the first member 242 to the beam 160.
The battery assembly 174 can include one or more battery modules 300. The battery modules 300 can be positioned within the housing 200 in any one or more of the lateral portions 204, 208, or the central portion 206. For example, the first lateral portion 204 can have one, two, three, or more battery modules 300. In addition to the W-shaped configuration of
While the battery module 300 is illustrated as being used in a battery assembly for a vehicle, the bus bars described herein can be used in battery modules used in any context where battery modules are used. For example, battery modules for passenger vehicles, battery modules for heavy-duty vehicles, battery modules for home energy storage, battery modules for storage of electricity generated by various systems and sources (e.g., solar, wind, water) may use the bus bars described herein.
The battery cells 312 positioned in a physical row 313 can be separated a distance D, as shown in
The bus bars 316 can extend along a top plate (or “cell holder”) 320, shown in
The bus bars 316 can separate the battery cells 312 into electrical rows 315, discussed in more detail below and shown in
The bus bars 316 can connect any number of battery cells 312. In some embodiments, a single bus bar 316 can connect more battery cells 312 than the number of battery cells 312 in a single physical row 313. The bus bars 316 can connect battery cells 312 from two physical rows 313, as described in more detail below. The bus bars 316 can connect battery cells 312 from three physical rows 313, as described in more detail below. The bus bars 316 can connect battery cells 312 from more than three physical rows 313. The appearance and/or pattern of the bus bars 316 can be determined based on the battery cells 312 being connected. For example, portions of the bus bars 316 can extend length-wise, width-wise, and angled directions in a horizontal plane to be positioned in a location to be able to connect to the necessary battery cells 312, as described in more detail below.
The battery module 300 can have electrical connectors. A first electrical connector 328 can electrically connect a first terminal 346 to the bus bars 316. A second electrical connector 336 can electrically connect the bus bars 316 to a second terminal 348. The first terminal 346 and the second terminal 348 are used to couple the battery module 300 to other battery modules and/or other vehicle systems. As will be described herein, the first terminal 346 and the second terminal 348 may be configured to have different polarities, depending on the configuration of the wire bonds used to couple the battery cells to the bus bars. That is, in some embodiments, the first terminal 346 is a positive terminal and the second terminal 348 is a negative terminal, and in other embodiments, the first terminal 346 is a negative terminal and the second terminal 348 is a positive terminal.
The first electrical connector 328 and the second electrical connector 336 can be positioned along first and second sides of the battery module 300, extending along the length L of the battery module 300 and opposite each other. In some embodiments, the first electrical connector 328 and the second electrical connector 336 have an L shape, wrapping around a portion of the length of the battery module and a portion of the width of the battery module. In some embodiments, the first electrical connector 328 and the second electrical connector 336 have a straight shape along the length of the battery module, and the terminals 346 and 348 are located along the length of the battery module. The first electrical connector 328 and the second electrical connector 336 may each be made of a single piece of conductive material or may be made of a plurality of pieces of conductive material coupled together. The first electrical connector 328 and the second electrical connector 336 can span a portion of the height H of the battery module 300 and connect to the bus bars 316 at multiple discrete locations or continuously along a length of the outermost bus bars 316. The first electrical connector 328 and the second electrical connector 336 may have features, shapes, or dimensions that promote distribution of current along the length of the module.
A cooling system may be used to regulate the temperature of the battery cells 312 of the battery module 300. In some embodiments, a cooling fluid or substance is located between the battery cells 312 within the battery module 300. In some embodiments, cooling tubes are disposed between the battery cells 312 and a fluid is circulated within the cooling tubes to absorb heat from the battery cells 312. In some embodiments, a cooling plate is used to facilitate cooling of the battery cells 312. The cooling system can provide for uniform cooling across the battery module 300.
The plurality of openings 324 can have a variety of shapes. The shape of the openings 324 can be dependent upon the positioning of the battery cells 312 and the bus bars 316. The plurality of openings 324 can be sized and shaped to expose both negative and positive connection points or terminals on each battery cell 312. Some openings 324a can define an area having generally circular ends connected by an elongate, e.g., a generally rectangular portion. Some openings 324b can have a generally circular center connected by an elongate, e.g., a generally rectangular portions to ends having generally half-circular shapes. Some openings 324c can have a generally circular center with elongate, e.g., generally rectangular, ends. Some openings 324d can have one generally circular end, a generally circular center and a generally half-circular end connected by elongate, e.g., generally rectangular portions. Some openings 324e can have one generally circular end connected to a generally semi-circular end. Any combination of circular, half-circular, and elongate, e.g., rectangular opening 324 is possible. The half-circular openings allow a bus bar to be located over a battery cell while still allowing for access to the positive and negative terminals of the partially-covered battery cell. The partially-covered battery cell is electrically insulated and separated from the bus bar disposed above it.
The design and shape of the bus bars 316 can determine the size and shapes of the openings 324. For example, using the orientation of
While the configuration of
The battery cells 312 of each electrical row 315 can be connected in parallel. The electrical rows 315 can be connected in series. The battery cells 312 of each physical row 313 are not connected in parallel due to the winding shape of the bus bars. The physical rows 313 are not connected in series.
While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present inventions is defined only by reference to the appended claims.
Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.
Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.
For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.
Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.
Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.
The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.
| Number | Date | Country | |
|---|---|---|---|
| 63639427 | Apr 2024 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US2023/026954 | Jul 2023 | WO |
| Child | 18982442 | US |
