Battery module terminal system and method

Patent metadata

Field	Value
Publication number	US-2016197328-A1
Application number	US-201514620113-A
Country	US
Kind code	A1
Filing date	Feb 11, 2015
Priority date	Jan 5, 2015
Publication date	Jul 7, 2016
Grant date	—

Abstract

The present disclosure includes a battery module that includes an electrochemical cell having a minor terminal. The battery module also includes a major terminal electrically coupled to the electrochemical cell, wherein the major terminal includes a base and a post extending from the base. Further, the battery module includes an electrical path between the minor terminal of the electrochemical cell and the major terminal of the battery module. The electrical path includes a bus bar having an opening that receives the post of the major terminal and a pocket that retains the base of the major terminal

First claim

1 . A battery module, comprising:
an electrochemical cell having a minor terminal; a major terminal electrically coupled to the electrochemical cell, wherein the major terminal comprises a base and a post extending from the base; and an electrical path between the minor terminal of the electrochemical cell and the major terminal of the battery module, wherein the electrical path comprises a bus bar having an opening that receives the post of the major terminal and a pocket that retains the base of the major terminal.

2 . The battery module of claim 1 , wherein the bus bar comprises a first flap that wraps from a top surface of the base of the major terminal to a bottom surface of the base to at least partially define the pocket.

3 . The battery module of claim 2 , wherein the bus bar comprises a second flap and a third flap that each wrap from the top surface of the base of the major terminal over respective side surfaces of the base, wherein the respective side surfaces of the base extend between the top surface and the bottom surface of the base and are disposed opposite each other, and wherein the first flap, the second flap, and the third flap at least partially define the pocket.

4 . The battery module of claim 2 , wherein the bus bar comprises a body that extends from the first flap and over the base of the major terminal, wherein the body comprises the opening and the body at least partially defines the pocket.

5 . The battery module of claim 1 , wherein the base comprises a rectangular portion.

6 . The battery module of claim 5 , wherein the base comprises a cylindrical or circular portion disposed within an opening in the rectangular portion.

7 . The battery module of claim 1 , wherein the bus bar comprises:
a main body having the opening; a curved portion extending from the main body; and an extension extending from the curved portion, wherein the curved portion enables an angle between the extension and the main body to position the extension proximate to a component of the electrical path configured to be coupled to the extension.

8 . The battery module of claim 1 , wherein the post is integrally formed with the base.

9 . The battery module of claim 1 , wherein the major terminal comprises a first material and the bus bar comprises a second material different than the first material.

10 . The battery module of claim 9 , wherein the first material is copper or the second material is stainless steel.

11 . The battery module of claim 9 , wherein the electrical path comprises:
a bi-metal bus bar having a first metal portion coupled to the minor terminal of the electrochemical cell; and a bridge in electrical communication with, and extending between, the bus bar and a second metal portion of the bi-metal bus bar, wherein the first metal portion comprises a third material and the second metal portion comprises the second material.

12 . The battery module of claim 9 , wherein the electrical path comprises:
a connecting bar coupled to, and extending from, the minor terminal of the electrochemical cell; a bi-metal extension and a first metal portion of the bi-metal extension coupled to, and extending from, the connecting bar; a first bridge coupled to, and extending between, a second metal portion of the bi-metal extension and a shunt; and a second bridge coupled to, and extending between, the shunt and the bus bar, wherein the first bridge, the second bridge, the shunt, and the second metal portion of the bi-metal extension are formed of the second material and wherein the first metal portion of the bi-metal extension and the connecting bar are formed of a third material.

13 . The battery module of claim 1 , comprising a housing in which the electrochemical cell is disposed, wherein the housing receives the electrochemical cell, and wherein the base of the major terminal, a portion of the bus bar, or a combination thereof is embedded within the housing.

14 . The battery module of claim 1 , wherein the major terminal and the bus bar are coupled together without welds.

15 . The battery module of claim 1 , wherein the electrochemical cell comprises a prismatic electrochemical cell, a lithium-ion electrochemical cell, or a combination thereof.

16 . A method of manufacturing a battery module, comprising:
disposing a post of a module terminal through an opening in a bus bar; wrapping a first extension of the bus bar from a first surface of a base of the module terminal to a second surface of the base opposite to the first surface.

17 . The method of claim 16 , comprising wrapping a second side extension of the bus bar and a third side extension of the bus bar from the first surface of the base around a third surface of the base and a fourth surface of the base, respectively, wherein the third surface and fourth surface extend between the first surface and the second surface.

18 . The method of claim 17 , comprising stamping the first extension, the second side extension, the third side extension, or a combination thereof, around the base of the module terminal.

19 . The method of claim 17 , comprising heating the first extension, the second side extension, the third side extension, or a combination thereof to enable wrapping of the first extension, the second side extension, the third side extension, or the combination thereof around the base of the module terminal.

20 . The method of claim 16 , comprising cutting the bus bar from sheet metal.

21 . The method of claim 16 , comprising embedding the base of the module terminal, a portion of the bus bar, or a combination thereof, within a wall of a housing of the battery module.

22 . The method of claim 21 , wherein embedding the base of the module terminal, the portion of the bus bar, or the combination thereof within the wall of the housing of the battery module comprises injection molding.

23 . A battery module, comprising:
a first electrochemical cell having a first terminal, a second electrochemical cell having a second terminal, and one or more intermediate electrochemical cells electrically connected between, and to, the first electrochemical cell and the second electrochemical cell; a first electrical path extending between the first terminal of the first electrochemical cell and a first major terminal of the battery module and comprising a first major bus bar, wherein the first major terminal comprises a first post that extends through a first opening in the first major bus bar, and a first base that is coupled to the first post and retained within a first pocket of the first major bus bar at least partially defined by one or more first extensions of the first major bus bar that wrap around the first base of the first major terminal; and a second electrical path extending between the second terminal of the electrochemical cell and a second major terminal of the battery module and comprising a second major bus bar, wherein the second major terminal comprises a second post that extends through a second opening in the second major bus bar, and a second base that is coupled to the second post and retained within a second pocket of the second major bus bar at least partially defined by one or more second extensions of the second major bus bar that wrap around the second base of the second major terminal.

24 . The battery module of claim 23 , comprising a plastic housing that houses the first electrochemical cell, the second electrochemical ce

Assignees

• Johnson Controls Tech Co

Inventors

• Mack Robert J
• Dekeuster Richard M
• Thompson Michael L
• Lobert Jonathan P
• Soleski Edward J

Classifications

• H01M50/516 Primary

  by welding, soldering or brazing · CPC title

• H01M2220/20

  Batteries in motive systems, e.g. vehicle, ship, plane · CPC title

• H01M50/505 Primary

  comprising a single busbar · CPC title

• H01M50/566

  by welding, soldering or brazing · CPC title

• H01M50/562

  characterised by the material · CPC title