Configurations for power module having an integrated flexible circuit assembly

Patent metadata

Field	Value
Publication number	US-11038192-B2
Application number	US-201916429833-A
Country	US
Kind code	B2
Filing date	Jun 3, 2019
Priority date	Jun 2, 2017
Publication date	Jun 15, 2021
Grant date	Jun 15, 2021

Abstract

Configurations for a power module having a flexible circuit assembly and corresponding method. The flexible circuit assembly has at least one electrically conductive portion. A first plurality of cells is placed adjacent to one another to form a first cell layer, the first cell layer being positioned on a first side of the flexible circuit assembly. Each of the first plurality of cells has a respective cell body with at least four respective edges. The first plurality of cells has respective cell tabs, including a respective first tab and a respective second tab both extending from one of the at least four respective edges. The flexible circuit assembly is configured to be aligned with the first cell layer such that a voltage sensing circuit joint is concurrently completed when the respective cell tabs of the first cell layer are joined to respective captured portions of the flexible circuit assembly.

First claim

What is claimed is:

1. A power module comprising:
a flexible circuit assembly having at least one electrically conductive portion, the flexible circuit assembly defining a first side and a second side;
a first plurality of cells placed adjacent to one another to form a first cell layer, the first cell layer being positioned on the first side of the flexible circuit assembly;
wherein each cell of the first plurality of cells has a respective cell body with at least four respective edges;
wherein each cell of the first plurality of cells has respective cell tabs, including a respective first tab and a respective second tab both extending from one of the at least four respective edges of the respective cell body;
wherein the flexible circuit assembly includes at least one thermal sheet configured to experience a change in electrical resistance in response to a temperature change, the at least one thermal sheet including a heat-conducting element arranged with a thermistor material;
wherein the flexible circuit assembly includes a senselead portion having a plurality of traces respectively connected to a plurality of pads; and
wherein the flexible circuit assembly is configured to be aligned with the first cell layer such that a voltage sensing circuit joint is concurrently completed when the respective cell tabs of each cell of the first cell layer are joined to respective captured portions of the flexible circuit assembly.

2. The power module of claim 1 , wherein:
the at least four respective edges in each cell of the first plurality of cells include two long opposing edges and two short opposing edges; and
the respective first tab and the respective second tab in each cell of the first plurality of cells extend from one of the two long opposing edges of the respective cell body.

3. The power module of claim 1 , wherein:
the at least four respective edges in each cell of the first plurality of cells include two long opposing edges and two short opposing edges; and
the respective first tab and the respective second tab in each cell of the first plurality of cells extend from one of the two short opposing edges of the respective cell body.

4. The power module of claim 1 , wherein:
the plurality of traces is substantially parallel to one another and extends in a first direction; and
the plurality of pads is substantially parallel to one another and extends in a second direction orthogonal to the first direction.

5. The power module of claim 4 , wherein:
the plurality of pads is configured to extend along a first peripheral portion and a second peripheral portion of the flexible circuit assembly, the first peripheral portion and the second peripheral portion being parallel and on opposing sides.

6. The power module of claim 1 , further comprising:
a second plurality of cells placed adjacent to one another to form a second cell layer, the second cell layer being positioned on the second side of the flexible circuit assembly;
wherein each cell of the second plurality of cells has respective cell tabs; and
wherein the respective cell tabs of neighboring pairs of the first cell layer and the second cell layer are configured to be joined to respective captured portions of the flexible circuit assembly.

7. The power module of claim 6 , wherein:
the flexible circuit assembly is configured to be folded along at least one axis of rotation such that one of the first plurality of cells faces another one of the second plurality of cells.

8. The power module of claim 6 , further comprising:
a third cell layer positioned exterior to the first cell layer and including a third plurality of cells adjacent to one another; and
a fourth cell layer positioned exterior to the second cell layer and including a fourth plurality of cells adjacent to one another.

9. The power module of claim 1 , further comprising:
a second plurality of cells placed adjacent to one another to form a second cell layer; and
wherein the second cell layer is positioned on the first side of the flexible circuit assembly adjoining the first cell layer such that the first cell layer and the second cell layer are in a same plane.

10. The power module of claim 9 , wherein:
the first thermal sheet and a second thermal sheet are each respectively dimensioned such that at least a portion of the plurality of pads is exposed on the first side and the second side of the flexible circuit assembly.

11. A power module comprising:
a flexible circuit assembly having at least one electrically conductive portion, the flexible circuit assembly defining a first side and a second side;
a first plurality of cells placed adjacent to one another to form a first cell layer, the first cell layer being positioned on the first side of the flexible circuit assembly;
wherein each cell of the first plurality of cells has a respective cell body with at least four respective edges;
wherein each cell of the first plurality of cells has respective cell tabs, including a respective first tab and a respective second tab extending from opposing edges of the at least four respective edges of the respective cell body;
wherein the flexible circuit assembly includes at least one thermal sheet and a senselead portion having a plurality of traces respectively connected to a plurality of pads, the at least one thermal sheet being configured to experience a change in electrical resistance in response to a temperature change;
wherein the plurality of pads is electrically conductive on the first side and the second side, the plurality of pads being configured to interface with each cell of the first plurality of cells; and
wherein the flexible circuit assembly is configured to be aligned with the first cell layer such that a voltage sensing circuit joint is concurrently completed when the respective cell tabs of each cell of the first cell layer are joined to respective captured portions of the flexible circuit assembly.

12. The power module of claim 11 , wherein:
the at least four respective edges in each cell of the first plurality of cells include two long opposing edges and two short opposing edges; and
the respective first tab and the respective second tab of each cell of the first plurality of cells extend from the two short opposing edges of the respective cell body.

13. The power module of claim 11 , wherein:
the at least four respective edges in each cell of the first plurality of cells include two long opposing edges and two short opposing edges, the respective first tab and the respective second tab respectively extending from the two long opposing edges of the respective cell body; and
the respective first tab and the respective second tab of neighboring pairs of each cell of the first plurality of cells are configured to be joined.

14. The power module of claim 13 , wherein:
the respective first tab of a first of the neighboring pairs is offset from an imaginary center axis in a first direction, the imaginary center axis extending through a center of the respective cell body; and
wherein the respective second tab of a second of the neighboring pairs is offset from the imaginary center axis in a second direction opposite to the first direction.

15. The power module of claim 11 , wherein:
the plurality of pads is configured to interface along an entire length of the respective cell tabs of each cell of the first plurality of cells.

16. The power module of claim 11 , wherein:
the plurality of pads is configured to interface along a respective portion of the respective cell tabs of each cell of the first plurality of cells, and

Assignees

• Gm Global Tech Operations Llc

Inventors

• Dawley Evan J

Classifications

• H01M50/572

  Means for preventing undesired use or discharge · CPC title

• H01M50/569

  Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals (battery terminal connectors with integrated measuring arrangements G01R31/364) · CPC title

• H01M50/516

  by welding, soldering or brazing · CPC title

• H01M50/507 Primary

  comprising an arrangement of two or more busbars within a container structure, e.g. busbar modules · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title