The present invention relates to a battery cell contacting device for a battery module having a plurality of battery cells and/or battery cell groups electrically coupled to one another via a plurality of cell connectors and a battery module having such a battery cell contacting device.
Cell management controllers (CMC) which monitor the individual battery cells of the battery module in order to perform, for example, charging processes, balancing of the voltages and the states of charge, temperature adjustment processes, etc. for the battery cells require a battery cell contacting device for contacting the battery cells and/or the cell connectors in order to obtain corresponding measurement signals, for example, of the potentials and the temperatures of the battery cells. Conventional battery cell contacting devices involve a high degree of manufacturing-related and fitting-related complexity for the linking of the signal sources to the signal line system. In addition, there is often the risk in conventional battery cell contacting devices that the contacting of the battery cells or cell connectors is destroyed in the case of movements or swelling of the battery cells.
The object of the present invention consists in providing an improved battery cell contacting device having a simple design and simple and permanently reliable fitting.
This object is achieved by a battery cell contacting device having the features of the independent claim. Particularly advantageous configurations and developments of the invention are the subject matter of the dependent claims.
The battery cell contacting device of the invention is configured for a battery module having a plurality of battery cells and/or battery cell groups electrically coupled to one another via a plurality of cell connectors so that they are connected in series and/or parallel, depending on the arrangement and orientation of the battery cells. The battery cell contacting device has a printed circuit board, which, in the region next to the plurality of cell connectors, can be arranged over the battery cells/battery cell groups and can be connected to the plurality of cell connectors via a plurality of contact elements. Each of the plurality of contact elements has a first end section in the direction towards the printed circuit board and a second end section, which is opposite the first end section, in the direction towards a respective one of the plurality of cell connectors. In accordance with the present invention, it is proposed that each of the plurality of contact elements is formed from an electrically conductive wire which (i) runs between the first and the second end sections of the contact element, (ii) at the first end section of the contact element, is electrically conductively connected to the printed circuit board and (iii) at the second end section of the contact element, can be electrically conductively connected to the respective cell connector and/or is coupled to a sensor element which can be brought into contact with the respective cell connector. The plurality of cell connectors electrically coupling the plurality of battery cells and/or battery cell groups to one another can also be referred to as a busbar or busbar system. The feature that a contact element is formed from a wire is intended to mean in this context that the contact element not only contains a wire somewhere but substantially consists of a wire.
The use of electrically conductive wires for the contact elements has several advantages. Wires are standard component parts which have a simple structure, which can be configured variably and can be matched to specific application cases, and which enable simple electrical contact connections (for example by means of soldering or welding) to the printed circuit board (and therefore to signal lines of the printed circuit board) and to the cell connectors without additional special elements, which electrical contact connections can also take place in automated fashion. This enables simple and cost-effective fitting of the battery cell contacting device in a battery module. In addition, the flexibility of these contact elements can compensate for movements and swelling of the battery cells which can occur, for example, during charging and discharge cycles, which is not possible with rigid contact systems. The wires can also be coupled in a simple manner to sensor elements which detect properties of the battery cells and/or the cell connectors (for example temperature sensors). The flexibility of the wire contact elements advantageously also enables the use of a rigid printed circuit board, which enables simpler handling during manufacture and fitting and also the mounting of component parts such as, for example, electronic circuit elements thereon. The shape and the size of the rigid printed circuit board can in principle be matched to any desired constructions of battery modules, in particular to any desired arrangements, sizes and number of battery cells. Likewise, the number, the lengths, the orientations and the positions of the wire contact elements can in principle be matched to any desired constructions of battery modules, in particular to any desired arrangements, shapes and numbers of cell connectors for the battery cells.
The wires of the plurality of contact elements can preferably each be electrically conductively connected to the printed circuit board at the first end section of the contact element in at least one plated-through hole through the printed circuit board or at at least one contact panel on a surface of the printed circuit board. In the case of the plated-through holes, the wires can in principle be inserted into the plated-through hole from any desired side of the printed circuit board. In the case of the contact panels, these are preferably located on the upper side of the printed circuit board which is remote from the battery cells/battery cell groups. The contacting of the wires at the plated-through holes or contact panels can preferably take place by means of soldering, which can also take place in automated fashion.
In addition, the wires of the plurality of contact elements are preferably each configured to be able to be welded to a surface of the respective cell connector at the second end section of the contact element. The contacting of the wires at the cell connectors can preferably take place by means of an ultrasound welding method, which requires little time and can take place in automated fashion.
If the wire is coupled to a sensor element, this coupling can take place, for example, by means of soldering, and the sensor element is preferably configured to be able to be connected to the surface of the respective cell connector. Depending on the type of sensor element, the connection to the cell connector can take place by means of, for example, adhesive bonding, soldering or welding.
In one embodiment of the invention, the wire of a contact element runs in single-phase fashion between the first and the second end sections of the contact element. Wherein one end of the wire is electrically conductively connected to the printed circuit board at the first end section of the contact element, and the other end of the wire can be electrically conductively connected to the respective cell connector at the second end section of the contact element. The single-phase course of the wire means a single connecting line or, for example, an I shape of the contact element.
In another embodiment of the invention, the wire of a contact element runs in polyphase fashion between the first and the second end sections of the contact element. Wherein the ends of the wire are electrically conductively connected to the printed circuit board at the first end section of the contact element, and a bend (with a single curve, with a plurality of curves or a straight bend) in the wire can be electrically conductively connected to the respective cell connector at the second end section of the contact element. In yet another embodiment of the invention, the wire of a contact element runs in polyphase fashion between the first and the second end sections of the contact element, wherein a bend (with a single curve, with a plurality of curves or a straight bend) in the wire is electrically conductively connected to the printed circuit board at the first end section of the contact element, and the ends of the wire can be electrically conductively connected to the respective cell connector at the second end section of the contact element. The polyphase course of the wire means at least two connecting lines or, for example, a U shape or W shape of the contact element. The polyphase course of the wire has an additional advantage of a redundant connection and/or separate measurement and drive connections between the printed circuit board and the respective cell connector.
The plurality of contact elements of the battery cell contacting device can optionally be realized all in an identical or in different of the three abovementioned embodiments.
In one configuration of the invention, the battery cell contacting device furthermore has at least one signal management circuit, which is mounted on the printed circuit board or is connected to the printed circuit board. This signal management circuit is then for its part connected to a battery module controller or integrated therein. The battery module controller performs, for example, charging processes, balancing of the voltages and the states of charge, temperature adjustment processes, such as, in particular, cooling processes, and the like, at least partially depending on the measurement signals obtained by the battery cell contacting device. The battery cell contacting device, the signal management circuit and the battery module controller can also be referred to together as cell management controller (CMC).
In a further configuration of the invention, the printed circuit board of the battery cell contacting device can have at least one ventilation opening (for example in the form of a plurality of holes or a slit). Such ventilation openings can assist a cooling process of the battery cells beneath the rigid printed circuit board.
The subject matter of the invention is also a battery module having a plurality of battery cells and/or battery cell groups arranged next to one another and each having at least one positive electrode terminal and at least one negative electrode terminal. A plurality of cell connectors each electrically connect the electrode terminals of adjacent ones of the plurality of battery cells/battery cell groups to one another, Finally, an above-described battery cell contacting device of the invention is provided. Wherein, in the region next to the plurality of cell connectors, the printed circuit board is arranged over the battery cells/battery cell groups, and, at the second end section of the contact element, the electrically conductive wires of the plurality of contact elements are each electrically conductively connected to the respective cell connector and/or are coupled to a sensor element in contact with the respective cell connector. The wires of the plurality of contact elements are preferably each welded to the respective cell connectors at the second end section of the contact element by means of an ultrasound welding method.
The battery cells are connected to one another via cell connectors and are connectable to a consumer or a charging system via an electrical terminal of the battery module. The battery cells and the battery cell contacting device are preferably both accommodated in a module housing. The invention is not restricted to a specific number, size or arrangement of the plurality of battery cells/battery cell groups.
The invention is advantageously applicable for battery modules for vehicles, in particular electric vehicles and hybrid vehicles and in particular motor vehicles and motorcycles, and also for energy storage systems and other electrical appliances.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a battery cell contacting device, and a battery module containing such a battery cell contacting device, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
Referring now to the figures of the drawings in detail and first, particularly to
The battery module 10 has a multiplicity of battery cells 12 (optionally at least partially in the form of a plurality of battery cell groups) arranged in a module housing 11. In this exemplary embodiment, the battery cells are arranged next to one another in the right-to-left direction in
As illustrated in
As illustrated in
As indicated in
As illustrated in
The use of a wire for the contact element 30 naturally, i.e. without any further additional measures, generates an elasticity of the contact element, i.e. a possible movement of the second end section 31b relative to the first end section 31a on the rigid printed circuit board 21 both in a direction perpendicular to the plane of the rigid printed circuit board and in a plane parallel to the plane of the rigid printed circuit board. As a result, the contact elements 30 can compensate for both swellings and movements of the battery cells 12 in various orientations which can occur, for example, during charging and discharge cycles.
As illustrated in
In the exemplary embodiment in
The exemplary embodiment in
As illustrated in
In the text which follows, various specific embodiments of the contact elements 30 of the battery cell contacting device 20 will now be described in more detail by way of example.
The wire 32 of the contact element 30 can optionally be inserted into the plated-through hole 36 on the upper side of the printed circuit board 21 which is remote from the battery cells 12 (see, for example,
The wire 32 can run in single-phase fashion between the two end sections 31a, 31b of the contact element 30 (see, for example,
Alternatively, the wire 32 can run in polyphase fashion between the two end sections 31a, 31b of the contact element 30 (see, for example,
Preferably, a jumper wire can be used for the contact elements 30 illustrated in
In the embodiment in
In the embodiment in
In the embodiment in
Within the scope of the invention defined in the attached claims, further embodiments of the contact elements 30 which include, for example, other feature variants and/or other combinations of features of the embodiments in
The described battery modules 10 having the battery cell contacting devices 20 according to the invention can be used, for example, for vehicles, in particular electric vehicles and hybrid vehicles and in particular motor vehicles and motorcycles, or for energy storage systems or for other electrical appliances (for example electronic household appliances).
The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention.
Number | Date | Country | Kind |
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10 2020 128 195.4 | Nov 2020 | DE | national |
10 2021 103 388.8 | Feb 2021 | DE | national |
This application is a continuation, under 35 U.S.C. § 120, of copending International Patent Application PCT/EP2021/077271, filed Oct. 4, 2021, which designated the United States; this application also claims the priority, under 35 U.S.C. § 119, of German Patent Application DE 102020128915.4, filed Nov. 3, 2020, and DE 102021103388.8, filed Feb. 12, 2021; the prior applications are herewith incorporated by reference in their entirety.
Number | Date | Country | |
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Parent | PCT/EP2021/077271 | Oct 2021 | US |
Child | 18180312 | US |