CN107210388B - 用于电池模块的独立焊接平面 - Google Patents
用于电池模块的独立焊接平面 Download PDFInfo
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- CN107210388B CN107210388B CN201680003609.1A CN201680003609A CN107210388B CN 107210388 B CN107210388 B CN 107210388B CN 201680003609 A CN201680003609 A CN 201680003609A CN 107210388 B CN107210388 B CN 107210388B
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- Prior art keywords
- battery module
- conductive
- conductive material
- lithium ion
- cell
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- 239000004020 conductor Substances 0.000 claims abstract description 84
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 claims abstract description 42
- 229910001416 lithium ion Inorganic materials 0.000 claims abstract description 42
- 230000037361 pathway Effects 0.000 claims abstract description 19
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- 238000000034 method Methods 0.000 claims description 34
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- 239000000203 mixture Substances 0.000 claims description 2
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- 229910052721 tungsten Inorganic materials 0.000 description 3
- 239000010937 tungsten Substances 0.000 description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
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- 229910000831 Steel Inorganic materials 0.000 description 2
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- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000002708 enhancing effect Effects 0.000 description 2
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- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 229910052737 gold Inorganic materials 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
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- 229910052744 lithium Inorganic materials 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
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- 229910052759 nickel Inorganic materials 0.000 description 2
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- 150000003071 polychlorinated biphenyls Chemical class 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000001172 regenerating effect Effects 0.000 description 2
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- 239000010959 steel Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000013589 supplement Substances 0.000 description 2
- 229910052718 tin Inorganic materials 0.000 description 2
- 239000011135 tin Substances 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 230000001133 acceleration Effects 0.000 description 1
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- 239000003345 natural gas Substances 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
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Abstract
本公开涉及一种锂离子电池模块,所述锂离子电池模块包括具有基底的外壳、所述外壳中的电池单元,和经由电气通路联接至所述电池单元的电池模块端子;其中所述电池模块端子当联接至电负载时提供电气输出,并且其中所述电气通路由第一部分、第二部分和连接所述第一部分和所述第二部分的互连部分限定。所述第一部分具有多个第一导电部件,所述多个第一导电部件利用第一导电材料在第一连接平面内彼此联接,并且所述第一连接平面大体平行于所述基底。所述第二部分具有多个第二导电部件,所述多个第二导电部件利用不同于所述第一导电材料的第二导电材料在第二连接平面内彼此联接,并且所述第二连接平面横向于所述第一连接平面。
Description
相关申请的交叉引用
本申请要求提交于2015年1月5日的标题为“具有竖直和水平配置的锂离子电池模块的机械和电气方面(MECHANICAL AND ELECTRICAL ASPECTS OF LITHIUM ION BATTERYMODULE WITH VERTICAL AND HORIZONTAL CONFIGURATIONS)”的美国临时申请序列No.62/100,001和提交于2015年3月31日的标题为“用于电池模块的独立焊接平面(SEPARATEWELDING PLANES FOR A BATTERY MODULE)”的美国申请序列No.14/675,661的优先权和权益,这两个申请的全部内容通过引用并入本文用于所有目的。
背景技术
本公开总体涉及电池和电池模块领域。更具体地,本公开涉及用于电池模块的独立焊接平面。
该部分旨在向阅读者介绍本领域的各个方面,这些方面可涉及在下文进行描述的本公开的各个方面。该讨论据信有助于向阅读者提供背景信息以有利于更好理解本公开的各个方面。因此,应当理解,这些陈述要以该角度来阅读,并且不视为对现有技术的承认。
使用一个或多个电池系统以用于对车辆提供所有或一部分原动力的车辆可称为xEV,其中术语“xEV”在本文中定义为包括使用电力用作全部或部分车辆原动力的以下所有车辆,或其任何变型或组合。例如,xEV包括利用电力用作全部原动力的电动车辆(EV)。如本领域的技术人员将理解,也视为xEV的混合动力电动车辆(HEV)将内燃机推进系统和电池供能电动推进系统(诸如48伏特(V)或130V系统)相组合。术语“HEV”可包括混合动力电动车辆的任何变型。例如,全混合动力系统(FHEV)可利用一个或多个电动机,仅利用内燃机或利用两者将原动力和其它电力提供给车辆。相比之下,轻度混合动力系统(MHEV)在车辆空转时停用内燃机,并利用电池系统来继续对空气调节单元、收音机或其它电子装置供能以及需要推进时重新启动发动机。轻度混合动力系统还可例如在加速期间应用一定程度的动力辅助以补充内燃机。轻度混合动力通常为96V至130V,通过皮带或曲柄集成起动器发电机回收制动能量。另外,微混合动力电动车辆(mHEV)也使用类似于轻度混合动力的“起停”系统,但是微混合动力系统可向内燃机供应或不供应电力辅助并且以低于60V的电压操作。出于当前讨论的目的,应当指出的是,mHEV通常技术上不将直接提供至曲轴或传动装置的电力用于车辆的任何部分的原动力,但是mHEV仍可视为xEV,因为其在车辆空转(其中内燃机停用)以及通过集成起动器发电机回收制动能量时不使用电力来补充车辆的电力需求。此外,插入式电动车辆(PEV)为任何车辆,该车辆可从外部电源(诸如壁插座)进行充电,并且存储于可充电电池组中的能量驱动或有助于驱动车轮。PEV为EV的子类,包括纯电动或电池电动车辆(BEV)、插入式混合动力电动车辆(PHEV),以及混合动力电动车辆和传统内燃机车辆的电动车辆变换。
上文所描述的xEV相比于较传统的天然气动力车辆可提供多个优点,较传统天然气动力车辆仅使用内燃机和传统电气系统,该传统电气系统通常为由铅酸电池模块供电的12V系统。例如,相比于传统内燃机车辆,xEV可产生较少不期望排放产物并且可表现出较高的燃料效率,并且在一些情况下,此类xEV可完全消除汽油的使用,如同特定类型的EV或PEV那样。
随着技术持续发展,需要对此类车辆和其它实施方式提供改进的动力源,特别是电池模块。例如,电池模块的各种导电部件之间所建立的连接可利用焊接点来形成。遗憾的是,这些连接中的一些连接可能难以制备,或因存在不相似材料而可能达不到最佳。尽管可期望的是直接地简单联接不同导电材料,但是此类连接可受到不需要的电流效应,该电流效应可使连接劣化。因此,现已认识到,期望的是不相似导电材料之间的改进的过渡以用于增强电池的稳定性和寿命。
发明内容
下文说明了所公开的某些实施例的概述。应当理解,提出这些方面仅用于向阅读者提供这些特定实施例的简要概述并且这些方面不旨在限制本公开的范围。实际上,本公开可涵盖下文可能未提出的各个方面。
本公开涉及一种锂离子电池模块,该锂离子电池模块包括具有基底的外壳、设置于外壳中的电池单元,和经由电气通路电气联接至电池单元的电池模块端子;其中电池模块端子配置成当联接至电负载时提供电池模块的电气输出,并且其中电气通路由第一部分、第二部分和连接第一部分和第二部分的互连部分限定。电气通路的第一部分具有多个第一导电部件,该多个第一导电部件利用第一导电材料在第一连接平面内彼此电气联接,并且第一连接平面大体平行于外壳的基底。电气通路的第二部分包括多个第二导电部件,该多个第二导电部件利用不同于第一导电材料的第二导电材料在第二连接平面内彼此电气联接,并且第二连接平面相对于第一连接平面横向取向。
本公开还涉及一种用于构造锂离子电池模块的方法,该方法包括接近电池模块的外壳的第一侧,其中锂离子电池模块包括电池单元。该方法还经由第一侧上的第一多个焊接点将多个第一导电部件彼此联接,其中第一多个焊接点利用第一导电材料在第一连接平面内制备,并且第一连接平面大体平行于外壳的基底。该方法还接近横向于第一侧的外壳的第二侧,并且经由第二侧上的第二多个焊接点将多个第二导电部件彼此联接。第二多个焊接点利用不同于第一导电材料的第二导电材料在第二连接平面内制备,并且第二连接平面相对于第一连接平面横向取向;最后,该方法经由互连部分将多个第一导电部件联接至多个第二导电部件,该互连部分具有第一端部处的第一导电材料和第二端部处的第二导电材料。
本公开还涉及一种锂离子电池模块,该锂离子电池模块包括具有基底的外壳、设置于外壳中并且具有电池单元取向方向的电池单元,和经由电气通路电气联接至电池单元的电池模块端子。电气通路根据包括以下步骤的过程来制备:接近外壳的第一侧;经由第一侧上的第一多个焊接点将多个第一导电部件彼此联接,其中第一多个焊接点利用第一导电材料在第一连接平面内制备,并且第一连接平面大体平行于外壳的基底;和接近横向于第一侧的外壳的第二侧。制备电气通路的过程包括经由第二侧上的第二多个焊接点将多个第二导电部件彼此联接,其中第二多个焊接点利用不同于第一导电材料的第二导电材料在第二连接平面内制备,并且第二连接平面相对于第一连接平面横向取向。最后,制备电气通路的过程包括经由互连部分将多个第一导电部件联接至多个第二导电部件,该互连部分具有第一端部处的第一导电材料和第二端部处的第二导电材料。
附图说明
本公开的各个方面经阅读下述具体实施方式并参考附图可更好地理解,其中:
图1为根据本公开的一个方面的具有配置成对xEV的各种部件提供电力的电池系统的xEV的透视图;
图2为根据本公开的一个方面的利用图1的电池系统的xEV的实施例的剖面示意图;
图3为根据本公开的一个方面的利用独立焊接平面所构造的电池模块的示意图;
图4为根据本公开的一个方面的图3的电池模块的部件的分解图;
图5为根据本公开的一个方面的具有形成于独立焊接平面中的电连接的图4的电池模块部件的实施例的图示;
图6为根据本公开的一个方面的互连汇流条的实施例的图示;和
图7为根据本公开的一个方面的用于构造图3的电池模块的过程的流程图。
具体实施方式
下文将描述一个或多个具体实施例。为提供对这些实施例的简洁描述,说明书中未描述实际实施方式的所有特征。应当理解,在任何此类实际实施方式的开发中,如在任何工程或设计项目中,必须做出许多特定于实施方式的决策以达到开发者的特定目标,诸如符合系统相关和业务相关约束条件,这些约束条件可根据实施方式变化。此外,应当理解,此类开发工作可能是复杂且耗时的,然而对于受益于本公开的技术人员而言将为设计、制作和制造的例行任务。
电池模块的各种导电部件之间所建立的连接可为冶金的,并且可利用焊接技术或其它合适技术来形成。遗憾的是,这些连接中的一些可能难以制备,或因电池模块中存在不相似材料而可能达不到最佳。例如,电池端子可包括第一导电材料(例如,铝),而模块端子可包括第二导电材料(例如,铜)。尽管将不相似导电材料直接联接在一起看似可取,但是此类连接可能会受到不需要的电流效应(例如,腐蚀),该电流效应可使连接劣化。因此,现已认识到,期望的是不相似导电材料(例如,导电模块部件的金属)之间改进的过渡,例如用于增强电池的稳定性和寿命。
另外,本发明实施例总体涉及在电池模块(例如,锂离子电池模块)组装期间所执行的焊接平面的分离(例如,方向)。本公开中术语“焊接”的使用旨在涵盖用于将两种导电材料(例如,金属或含金属材料)联接在一起的任何合适方法(或由任何此类方法产生的结合)。本公开所涵盖方法的非限制性示例包括超声焊接、激光焊接、钨极惰性气体保护(TIG)焊接、电弧焊接、摩擦焊接,等等。尽管本公开集中讨论将所公开技术应用于锂离子电池模块,但是应当认识到,锂离子电池模块仅为可符合本公开的一个或多个方面的模块的一个示例并且不应视为将本公开限制于一个特定的模块配置。
为帮助说明,图1为车辆10的实施例的透视图,车辆可利用根据当前公开技术所构造的电池系统12。现已认识到,可期望的是非传统电池系统12(例如,锂离子汽车电池)很大程度上兼容传统车辆设计。在这方面,本发明实施例包括用于xEV和系统(包括xEV)各种类型的电池模块。因此,电池系统12可放置于车辆10中已容纳传统电池系统(例如,标准12V铅酸电池)的位置。例如,如图所示,车辆10可包括电池系统12,该电池系统位置类似于内燃机车辆的铅酸电池(例如,在车辆10的引擎盖下方)。
电池系统12的更详细视图示出于图2中。如图所示,电池系统12包括储能部件14,其联接至点火系统16、交流发电机18、车辆控制台20,并且任选地联接至电动机22。一般来讲,储能部件14可捕获/存储车辆10中产生的电能,并且输出电能以对车辆10中的电气部件供电。另外,储能部件14可输出电能以将内燃机24启动(例如,重新启动或重新点火)。例如,在起停应用中,为节约燃料,当车辆10停止时,内燃机24可空转。因此,当车辆10需要推进时,储能部件14可供应能量以重新启动内燃机24。
电池系统12还可将电力供应至车辆电气系统的部件,这些部件可包括散热器冷却风扇、气候控制系统、电动助力转向系统、主动悬架系统、自动泊车系统、电动油泵、电动机械/涡轮增压器、电动水泵、加热挡风玻璃/除霜器、车窗升降电机、阅读灯、胎压监测系统、天窗电机控制器、电动座椅、警报系统、信息娱乐系统、导航特征部、车道偏离报警系统、电动驻车制动器、外部灯或其任何组合。在所示实施例中,储能部件14将电力供应至车辆控制台20和点火系统16,点火系统14可用于启动(例如,用曲柄启动)内燃机24。
另外,储能部件14可捕获由交流发电机18和/或电动机22产生的电能。在一些实施例中,当内燃机24运行时,交流发电机18可产生电能。更具体地,交流发电机18可将内燃机24的旋转所产生的机械能转换成电能。另外或替代地,当车辆10包括电动机22时,电动机22可通过将车辆10的移动(例如,车轮的旋转)所产生的机械能转换成电能来产生电能。因此,在一些实施例中,储能部件14可捕获由交流发电机18和/或电动机22在再生制动期间产生的电能。因此,交流发电机和/或电动机22在本文中一般称为再生制动系统。
为便于捕获和供应电能,储能部件14可经由总线26电气联接至车辆的电力系统。例如,总线26可使储能部件14能够接收由交流发电机18和/或电动机22产生的电能。另外,总线26可使储能部件14能够将电能输出至点火系统16和/或车辆控制台20。
另外,如图所示,储能部件14可包括多个电池模块。例如,在所示实施例中,储能部件14包括锂离子(例如,第一)电池模块28和铅酸(例如,第二)电池模块30,其各自包括一个或多个电池单元。另外,储能部件14可包括任何数量的电池模块,所有或一些电池模块可根据当前所公开技术来构造。虽然将锂离子电池模块28和铅酸电池模块30描绘为彼此相邻,但是它们可位于车辆周围的不同区域。例如,铅酸电池模块30可位于车辆10的内部中或内部附近,而锂离子电池模块28可位于车辆10的引擎盖下方。
在一些实施例中,储能部件14可包括多个电池模块以利用多种不同电池化学成分。例如,当使用锂离子电池模块28时,可以提高电池系统12的性能,因为相比于铅酸电池化学成分,锂离子电池化学成分一般具有较高库仑效率和/或较高功率充电接收率(例如,较高的最大充电电流或充电电压)。因此,可以提高电池系统12的捕获、存储和/或分配效率。
为便于控制电能的捕获和存储,电池系统12可额外包括控制模块32(例如,电池管理系统)。更具体地,控制模块32可控制电池系统12中的部件的操作,诸如储能部件14、交流发电机18和/或电动机22内的继电器(例如,开关)。例如,控制模块32可调控由每个电池模块28或30所捕获/供应的电能的量(例如,以对电池系统12降低定额和重新定额),在电池模块28和30之间执行负载平衡,确定每个电池模块28或30的充电状态,确定每个电池模块28或30的温度或电压(例如,经由接收自一个或多个感测部件的信号),控制由交流发电机18和/或电动机22所输出的电压,等等。
因此,控制单元32可包括一个或多个处理器单元34和一个或多个存储器部件36。更具体地,一个或多个处理器单元34可包括一个或多个专用集成电路(ASIC)、一个或多个现场可编程门阵列(FPGA)、一个或多个通用处理器,或其任何组合。另外,一个或多个存储器部件36可包括易失性存储器,诸如随机存取存储器(RAM),和/或非易失性存储器,诸如只读存储器(ROM)、光驱、硬盘驱动器或固态驱动器。在一些实施例中,控制单元32可包括部分的车辆控制单元(VCU)和/或独立电池控制模块。此外,如图所示,锂离子电池模块28和铅酸电池模块30跨其端子并联连接。换句话讲,锂离子电池模块28和铅酸电池模块30可以经由总线26并联联接至车辆的电气系统。
如先前所讨论,电池模块28可包括具有不相似导电材料的部件。此类部件可联接以形成一个或多个电连接;然而,直接联接不相似导电材料可产生不期望效应(例如,电偶腐蚀),现已认识到,利用独立焊接平面,在构造电池模块28和将不相似导电材料与互连汇流条(例如,具有第一端部上的第一导电材料和第二端部上的第二导电材料的汇流条)联接时,可减小此类不期望效应(例如,电偶腐蚀)并且提高电池模块28的寿命。
图3示出了根据当前公开技术所构造的电池模块28的框图。电池模块28可包括多个第一导电部件50和多个第二导电部件52。多个第一导电部件50可具有第一导电材料。在某些实施例中,第一导电材料为铜。在其它实施例中,第一导电材料可包括铝、银、金、镍、钙、钨、锌、锂、铂、钛、铅、锡、铁、钢,或其任何组合。多个第一导电部件50可包括例如电池模块端子、模块端子汇流条、电缆、分流器、分流桥接器、印刷电路板("PCB")、继电器汇流条、继电器连接器、继电器等,但并不限于此类部件。多个第一导电部件50可经由一个或多个焊接点来彼此联接,该一个或多个焊接点建立多个第一导电部件50之间的电连接。
一般来讲,第一导电部件50可经由在锂离子电池模块28的第一侧53或面处执行的操作来联接。根据本公开的某些实施例,多个第一导电部件50可在第一连接平面54(例如,第一焊接平面)中彼此联接。第一连接平面54可包括彼此大体平行的一个或多个平面。第一连接平面54可沿着电池单元取向方向56延伸。电池单元取向方向56可为电池模块的电池单元所位于的方向(例如,电池单元端子的方向)。另外,第一连接平面54可大体平行于电池模块28的外壳的基底58。
在某些实施例中,多个第二导电部件52可具有第二导电材料,第二导电材料不同于第一导电部件50的第一导电材料。在某些实施例中,第二导电材料为铝。在其它实施例中,第二导电材料可包括铜、银、金、镍、钙、钨、锌、锂、铂、钛、铅、锡、铁、钢,或其任何组合。多个第二导电部件52可包括例如电池单元端子、电池单元汇流条、线缆、分流器、分流桥接器、PCB、继电器汇流条、继电器连接器、继电器等,但并不限于此类部件。因此,在某些实施例中,在第二导电部件52之间制备的许多或所有连接可包含对锂离子电池模块28的电池单元的直接连接。
一般来讲,第二导电部件52可经由在锂离子电池模块28的第二侧59或面处执行的操作来联接。多个第二导电部件52可经由一个或多个焊接点来彼此联接,该一个或多个焊接点建立多个第二导电部件52之间的电连接。在某些实施例中,多个第二导电部件52可在第二连接平面60(例如,第二焊接平面)中彼此联接。第二连接平面60可包括彼此大体平行的一个或多个平面。第二连接平面60可大体平行于电池模块28的外壳的面62。在某些实施例中,第二连接平面60可横向于(例如,大体垂直于)第一连接平面54。
在某些实施例中,利用第一连接平面54和第二连接平面60来区分在某些导电部件之间所制备的连接的性质可提高电池模块构造过程的效率。如上文所讨论,将不相似导电材料彼此焊接(例如,将铜焊接至铝)可产生不期望效应(例如,电偶腐蚀)。因此,第一焊接过程(该第一焊接过程联接具有第一导电材料的部件)可包括与第二焊接过程(该第二焊接过程联接具有第二导电材料的部件)不同的焊接设置(例如,功率、惰性气体、焊接速率等)。利用第一连接平面54可允许组装者(例如,人或驱动过程)制备联接多个第一导电部件50的所有焊接点,而无需修改或调整焊接设置。相似地,利用第二连接平面60可允许组装者(例如,人或自动过程)制备所有联接多个第二导电部件52的焊接点,而无需修改或调整焊接设置。根据本发明实施例,第一焊接过程可在锂离子电池模块28的第一侧53执行,而第二焊接过程可在第二侧59执行。
为实现电池模块28和外部负载之间的电连接,可形成电池单元端子和模块端子之间的电连接。例如,多个第一导电部件50可联接至多个第二导电部件52以建立此类电连接。在某些实施例中,电池模块28可包括双金属互连汇流条64,该双金属互连汇流条包括第一端部66上的第一导电材料和第二端部68上的第二导电材料。互连汇流条64可允许在多个第一导电部件50和多个第二导电部件52之间制备连接,而无需将两种不相似导电材料焊接在一起。例如,第一端部66可在第一连接平面54中联接至第一导电部件50,并且第二端部68可在第二连接平面60中联接至第二导电部件52。在其它实施例中,互连汇流条64可包括单一导电材料,使得将不同导电材料彼此联接的焊接得以执行。例如,互连汇流条64可包括第三导电材料,该第三导电材料具有在第一连接平面54中与第一导电材料和在第二连接平面60中与第二导电材料制备强固可靠焊接点的能力。在其它实施例中,第一端部66或第二端部68中的任一者可包括第三材料。
如上文所述及,多个第一导电部件50和多个第二导电部件52可为设置于电池模块28之中和/或之上的多种部件。图4示出了具有集成于电池模块28的外壳80之上或之内的一些示例部件的电池模块28的实施例。部件在电连接时能够在电池模块28的模块端子82处提供电气输出。例如,多个电池单元84可位于模块外壳80中,并且经由在某些居间导电部件之间制备的许多物理连接可电连接至模块端子82。允许电池单元84电气联接至模块28的端子82的各种互连可视为建立电气通路,其性质可取决于居间导电部件的类型和数量。
如图4所示,在电池单元84和模块端子82之间建立电气通路的部件以非限制性示例的方式可包括电池端子86、电池单元汇流条88、线缆90、端子汇流条92、继电器汇流条94、继电器连接器96、继电器98和模块端子82。另外,某些部件可设置于托架100上,托架可包括配置成承载并集成某些部件(例如,第二导电部件52)的一体式结构。如本文参考图6进一步详细描述,也可存在其它导电部件,包括双金属互连汇流条64。
在某些实施例中,例如,也可建立额外电连接以使印刷电路板(PCB)102上的控制模块(例如,图2的控制模块32)能够监测并控制电池单元84和整体电池模块28的操作参数。如图所示,此类电连接可利用连接至PCB 102的分流器104以及分流桥接器106来建立。在某些实施例中,PCB 102上的控制模块可配置成经由感测部件监测电池单元84的参数,该感测部件设置于托架100上或电池模块外壳80内(例如,在线缆90上)。例如,感测部件可将涉及电池模块28内的温度和/或电压的信号发送至PCB 102。PCB 102上的控制模块响应于所接收的信号可控制电池模块28的操作参数。同样,这些特征为示例,并且不应视为限制本公开。
这些各种部件布置于电池模块28中的方式可参考图5来进一步理解,图5示出了远离外壳80分解的托架100。另外,若干个电连接被描绘为被建立,除了电池单元84之间的电互连和至模块端子82的电互连。
如图5所示,导电部件之间的电连接分为第一连接平面54和第二连接平面60。每组大体平行的连接平面54和60可视为可从电池模块28的单个取向接近的一组平面。这样,当电池模块28处于单一取向上时,可制备多个电气部件的连接(例如,焊接连接)。
在第一连接平面54中,例如,可沿着电池单元84和模块端子82之间的电气通路的第一部分120在导电元件之间建立电连接。第一部分120可包括导电部件,这些导电部件延伸自托架100并且延伸至模块端子82。此外,第一连接平面54可包括在继电器98(参见图4)和某些导电部件之间所制备的连接,以及PCB 102(参见图4)和某些部件之间的连接。这些连接无需位于单个平面中,但是通常将取向为沿着大体平行于第一基准平面122的一组平面54。沿着第一连接平面54所制备的连接可取向为大体平行于第一基准平面122,第一基准平面示出为大致沿着电池单元取向方向56延伸并且大体平行于模块外壳80的基底58。
在第二连接平面60中,电连接可沿着电池单元84和模块端子82之间的电气通路的第二部分124建立在导电元件之间。第二部分124可包括导电部件,这些导电部件自电池单元84延伸并且延伸至托架100。这些连接无需位于单个平面中,但是通常将取向为沿着大体平行于第二基准平面126的一组平面60。沿着第二连接平面60所制备的连接通常可取向为横向于(例如,横向于或大体垂直于)第一连接平面54,并且第二连接平面60示出为通常相对于电池单元取向方向56横向(例如,大体垂直)延伸并且相对于模块外壳80的基底58横向延伸。
出于一些原因,以上文所示出的方式分离焊接平面可为有利的。例如,在电池模块28组装期间(该组装期间涉及定位和连接不同模块部件),由于组装系统的站点之间的参数变化减少,此类组装和互连可为更有效的。
同样,第一连接平面54可包括具有第一导电材料的部件之间的连接,并且第二连接平面60可包括具有第二导电材料的部件之间的连接。在某些实施例中,相应连接平面54和60可仅包括单一导电材料的连接,除了连接平面54和60之间的利用例如如图6所示的互连汇流条65的单一过渡。根据图6的所示实施例,互连汇流条64可为双金属的,其中第一端部66(例如,第一部分)包括第一导电材料(例如,铜),并且第二端部68(例如,第二部分)包括第二导电材料(例如,铝)。因此,在某些实施例中,互连汇流条64的第一端部66可联接至模块端子82。另外,参考图4所示的某些部件,互连汇流条64可联接至分流桥接器106,分流桥接器联接至分流器104。另一方面,互连汇流条64的第二端部68可联接至另一导电材料,诸如构成电池单元汇流条88的材料。
在采用双金属汇流条64的实施例中,双金属汇流条64可包括材料梯度部分128(例如,汇流条64的过渡部分,其可包括第一导电材料和第二导电材料的混合物),或双金属汇流条64可不包括材料梯度(例如,第一导电材料和第二导电材料之间的直接连接)。在进一步的实施例中,双金属汇流条64可包括第三导电材料,该第三导电材料可位于第一端部66上的第一导电材料和第二端部68上的第二导电材料之间。
图7为根据本发明实施例示出用于构造电池模块28的过程的方法140的流程图。在框142处,电池模块外壳80可开始于第一取向上。例如,模块28(例如,外壳80)可位于第一取向上的组装生产线上。在框144处,当电池模块28处于第一取向上时,各种部件(例如,多个第一导电部件50)可集成于外壳80之上或之中,并且可执行第一焊接操作。将部件集成于外壳80之上或之中可包括定位部件和将部件准备用于后续焊接操作(例如,第一焊接操作)。
第一焊接操作旨在表示利用例如第一组参数146制备一个或多个焊接连接,第一组参数146适于将第一类型的导电材料(例如,铜)焊接至相同类型的导电材料或与第一类型材料电气兼容(例如,经历很少至未出现不需要的电流效应)的另一种材料。例如,第一焊接操作可包括利用第一组参数146执行焊接,第一组参数146可适于将多个第一导电部件50彼此联接。在某些实施例中,部件集成和第一焊接操作可利用第一组装参数例如在第一组装站点处执行。这样,组装生产线(例如,自动化组装生产线)的单个站点或部分可具有专用组参数,该专用组参数在多个模块组装过程中重复。因此,组装生产线的部件(例如,自动化部件)无需在模块之间重新启动或重新加载一组参数,这可提高效率。
在第一取向上对电池模块28执行操作之后,过程可包括在框148处将外壳80重新定位至第二取向。在某些实施例中,模块28可处于第二组装站点(例如,使用第二组组装参数),并且可执行额外部件集成。额外部件集成可包括将具有第二导电材料的部件(例如,多个第二导电部件52)集成至电池模块28之中或之上。在框150处,执行第二焊接操作,该第二焊接操作旨在表示利用例如第二组参数152制备一个或多个焊接点,第二组参数152适于焊接第二导电材料。在某些实施例中,第二组参数152不同于第一组参数146,并且第二导电材料不同于第一导电材料。例如,第二焊接操作可包括利用第二组参数152执行焊接,第二组参数可适于将多个第二导电部件52彼此联接。
在某些实施例中,在框152处,多个第一导电部件50和多个第二导电部件52可彼此联接(例如,经由互连汇流条64)。例如,在多个第一导电部件50彼此联接之后并且在多个第二导电部件52彼此联接之后,多个第一导电部件50和多个第二导电部件52可经由双金属互连汇流条64彼此联接。例如,双金属互连汇流条64可在第一连接平面54中联接至第一导电部件50,并且可在第二连接平面60中联接至第二导电部件52。在其它实施例中,多个第一导电部件50可彼此联接和/或多个第二导电部件52可同时或在其之后彼此联接,互连汇流条64建立多个第一导电部件50的一个第一导电部件和多个第二导电部件52的一个第二导电部件之间的连接。
所公开实施例中的一者或多者(单独或组合)可提供一个或多个技术效应,包括建立电化学电池的电池端子和电池模块(包括电化学电池)的模块端子之间的电气通路。电气通路通常包括自电池端子的延伸第一部段、自模块端子延伸的第二部段,和在第一部段和第二部段之间延伸的过渡部段。第一部段和第二部段可焊接至过渡部段。为便于制造,连接第一部段的所有焊接点设置于大体平行的第一平面中,并且连接第二部段的所有焊接点设置于大体平行的第二平面中。本说明书中的技术效果和技术问题为示例性的而非限制性的。应当指出的是,本说明书中所描述的实施例可具有其它技术效果,并且可解决其它技术问题。
上文所描述的具体实施例已通过示例的方式示出,并且应当理解,这些实施例可易受各种修改和替代形式的影响。还应当理解,权利要求书不旨在限于所公开的特定形式,而是涵盖落入本公开的精神和范围内的所有修改、等同物和替代形式。
Claims (17)
1.一种锂离子电池模块,包括:
外壳,所述外壳具有基底;
电池单元,所述电池单元在电池单元取向方向上设置于所述外壳中,其中所述电池单元取向方向大体平行于所述基底;以及
电池模块端子,所述电池模块端子经由电气通路电气联接至所述电池单元的电池单元端子,其中所述电池单元端子在所述电池单元取向方向上从所述电池单元延伸,其中所述电池模块端子配置成当联接至电气负载时提供所述电池模块的电气输出,并且其中所述电气通路从所述电池单元端子延伸至所述电池模块端子,并且所述电气通路由第一部分、第二部分和连接所述第一部分和所述第二部分的互连部分限定;
其中所述电气通路的所述第一部分包括具有第一导电材料的多个第一导电部件,所述多个第一导电部件利用第一焊接技术在多个第一连接平面内彼此电气联接,所述多个第一导电部件的中至少一个直接联接至所述电池模块端子,并且所述多个第一连接平面大体平行于所述外壳的所述基底;以及
其中所述电气通路的所述第二部分包括具有第二导电材料的多个第二导电部件,所述多个第二导电部件利用不同于所述第一焊接技术的第二焊接技术在多个第二连接平面内彼此电气联接,所述多个第二导电部件中的至少一个直接联接至所述电池单元的所述电池单元端子,并且所述多个第二连接平面相对于所述多个第一连接平面以及所述电池单元取向方向横向取向。
2.根据权利要求1所述的锂离子电池模块,其中所述第一焊接技术包括第一组焊接参数,并且所述第二焊接技术包括不同于所述第一组焊接参数的第二组焊接参数。
3.根据权利要求1所述的锂离子电池模块,其中所述第一导电部件被配置为响应于第一组焊接参数,并且所述第二导电部件被配置为响应于不同于所述第一组焊接参数的第二组焊接参数。
4.根据权利要求1所述的锂离子电池模块,其中所述多个第二连接平面彼此大体平行。
5.根据权利要求1所述的锂离子电池模块,其中所述互连部分包括第一端部处的所述第一导电材料和第二端部处的所述第二导电材料,并且其中所述互连部分将所述多个第一导电部件电气联接至所述多个第二导电部件。
6.根据权利要求5所述的锂离子电池模块,其中所述互连部分包括材料梯度部分,所述材料梯度部分设置于所述第一端部和所述第二端部之间,并且具有所述第一导电材料和所述第二导电材料的混合物。
7.根据权利要求5所述的锂离子电池模块,其中所述互连部分包括位于所述第一端部和所述第二端部之间的第三导电材料。
8.根据权利要求5所述的锂离子电池模块,其中所述互连部分经由在所述第一端部和所述第二端部中的每一个处设置的焊接点而将所述多个第一导电部件联接至所述多个第二导电部件。
9.根据权利要求8所述的锂离子电池模块,其中所述焊接点通过超声焊接或激光焊接形成。
10.根据权利要求1所述的锂离子电池模块,其中所述多个第一导电部件仅利用所述第一焊接技术彼此物理地和电气地联接,并且所述多个第二导电部件仅利用所述第二焊接技术彼此物理地和电气地联接。
11.根据权利要求1所述的锂离子电池模块,其中所述多个第一导电部件包括端子汇流条、继电器汇流条、继电器连接器、分流器和分流桥接器中的一者或多者。
12.根据权利要求11所述的锂离子电池模块,其中所述多个第二导电部件包括多个电池单元汇流条、继电器和印刷电路板中的一者或多者。
13.根据权利要求1所述的锂离子电池模块,其中所述第一导电材料包括铜,并且所述第二导电材料包括铝。
14.一种用于构造锂离子电池模块的方法,包括:
接近所述锂离子电池模块的外壳的第一侧,其中所述锂离子电池模块包括电池单元,其中所述电池单元在电池单元取向方向上设置于所述外壳中,其中所述电池单元取向方向大体平行于所述外壳的基底,并且其中所述电池单元包括在所述电池单元取向方向上从所述电池单元延伸的电池单元端子;
经由所述第一侧上的第一多个焊接点将多个第一导电部件彼此联接,其中所述多个第一导电部件中的至少一个直接联接至所述锂离子电池模块的电池模块端子,所述第一多个焊接点利用第一导电材料在多个第一连接平面内制备,并且所述多个第一连接平面大体平行于所述外壳的所述基底;
接近横向于所述第一侧的、所述外壳的第二侧;
经由所述第二侧上的第二多个焊接点将多个第二导电部件彼此联接,其中所述多个第二导电部件中的至少一个直接联接至所述电池单元的所述电池单元端子,所述第二多个焊接点利用不同于所述第一导电材料的第二导电材料在多个第二连接平面内制备,并且所述多个第二连接平面相对于所述多个第一连接平面以及所述电池单元取向方向横向取向;以及
经由互连部分将所述多个第一导电部件联接至所述多个第二导电部件,所述互连部分包括第一端部处的所述第一导电材料和第二端部处的所述第二导电材料。
15.根据权利要求14所述的方法,其中所述第一多个焊接点利用第一组焊接参数来制备,所述第一组焊接参数配置成将两个铜部件彼此焊接,并且所述第二多个焊接点利用第二组焊接参数来制备,所述第二组焊接参数配置成将两个铝部件彼此焊接。
16.一种锂离子电池模块,包括:
外壳,所述外壳具有基底;
电池单元,所述电池单元设置于所述外壳中并且具有电池单元取向方向,其中所述电池单元取向方向大体平行于所述基底;
电池模块端子,所述电池模块端子经由电气通路电气联接至所述电池单元的电池单元端子,其中所述电池单元端子在所述电池单元取向方向上从所述电池单元延伸,其中所述电气通路从所述电池单元的所述电池单元端子延伸至所述电池模块端子,并且其中所述电气通路根据包括以下步骤的过程来制备:
接近所述外壳的第一侧;
经由所述第一侧上的第一多个焊接点将多个第一导电部件彼此联接,其中所述多个第一导电部件中的至少一个直接联接至所述锂离子电池模块的所述电池模块端子,所述第一多个焊接点利用第一导电材料在多个第一连接平面内制备,并且所述多个第一连接平面大体平行于所述外壳的基底;
接近横向于所述第一侧的、所述外壳的第二侧;
经由所述第二侧上的第二多个焊接点将多个第二导电部件彼此联接,其中所述多个第二导电部件中的至少一个直接联接至所述电池单元的所述电池单元端子,所述第二多个焊接点利用不同于所述第一导电材料的第二导电材料在多个第二连接平面内制备,并且所述多个第二连接平面相对于所述第一连接平面以及所述电池单元取向方向横向取向;以及
经由互连部分将所述多个第一导电部件联接至所述多个第二导电部件,所述互连部分包括第一端部处的所述第一导电材料和第二端部处的所述第二导电材料。
17.根据权利要求16所述的锂离子电池模块,其中所述第一导电材料包括铜,并且所述第二导电材料包括铝。
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