BACKGROUNDOF THE INVENTION

1. Field of the Invention

The present invention relates generally to a battery assembly, and more specifically to a high voltage battery assembly for a motor vehicle.

2. Background Art

Motor vehicles, such as electric or hybrid electric vehicles, may include a battery configured to provide a high level of voltage. Previously, high voltage batteries or vehicles having a high voltage battery were transported to an originalequipment manufacturer for maintenance and servicing.

Before applicant's invention, there was a need for a battery assembly that could be quickly and easily reconfigured to supply a reduced output voltage level. In addition, there was a need for a battery assembly that could be manuallyreconfigured to facilitate servicing or automatically reconfigured during vehicle operation. In addition, there was the need for a battery assembly that could be serviced by a vehicle dealership to reduce service time and cost. Problems noted above andother problems are addressed by applicant's invention as summarized below.

SUMMARY OF THE INVENTION

In at least one embodiment of the present invention, a battery assembly is provided. The battery assembly includes a plurality of voltage modules that each have a terminal and a connection device having conductive and nonconductive portions. The conductive portion contacts the terminals of at least two voltage modules when disposed in a first position. The nonconductive portion contacts at least one member of the at least two voltage modules when disposed in a second position.

The conductive and nonconductive portions may be coaxially disposed. The conductive portion may have a generally cylindrical configuration and may be disposed around a nonconductive core. The conductive portion may be disposed adjacent to aplurality of nonconductive portions.

The connection device may include first and second ends. The first end may have a tool engagement feature. The second end may have a retention feature. The first end may be coupled to an actuator adapted to move the connection device betweenthe first and second positions in response to an actuation signal.

The battery assembly may include a housing for receiving the plurality of voltage modules. The housing may include first and second apertures. The first and second ends of the connection device may be disposed proximate the first and secondapertures, respectively, when the connection device is in the first position.

The housing may have a compartment that receives the plurality of voltage modules. The connection device may cover the compartment and the conductive portion may be disposed proximate a surface of the nonconductive portion of the connectiondevice that faces the compartment.

The conductive portion may have a non-planar configuration for providing a biasing force against the terminals of the at least two voltage modules when disposed in the first position.

In at least one other embodiment of the present invention, a battery assembly for a vehicle is provided. The battery assembly includes a first set of voltage modules connected in series, a second set of voltage modules connected in series, ahousing for receiving the first and second sets of voltage modules, and a connection device. The housing has an end surface. The connection device is configured to engage the end surface and has a conductive portion disposed proximate a nonconductiveinterior surface. The first and second sets of voltage modules are connected in series when the conductive portion contacts a member of the first set and a member of the second set.

The first set of voltage modules may not be connected in series with the second set of voltage modules when the connection device is spaced apart from the end surface.

The connection device may be configured to move along the end surface between a first position in which the conductive portion connects the first and second sets of voltage modules in series and a second position in which the conductive portionis spaced apart from at least one of the first and second sets of voltage modules.

A section of the conductive portion may protrude from the nonconductive interior surface. The conductive portion may have a corrugated configuration for providing a biasing force against members of the first and second sets of voltage moduleswhen the conductive portion contacts a member of the first set and a member of the second set.

In at least one other embodiment of the present invention, a high voltage battery assembly for a vehicle is provided. The high voltage battery assembly includes a housing, first and second sets of voltage modules, and a connection device. Thefirst and second sets of voltage modules are at least partially disposed in the housing. The members of the first set are connected in series. The members of the second set are connected in series. The connection device has coaxial conductive andnonconductive portions at least partially disposed in the housing. The connection device moves linearly between a first position in which the conductive portion connects the first and second sets of voltage modules in series and a second position inwhich the conductive portion does not connect the first and second sets of voltage modules in series.

A member of the first set may include a first terminal having a first terminal aperture. A member of the second set may include a second terminal having a second terminal aperture. The connection device may be moveably disposed in the first andsecond terminal apertures. The nonconductive portion may be disposed proximate at least one of the first and second terminals when disposed in the second position.

The connection device may include a first end. The first end may be coupled to an actuator or have a tool engagement feature.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a voltage module.

FIG. 2 is a section view of a battery assembly having a plurality of voltage modules and a connection device disposed in a first position.

FIG. 3 is a section view of the battery assembly shown in FIG. 2 with the connection device disposed in a second position.

FIG. 4 is a perspective view of one embodiment of the connection device.

FIG. 5 is a perspective view of one embodiment of a nonconductive portion of the connection device.

FIG. 6 is a perspective view of another embodiment of the connection device.

FIG. 7 is a section view of a battery assembly having an actuator for positioning a connection device.

FIG. 8 is a partially exploded perspective view of another embodiment of the battery assembly including a connection device having conductive and nonconductive portions.

FIG. 9 is a perspective view of another embodiment of the conductive portion of a connection device.

FIG. 10 is a perspective view of another embodiment of a connection device.

FIG. 11 is a perspective view of another embodiment of a connection device.

FIG. 12 is a side view of another embodiment of the battery assembly having a connection device disposed in a first position.

FIG. 13 is a side view of the battery assembly shown in FIG. 12 with the connection device disposed in a second position.

DETAILED DESCRIPTION

Referring to FIG. 1, an exemplary embodiment of a voltage module 10 is shown. The voltage module 10 is configured to provide electrical voltage to a vehicle electrical system or vehicle electrical system component. The voltage module 10 mayhave any suitable configuration. For example, the voltage module 10 may include one or more cells and one or more terminals. In the embodiment shown in FIG. 1, the voltage module 10 includes five cells 12 connected in series and two terminals 14.

The cells 12 may have any suitable configuration and may be of any suitable type, such as nickel-metal hydride (Ni-MH), nickel-iron (Ni--Fe), nickel-cadmium (Ni--Cd), lead acid, zinc bromine (Zn--Br), sodium nickel chloride, sodium sulfur, orlithium based. Each cell 12 may provide a same or different nominal level of voltage. In one embodiment, each cell 12 may provide a nominal voltage level of approximately 1.3 volts. Optionally, the cells 12 may be disposed in a sleeve or any suitablecontainment device. In the embodiment shown, the cells 12 are coaxially arranged.

The terminals 14 are configured to electrically connect the voltage module 10 to at least one another component. In the embodiment shown, the terminals 14 are disposed at opposite ends of the voltage module 10. The terminals may be made of anelectrically conductive material, such as a metal, and may have any suitable configuration. In the embodiment shown, each terminal 14 has a generally planar configuration and includes an opening 16, such as a slot or aperture. Alternatively, one ormore terminals 14 may be configured without an opening in various embodiments of the present invention.

Referring to FIG. 2, an exemplary battery assembly 20 is shown. The battery assembly 20 may be a high voltage battery configured to provide an elevated level of voltage (e.g, greater than 50 to 60 volts), such as that which may be used in anelectric, hybrid electric, or fuel cell vehicle. A high voltage battery may include various parts and subsystems for containing, controlling, and protecting the battery assembly and associated components. In the embodiment shown, the battery assembly20 includes a housing 22, a set of voltage modules 24, and a connection device 26.

The housing 22 is configured to receive at least a portion of the set of voltage modules 24. The housing 22 may be made of any suitable material, such as a metal or a polymeric material. In at least one embodiment, the housing 22 may includeone or more apertures for receiving a portion of the connection device 26. In the embodiment shown in FIGS. 2 and 3, the housing 22 includes a first aperture 30 and a second aperture 32. Optionally, the first and/or second apertures 32 may be threaded.

The set of voltage modules 24 may be selectively connected in series to provide a nominal battery voltage level. Any suitable number of voltage modules may be provided in any suitable configuration. For example, a nominal output voltage levelof approximately 325 volts may be attained by combining fifty 6.5 volt voltage modules in series. For simplicity, the battery assembly 20 shown in FIGS. 2 and 3 includes six voltage modules 10, designated by letters A through F.

Voltage modules A and F may be connected to negative (-) and positive terminals (+), respectively. Voltage modules B and C and voltage modules D and E may be connected in series with electrically conductive couplings 34. The conductivecouplings 34 may be made of any suitable material, such as a metal. Moreover, the conductive couplings 34 may be fixedly positioned relative to their associated voltage modules.

The connection device 26 is adapted to selectively connect one or more voltage modules in series. The connection device 26 may have any suitable configuration and may include one or more conductive portions 40 and one or more insulating ornonconductive portions 42. The conductive portions 40 and optionally the nonconductive portions 42 may be configured to contact the terminals 14 of one or more voltage modules. In the embodiment shown, the connection device 26 extends through aplurality of terminal openings 16 such that the conductive and nonconductive portions 40,42 may selectively contact one or more terminals 14. In addition, the connection device 26 or a portion thereof may be disposed in the housing 22.

In the embodiment shown in FIGS. 2 and 3, the connection device 26 is adapted to move between a first position shown in FIG. 2 in which each conductive portion 40 connects voltage modules in series and a second position shown in FIG. 3 in whicheach conductive portion 40 does not connect voltage modules in series. More particularly, a conductive portion 40 may contact at least two voltage modules when disposed in the first position and may contact less than two voltage modules when disposed inthe second position. In the embodiment shown in FIG. 2, different conductive portions connect voltage modules A and B, voltage modules C and D, and voltage modules E and F when disposed in the first position.

Referring to FIG. 4, the connection device 26 is shown in more detail. In this embodiment, the conductive portions 40 and nonconductive portions 42 have generally cylindrical configurations and are coaxially arranged. Moreover, the conductiveportions 40 are isolated from each other to inhibit the conduction of electricity. The conductive portions 40 may be made of any suitable material, such as a metal like a copper containing alloy. Similarly, the nonconductive portions 42 may be made ofany suitable material, such as a polymeric material. The conductive and nonconductive portions 40,42 may have similar shapes and/or surface areas as shown in FIG. 4 or may have different shapes and/or surface areas.

Referring to FIG. 5, part of one embodiment of a connection device is shown with the conductive portions removed. In this embodiment, pairs of nonconductive portions 42 are interconnected by a core portion 44. The nonconductive portions 42 andcore portions 44 may be integrally formed or may be assembled in any suitable manner, such as with fasteners or an adhesive. A conductive portion 40 may be wrapped or formed around each core portion 44. Alternatively, some or all of the core portions44 may be omitted and the conductive and nonconductive portions 40,42 may be attached to each other.

The connection device 26 may include a first end 50 and a second end 52. The first end 50 may be provided with a tool engagement feature 54. The tool engagement feature 54 may have any suitable configuration, such as a male configuration forengaging a tool like a socket or wrench, or a female configuration for engaging a tool like a screwdriver or drive bit. In the embodiment shown, the tool engagement feature 54 has a hexagonal configuration. The tool engagement feature 54 may be spacedapart from the housing 22 when the connection device 26 is disposed in the second position. Alternatively, the first end 50 may be include a manual actuation feature 56 like a knob, lever, or handle as shown in FIG. 6 or may be connected to an automaticactuation device, such as an actuator as is described in more detail below.

The second end 52 may include any suitable retention feature, such as a tab or threaded section 58 for engaging mating threads of the second aperture 32 of the housing 22. In the embodiment shown, the second end 52 has a male configuration andthe second aperture 32 has a female configuration. The present invention also contemplates embodiments where the second end 52 has a female configuration and the housing 22 has a mating feature with a male configuration. Alternatively, the second end52 may be provided without threads, may be coupled to an actuator, or may be spaced apart from the housing 22.

Referring to FIG. 7, another embodiment of a battery assembly 60 is shown. In this embodiment, the battery assembly 60 includes an array 62 of voltage modules. The array 62 may be organized into sets of voltage modules, with each set having asame or different number of members. In this exemplary embodiment, the array 62 is organized into a first set 64, a second set 66, and a third set 68, denoted by the dashed lines. In the embodiment shown, the first, second, and third sets 64,66,68 eachinclude six voltage modules connected in series with conductive couplings 70. A connection device 72 is configured to selectively connect one or more sets in series. More particularly, the connection device 72 may be configured similar to theembodiment shown in FIG. 4 and may be adapted to move in the direction shown by the arrowed line between a first position in which one or more conductive portions connect two sets of voltage modules in series and a second position in which one or moreconductive portions do not connect at least two sets of voltage modules in series. In the embodiment shown, the first and second sets 64,66 are connected in series by a first conductive portion 74 and the second and third sets 66,68 are connected inseries by a second conductive portion 76 when the connection device 72 is disposed in the first position as shown in FIG. 7.

The connection device 72 may be automatically or manually actuated between the first and second positions. In the embodiment shown, an actuator 80 is coupled to the connection device 72 and is adapted to move the connection device 72 between thefirst and second positions. The actuator 80 may be of any suitable type, such as a solenoid. The actuator 80 may receive a control signal from another component, such as a control module 82 and/or an input device 84 like a button, sensor, or othervehicle component or system. For example, the control signal may be provided by an impact sensor adapted to detect a collision with the vehicle or a pre-collision detection system, such as lidar, radar, or vision-based system. More particularly, theactuator 80 may move the connection device 72 from the first position toward the second position when a potential or actual vehicle impact event is detected.

Referring to FIG. 8, another embodiment of a battery assembly is shown. In this embodiment, the battery assembly 100 includes an array 102 of voltage modules, a housing 104, and a connection device 106.

The array 102 may be organized into sets of voltage modules as previously discussed. In this exemplary embodiment, the array 102 is organized into a first set 110, a second set 112, and a third set 114, as denoted by the dashed lines. In theembodiment shown, the first, second, and third sets 110,112,114 each include five voltage modules connected in series with conductive couplings 116 (the conductive couplings hidden by the housing 104 are not shown for clarity).

The housing 104 may include a compartment 120 for receiving at least a portion of the first, second, and third sets 110,112,114. An end surface 122 is disposed proximate the compartment 120.

The connection device 106 is configured to selectively connect one or more sets in series. The connection device 106 may be configured as a cover that is configured to engage the end surface 122 and/or at least partially conceal the compartment120. More specifically, the connection device 106 includes at least one conductive portion disposed proximate a nonconductive interior surface 124. In the embodiment shown in FIG. 8, the connection device 106 includes first and second conductiveportions 126,128.

The conductive portions 126,128 may have any suitable configuration. For example, the conductive portions 126,128 may be configured as a busbar having a generally planar configuration. Alternatively, the conductive portions 126,128 may have anon-planar configuration. For instance, one or more conductive portions may have a corrugated configuration as shown in FIG. 9 that is configured to provide a biasing force against one or more associated voltage modules to accommodate dimensionaltolerances and to inhibit intermittent electrical connections. Alternatively, a connection device 106' may have an interior surface 124' and conductive portions 126',128' with male and/or female configurations disposed proximate the interior surface124' as shown in FIG. 10. In addition, a connection device 106'' may be provided having an interior surface 124'' and a conductive portion that combines one or more non-planar surfaces with a male or female configuration as shown in FIG. 10. Theconnection device 106'' may include a conductive portion 126'' configured as a clip and may include one or more non-planar or corrugated surfaces that provide a biasing force as previously discussed.

The conductive portions 126,126',126'',128,128' may be integrally formed with or attached to the interior surface 124,124',124'' in any suitable manner, such as with fasteners or an adhesive.

Referring again to FIG. 8, the first and second sets 110,112 are connected in series by the first conductive portion 126 and the second and third sets 112,114 are connected in series by the second conductive portion 128 when the connection device106 is disposed proximate the end surface 122 and aligned with corresponding voltage module terminals. The first and second sets 110,112 are not connected in series by the first conductive portion 126 and the second and third sets 112,114 are notconnected in series by the second conductive portion 128 when the connection device 106 is moved away from the array of voltage modules 102 and/or the end surface 122.

Referring to FIGS. 12 and 13, another embodiment of a battery assembly is shown. In this embodiment, the battery assembly 130 includes an array 132 of voltage modules, a housing 134, and a connection device 136. In this embodiment, theconnection device 136 has a similar configuration to that shown in FIG. 8, but is configured to move along a surface of the housing 134 between a first position shown in FIG. 12 and a second position shown in FIG. 13.

First and second sets 140,142 of voltage modules are connected in series by a first conductive portion 144 and second and third sets 142,146 are connected in series by a second conductive portion 148 when the connection device 136 is disposed inthe first position (FIG. 12). Similarly, the first and second sets 140,142 of voltage modules and second and third sets 142,146 are not connected in series by the conductive portions 144,148 when the connection device 106 is disposed in the secondposition (FIG. 13).

The connection device 136 may be configured to move in any suitable direction or directions between the first and second positions. For instance, the present invention contemplates embodiments in which the connection device 136 may move inmultiple directions to connect and disconnect voltage modules or may move perpendicularly or at an angle to the direction of movement shown in FIGS. 12 and 13.

The present invention allows a battery assembly to be easily and quickly reconfigured to reduce battery output voltage, thereby improving safety and serviceability. Furthermore, at least one embodiment of the present invention may allow batteryoutput voltage to be reconfigured in response to a vehicle impact event to help improve safety. Moreover, the present invention may facilitate servicing and maintenance of a high voltage battery system at a vehicle dealership, thereby reducing servicetime, reducing associated costs, and/or improving customer satisfaction. Moreover, in at least one embodiment overall repair costs may be reduced since repairs may be made to specific battery assembly components instead of replacing an entire batteryassembly.

While the best mode for carrying out the invention has been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by thefollowing claims.

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