Battery module printed circuit board assembly system and method

Patent metadata

Field	Value
Publication number	US-2017324075-A1
Application number	US-201715658239-A
Country	US
Kind code	A1
Filing date	Jul 24, 2017
Priority date	Sep 6, 2013
Publication date	Nov 9, 2017
Grant date	—

Abstract

A battery module includes a housing, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

First claim

1 . A battery module, comprising:
a housing; a plurality of battery cells disposed in the housing; and a printed circuit board (PCB) assembly disposed in the housing, the PCB assembly comprising:
a PCB; and
a shunt disposed across a first surface of the PCB, wherein a second surface of the shunt directly contacts the first surface of the PCB, and wherein the shunt is electrically coupled between the plurality of battery cells and a terminal of the battery module.

2 . The battery module of claim 1 , comprising a bus bar that is in electrical communication with one of the plurality of battery cells and a connector that is in electrical communication with the terminal of the battery module, wherein the shunt provides a low resistance path between the bus bar of the battery module and the connector of the battery module.

3 . The battery module of claim 2 , wherein the connector comprises an integral bladed portion that extends over and in contact with the shunt, such that the shunt is held between the first surface of the PCB and a bottom surface of the bladed portion of the connector.

4 . The battery module of claim 2 , wherein the bus bar comprises an extension that extends over and in contact with the shunt, such that the shunt is disposed between the first surface of the PCB and a bottom surface of the extension of the bus bar.

5 . The battery module of claim 1 , comprising a lid disposed between the PCB assembly and the plurality of battery cells, wherein the lid is configured to support the PCB assembly, wherein the lid comprises a shunt clip extending upwardly from the lid, and wherein the shunt clip comprises an extension configured to contact a top surface of the shunt, such that the shunt is disposed between the first surface of the PCB and a bottom surface of the extension of the shunt clip.

6 . The battery module of claim 5 , wherein the shunt clip extends upwardly from the lid through an aperture in the PCB.

7 . The battery module of claim 1 , wherein the PCB comprises an electrical connection exposed on the first surface, wherein the electrical connection is in contact with the second surface of the shunt, and wherein the electrical connection enables the PCB to monitor characteristics of an electrical flow through the shunt.

8 . The battery module of claim 7 , wherein the characteristics of the electrical flow comprise voltage output from the battery module.

9 . The battery module of claim 1 , wherein the second surface of the shunt directly contacts the first surface of the PCB without the shunt extending off the first surface of the PCB.

10 . The battery module of claim 1 , wherein the shunt is integral with the PCB.

11 . A method, comprising:
enabling an electric current to flow from a plurality of battery cells in a battery module to an output terminal of the battery module via a shunt of a printed circuit board (PCB) assembly in the battery module, wherein a bottom surface of the shunt directly contacts a top surface of a PCB of the PCB assembly, wherein the bottom surface of the shunt directly contacts an electrical connection of the PCB exposed through the top surface of the PCB; receiving a signal indicative of the electric current flowing through the shunt at a measurement device of the PCB via the electrical connection; and measuring characteristics of the battery module based on the signal received via the measurement device.

12 . The method of claim 11 , wherein enabling an electric current to flow from a plurality of battery cells in a battery module to an output terminal of the battery module comprises:
enabling electric current to flow from a terminal of one of the plurality of battery cells through a bus bar to the shunt; and enabling electric current to flow from the shunt to the output terminal of the battery module through a connector.

13 . The method of claim 12 , wherein the shunt is disposed above the top surface of the PCB and below a bottom surface of an extension of the bus bar, a bottom surface of a bladed portion of the connector, or a combination thereof.

14 . The method of claim 11 , wherein receiving the signal comprises receiving a second flow of electric current flowing from the shunt through the electrical connection of the PCB, wherein the electrical connection is configured to direct the second flow of electric current to the measurement device.

15 . The method of claim 11 , wherein the characteristics comprise a voltage output of the battery module.

16 . The method of claim 11 , comprising:
supporting the PCB assembly on a lid of the battery module, wherein the lid is disposed over the plurality of battery cells; and pressing the shunt against the top surface of the PCB via a shunt clip extending upwardly from the lid, wherein the shunt clip exerts a downward force against a top surface of the shunt.

17 . A method of manufacturing a battery module, the method comprising:
disposing a printed circuit board (PCB) on top of a lid of the battery module; disposing a shunt on top of and directly against the PCB; coupling the shunt to a bus bar on a first end of the shunt and to a connector on a second end of the shunt opposite the first end, wherein the connector is coupled to an output terminal of the battery module; coupling the bus bar to a terminal of a battery cell of the battery module; coupling a bottom surface of the shunt with electrical connectors exposed on a top surface of the PCB; and restraining the shunt on top of the PCB via a shunt clip extending upwardly from the lid and over the shunt, wherein the shunt clip comprises an extension configured to exert a downward force against a top surface of the shunt.

18 . The method of claim 17 , comprising coupling the shunt to the PCB via adhesive applied between the bottom surface of the shunt and the top surface of the PCB.

19 . The method of claim 17 , wherein the connector extends from below the lid through an aperture in the lid, wherein a bladed portion of the connector extends over and in contact with a top surface of the shunt.

20 . The method of claim 17 , wherein an extension of the bus bar extends over and in contact with a top surface of the shunt.

Assignees

• Johnson Controls Tech Co

Inventors

• Dulle Ronald J
• Gunderson Mark D
• Thieme Bryan L

Classifications

• B60L58/24

  for controlling the temperature of batteries · CPC title

• B60L58/15

  Preventing overcharging · CPC title

• H01M50/35

  Gas exhaust passages comprising elongated, tortuous or labyrinth-shaped exhaust passages · CPC title

• H01M50/572

  Means for preventing undesired use or discharge · CPC title

• H01M50/543

  Terminals · CPC title