# US 10,375,830 B2 · Method of assembling power module via folding

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- Number: US 10,375,830 B2
- Document ID: US10375830B2
- Status: Granted
- Kind: B2
- Application number: 15/612,145
- Filed: 2017-06-02
- Published: 2018-12-06
- Granted: 2019-08-06
- Earliest claimed: 2017-06-02
- Assignees: GM Global Technology Operations LLC
- Applicants: GM Global Technology Operations LLC
- Inventors: Evan J. Dawley; Roger M. Brisbane
- Web page: https://patentgrep.com/patent/US10375830B2

## CPC

- H05K 1/189: characterised by the use of flexible or folded printed circuits
- H01M 10/04: Construction or manufacture in general (H01M10/058, H01M10/12, H01M10/28, H01M10/38 take precedence)
- H01M 10/4207: {for several batteries or cells simultaneously or sequentially}
- H01M 10/613: Cooling or keeping cold
- H01M 10/655: Solid structures for heat exchange or heat conduction
- H01M 10/6555: arranged between the cells
- H01M 50/211: adapted for pouch cells
- H01M 50/24: adapted for protecting batteries from their environment, e.g. from corrosion (thermal insulation H01M10/658)
- H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64)
- H01M 50/516: by welding, soldering or brazing
- H01M 50/528: Fixed electrical connections, i.e. not intended for disconnection
- H01M 50/284: with incorporated circuit boards, e.g. printed circuit boards [PCB]
- H01M 50/519: comprising printed circuit boards [PCB]
- H01M 2010/4271: {Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing}
- H05K 2201/10037: Printed or non-printed battery
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

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.

## Claims

### Claim 1

A method of assembling a power module, the method comprising:
placing a first plurality of cells adjacent to one another to form a first cell layer;
positioning a flexible circuit layer above the first cell layer, the flexible circuit being electrically conductive;
positioning a second plurality of cells adjacent to one another to form a second cell layer aligned relative to the first plurality of cells;
sandwiching the flexible circuit layer between the first cell layer and the second cell layer;
placing a plurality of heat spreaders in an alternating pattern directly outward of the first plurality of cells and the second plurality of cells, the plurality of heat spreaders including a first heat spreader and a second heat spreader;
wherein the alternating pattern is such that the first heat spreader is positioned directly outward of one of the first plurality of cells and the second heat spreader is positioned directly outward of an adjacent one of the second plurality of cells;
wherein the plurality of heat spreaders is configured to dissipate heat away from the flexible circuit layer; and
folding the flexible circuit layer along each of a plurality of axes of rotation such that at least one of the first plurality of cells directly faces another one of the first plurality of cells and at least one of the second plurality of cells directly faces another one of the second plurality of cells.

### Claim 2 (depends on 1)

The method of claim 1, wherein:
each of the first plurality of cells and the second plurality of cells has a respective cell body with respective long ends and respective short ends, the respective cell bodies of the first and the second plurality of cells being aligned;
each of the first and the second plurality of cells has respective first tabs extending from one of the respective short ends and respective second tabs extending from another of the respective short ends; and
the method further includes welding the respective first tabs and the respective second tabs of the first plurality of cells and the second plurality of cells to the flexible circuit layer to form respective cell tab joints.

### Claim 3 (depends on 2)

The method of claim 2, further comprising:
compressing the power module after folding the flexible circuit layer.

### Claim 4 (depends on 1)

The method of claim 1, wherein the plurality of heat spreaders are C-channel plates.

### Claim 5 (depends on 1)

The method of claim 1, further comprising:
configuring the flexible circuit layer with a central portion and a plurality of sense lines traces at least partially extending along a perimeter of the central portion;
electrically isolating the sense lines traces from the central portion; and
connecting alternate ones of the respective cell tab joints to the sense lines traces.

### Claim 6 (depends on 2)

The method of claim 2, wherein after positioning the second plurality of cells and prior to welding, the method further includes:
bending the respective first and second tabs in an upwards direction or a downwards direction such that adjacent ones of the respective first and second tabs are bent in opposite directions.

### Claim 7

A method of assembling a power module, the method comprising:
placing a first plurality of cells adjacent to one another to form a first cell layer;
placing a flexible circuit layer above the first cell layer, the flexible circuit being electrically conductive;
positioning a second plurality of cells adjacent to one another to form a second cell layer aligned relative to the first cell layer such that the flexible circuit layer is sandwiched between the first cell layer and the second cell layer;
wherein each of the first plurality of cells and the second plurality of cells has a respective cell body with respective long ends and respective short ends, the respective cell bodies of the first and the second plurality of cells being aligned;
wherein each of the first and the second plurality of cells has respective first tabs extending from one of the respective short ends and respective second tabs extending from another of the respective short ends;
welding the respective first tabs and the respective second tabs of the first plurality of cells and the second plurality of cells to the flexible circuit layer to form respective cell tab joints;
configuring the flexible circuit layer with a central portion and a plurality of sense line traces at least partially extending along a perimeter of the central portion;
electrically isolating the plurality of sense line traces from the central portion and connecting alternate ones of the respective cell tab joints to the plurality of sense line traces; and
folding the flexible circuit layer along each of a plurality of axes of rotation such that at least one of the first plurality of cells directly faces another one of the first plurality of cells and at least one of the second plurality of cells directly faces another one of the second plurality of cells.

### Claim 8 (depends on 7)

The method of claim 7, wherein:
the respective first tabs and the respective second tabs are composed of at least one of an aluminum, an aluminum alloy, copper and a copper alloy.

### Claim 9 (depends on 7)

The method of claim 7, further comprising:
prior to folding, placing multiple resilient portions between the flexible circuit layer and the first plurality of cells such that the multiple resilient portions extend over the respective cell bodies of the first plurality of cells; and
wherein the multiple resilient portions are configured to provide a spring force to accommodate an expansion and contraction of the first and second plurality of cells, the multiple resilient portions including at least one sheet of foam.

### Claim 10 (depends on 7)

The method of claim 7, further comprising:
placing a plurality of heat spreaders in an alternating pattern directly outward of the first plurality of cells and the second plurality of cells;
wherein the plurality of heat spreaders includes a first heat spreader and a second heat spreader such that the first heat spreader is positioned directly outward of one of the first plurality of cells and the second heat spreader is positioned directly outward of an adjacent one of the second plurality of cells cell layer; and
wherein the plurality of heat spreaders are configured to dissipate heat away from the flexible circuit layer.

### Claim 11 (depends on 7)

The method of claim 7, wherein:
placing the first plurality of cells adjacent to one another includes positioning the first plurality of cells along their respective short ends;
the respective first tabs and the respective second tabs of adjacent ones of the first plurality of cells are configured to overlap at an overlap zone; and
the respective first tabs and the respective second tabs are configured to be welded to the flexible circuit layer at the overlap zone.

### Claim 12 (depends on 7)

The method of claim 7, wherein:
placing the first plurality of cells adjacent to one another includes positioning the first plurality of cells along their respective short ends;
the respective first tabs and the respective second tabs of adjacent ones of the first plurality of cells are configured to be spaced by a respective gap, the plurality of axes of rotation being located at the respective gaps; and
welding the plurality of tabs includes welding the respective first tabs in a first weld zone and welding the respective second tabs in a second weld zone.

### Claim 13 (depends on 7)

The method of claim 7, wherein:
placing the first plurality of cells adjacent to one another includes positioning the first plurality of cells along their respective long ends; and
the flexible circuit layer includes respective first and second exposed portions configured to be welded to the respective first and second tabs.

### Claim 14 (depends on 7)

The method of claim 7, wherein:
the flexible circuit layer includes one or more exposed portions configured to be welded to the respective first and second tabs; and
the one or more exposed portions have a substantially arcuate profile.

### Claim 15 (depends on 14)

The method of claim 14, wherein after positioning the second plurality of cells and prior to welding, the method further includes:
bending the respective first and second tabs in an upwards direction or a downwards direction; and
wherein adjacent ones of the respective first and second tabs are bent in opposite directions.

### Claim 16 (depends on 15)

The method of claim 15, wherein the one or more exposed portions are configured to be bent with the respective first and second tabs.

### Claim 17

A power module assembly comprising:
a first cell layer including a first plurality of cells placed adjacent to one another;
a flexible circuit layer positioned adjacent to the first cell layer, the flexible circuit being electrically conductive;
a second cell layer positioned adjacent to the flexible circuit layer such that the flexible circuit layer is sandwiched between the first cell layer and the second cell layer, the second cell layer including a second plurality of cells placed adjacent to one another;
a plurality of heat spreaders placed in an alternating pattern directly outward of the first plurality of cells and the second plurality of cells, the plurality of heat spreaders including a first heat spreader and a second heat spreader;
wherein the alternating pattern is such that the first heat spreader is positioned directly outward of one of the first plurality of cells and the second heat spreader is positioned directly outward of an adjacent one of the second plurality of cells;
wherein the plurality of heat spreaders is configured to dissipate heat away from the flexible circuit layer; and
wherein the flexible circuit layer is configured to be folded along each of a plurality of axes of rotation such that at least one of the first plurality of cells directly faces another one of the first plurality of cells and at least one of the second plurality of cells directly faces another one of the second plurality of cells.

### Claim 18 (depends on 17)

The power module assembly of claim 17, wherein the plurality of heat spreaders are C-channel plates.

### Claim 19 (depends on 17)

The power module assembly of claim 17, wherein:
the flexible circuit layer includes a central portion and a plurality of sense lines traces at least partially extending along a perimeter of the central portion;
the sense lines traces are configured to be electrically isolated from the central portion; and
cell tab joints are connected to the sense lines traces.

### Claim 20 (depends on 17)

The power module assembly of claim 17, further comprising:
multiple resilient portions positioned between the flexible circuit layer and the first plurality of cells such that the multiple resilient portions extend over respective cell bodies of the first plurality of cells; and
wherein the multiple resilient portions are configured to provide a spring force to accommodate an expansion and contraction of the first and second plurality of cells, the multiple resilient portions including at least one sheet of foam.

### Claim 21 (depends on 17)

The power module assembly of claim 17, wherein:
each of the first plurality of cells and the second plurality of cells has a respective cell body with respective long ends and respective short ends, the respective cell bodies of the first and the second plurality of cells being aligned;
each of the first and the second plurality of cells has respective first tabs extending from one of the respective short ends and respective second tabs extending from another of the respective short ends; and
the respective first tabs and the respective second tabs of the first plurality of cells and the second plurality of cells are welded to the flexible circuit layer to form respective cell tab joints.

### Claim 22 (depends on 21)

The power module assembly of claim 21, wherein:
prior to being welded, the respective first and second tabs are configured to be bent in an upwards direction or a downwards direction such that adjacent ones of the respective first and second tabs are bent in opposite directions.

### Claim 23 (depends on 21)

The power module assembly of claim 21, wherein:
the respective first tabs and the respective second tabs are composed of at least one of an aluminum, an aluminum alloy, copper and a copper alloy.

### Claim 24 (depends on 21)

The power module assembly of claim 21, wherein:
the first plurality of cells is positioned adjacent to one another along their respective short ends;
the respective first tabs and the respective second tabs of adjacent ones of the first plurality of cells are configured to overlap at an overlap zone; and
the respective first tabs and the respective second tabs are configured to be welded to the flexible circuit layer at the overlap zone.

### Claim 25 (depends on 21)

The power module assembly of claim 21, wherein:
the first plurality of cells is positioned adjacent to one another along their respective short ends;
the respective first tabs and the respective second tabs of adjacent ones of the first plurality of cells are configured to be spaced by a respective gap, the plurality of axes of rotation being located at the respective gaps; and
the respective first tabs and the respective second tabs are configured to be welded to the flexible circuit layer in a first weld zone and a second weld zone, respectively.