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1.发明授权公开(公告)号：US10530019B2
公开(公告)日：2020-01-07
申请号：US15341392
申请日：2016-11-02
发明人： Evan J. Dawley , Wayne W. Cai
摘要： A battery module includes a battery cell, a bus bar, and a multilayered cell sense flex circuit having a senseline tab containing a portion of a senseline. The flex circuit determines a battery cell voltage. The bus bar has surface projections, possibly with a variable height and/or width, such that the bus bar penetrates into the tab at least as far as the senseline. Adhesive material may be used on the welded joint. A method of manufacturing the battery module includes forming, in the bus bar, one or more surface projections, e.g., multiple projections having the variable height and/or width, positioning a senseline tab of the flex circuit adjacent to such projections, and joining the tab to the surface projections such that the projections penetrate at least partially into the flex circuit at least as far as the senseline.
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2.发明申请公开(公告)号：US20190312280A1
公开(公告)日：2019-10-10
申请号：US15946803
申请日：2018-04-06
发明人： Evan J. Dawley , Sherman H. Zeng
IPC分类号： H01M4/66 , H01M10/04 , H01M10/647 , H01M2/26 , H01M2/10
摘要： A battery cell has positive and negative cell tabs protruding from a first edge and a cell stack-up within a pouch. Anode and cathode foils are connected to the cell tabs proximate the first edge, with the anode foils connected to each other proximate a second edge. An outermost current collector of the anode foils exists with respect to a thickness of the cell stack-up. The cathode foils are connected to the positive cell tab proximate the first edge. The anode foils are connected to each other and the negative cell tab proximate the second edge, such that the outermost current collector forms an internal bus bar between the first and second edges. The battery cell has asymmetrical packaging and symmetrical internal current paths. A system includes a battery pack driving a load, with the battery pack having battery cells constructed as set forth above.
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公开(公告)号：US20180352656A1
公开(公告)日：2018-12-06
申请号：US15612145
申请日：2017-06-02
发明人： Evan J. Dawley , Roger M. Brisbane
CPC分类号： H05K1/189 , H01M2/1072 , H01M2/206 , H01M2/22 , H01M10/04 , H01M10/4207 , H01M10/613 , H01M10/655 , H01M10/6555 , H01M2010/4271 , H05K2201/10037
摘要： A method of assembling a power module includes placing a first plurality of cells adjacent to one another to form a first cell layer. A flexible circuit layer is positioned above the first cell layer, the flexible circuit being electrically conductive. A second plurality of cells is positioned adjacent to one another to form a second cell layer aligned with the first cell layer such that the flexible circuit layer is sandwiched between the first cell layer and the second cell layer. The flexible circuit layer is folded along each of a plurality of axes of rotation such that each one of the first plurality of cells faces another one of the second plurality of cells. Each of the first plurality of cells and the second plurality of cells has respective first and second tabs (extending from their respective short ends) which are welded to the flexible circuit layer.
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公开(公告)号：US10991998B2
公开(公告)日：2021-04-27
申请号：US16259295
申请日：2019-01-28
IPC分类号： H01M10/653 , H01M10/617 , H01M10/6551 , H01M10/625 , H01M10/613
摘要： A thermal interface member may comprise a substrate having a first surface and an opposite second surface, an electrically conductive layer disposed on the first surface of the substrate, and an electrically resistive layer disposed on the first surface of the substrate. The substrate may comprise a compliant electrically insulating and thermally conductive material including a polymeric matrix phase and a dispersed phase of thermally conductive particles. The conductive layer may be patterned into a first electrode and a second electrode spaced apart from the first electrode on the first surface of the substrate. The resistive layer may be in electrical contact with the first and second electrodes of the conductive layer and may comprise a resistive material having a positive resistance temperature coefficient and a resistance that increases with an increase in temperature.
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5.发明申请公开(公告)号：US20200275555A1
公开(公告)日：2020-08-27
申请号：US16285952
申请日：2019-02-26
发明人： Evan J. Dawley
摘要： A method of manufacturing an interconnect board (ICB) assembly for a battery module, the ICB assembly having a printed circuit board assembly (PCBA) and a carrier frame, includes depositing solder paste onto a printed circuit board (PCB) and/or a flexible printed circuit (flex circuit). The flex circuit has a conductive foil substrate coated with insulating material, and defines tabular flying leads radially-projecting from the flex circuit's periphery. The method may include positioning the PCB adjacent to the flex circuit such that the PCB and flex circuit are in direct contact along a flex interface surface of the PCB, and integrally joining the PCB and flex circuit along the interface surface to form the PCBA. The PCBA connects to the carrier frame to construct the ICB assembly. The battery module may be manufactured by connecting the ICB assembly to battery cells of the battery module.
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公开(公告)号：US20200243927A1
公开(公告)日：2020-07-30
申请号：US16429802
申请日：2019-06-03
IPC分类号： H01M10/653 , H01M10/6551 , H01M10/613 , H01M10/617 , H01M10/625
摘要： A thermal interfacing assembly for use in a power module having at least one battery module and a cooling plate, and corresponding method of forming the thermal interfacing assembly. The thermal interfacing material is deposited over a first surface of the cooling plate such that the thermal interfacing material conforms to the shape of the first surface. The thermal interfacing material is configured to be electrically insulating and thermally conductive. A first embedded heater is positioned adjacent to the thermal interfacing material. The first embedded heater includes an electrically-conductive portion and a resistive portion. The battery module is installed adjacent to the first embedded heater such that the first embedded heater is directly in contact with a first face of the battery module. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.
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公开(公告)号：US10680226B2
公开(公告)日：2020-06-09
申请号：US15979900
申请日：2018-05-15
发明人： Evan J. Dawley
摘要： A battery assembly includes a battery cell, conductive bus bar, and printed circuit board assembly (PCBA). A cell tab of the battery assembly has a first portion extending from a perimeter edge of a pouch and a second portion arranged orthogonally with respect to the first portion. The bus bar defines a tab slot through which the first portion extends, and has a major surface adjacent to the second portion. The PCBA defines an elongated welding window orthogonal to a longitudinal axis of the PCBA. The PCBA is mounted over the bus bar such that surface area of the second portion is exposed through the welding window, and in turn is welded to the bus bar through and within the welding window. A spring element may be positioned between the carrier frame and the PCBA. A method of making the battery assembly is also provided.
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公开(公告)号：US20190288323A1
公开(公告)日：2019-09-19
申请号：US16429833
申请日：2019-06-03
发明人： Evan J. Dawley
IPC分类号： H01M10/04 , H01M10/0525 , H01M2/20
摘要： 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.
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公开(公告)号：US09912018B2
公开(公告)日：2018-03-06
申请号：US14461566
申请日：2014-08-18
发明人： Evan J. Dawley , Glenn F. Carroll
CPC分类号： H01M10/482 , G01R31/362 , G01R31/3696 , H01M2/1077 , H01M2/206 , H01M10/0413 , H01M10/0486 , H01M10/425 , H01M2200/103 , H01M2220/20 , Y10T29/49108
摘要： A battery pack, an integrated device for sensing individual battery voltage in a battery pack and a method of forming an integrated voltage-sensing circuit for use in a battery-powered automobile propulsion system. The integrated voltage-sensing circuit includes a busbar, a terminal pin and a voltage-sensing fuse electrically disposed between the busbar and the terminal pin. The construction of the voltage-sensing circuit is such that it forms an integral structure upon being coupled to the modular housing or related structure that may subsequently be secured to a frame that is used to provide support to each battery cell within the battery pack. In one form, the modular housing and voltage-sensing circuit may be secured to the frame during a frame molding process such that upon completion of the molding, the housing and at least a portion of the voltage-sensing circuit are encapsulated within the frame. In another form, the busbar or related voltage trace that signally couples each of the battery cells in a pack may be integrated into the frame, such as by overmolding.
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公开(公告)号：US11621462B2
公开(公告)日：2023-04-04
申请号：US17174739
申请日：2021-02-12
IPC分类号： H01M50/56 , H01M50/505 , H01M50/517 , H01M50/204
摘要： Presented are finger-proof electrical terminals for battery assemblies, methods for making/using such electrical terminals, and vehicles with battery modules having finger-proof electrical terminals for bolted busbar connections. A battery assembly includes one or more electrochemical battery cells and one or more electrical terminals each electrically connected to the battery cell(s) and having a contact face to electrically connect the battery assembly to an electrical connector. A threaded nut attaches each electrical terminal to one of the electrical connectors. An electrically insulating nut cap is attached to each threaded nut. A battery housing, which stores therein the battery cell(s), includes an electrically insulating housing wall with one or more terminal jackets each mounting therein one of the electrical terminals. Each terminal jacket has a jacket window that circumscribes one of the nut caps, spaced therefrom by a predefined clearance sufficient to expose the contact face of the electrical terminal.
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