DE102020111100A1 - Pluggable high-current terminal contact for battery cells - Google Patents

Abstract

The present invention relates to a system (100) for connecting battery poles (101, 102) of individual prismatic battery cells of a battery module which provides more than 30A. An electrically conductive cell connector (110) is designed with a first fastening section (111) and a second fastening section (112), the first fastening section having a first through opening for receiving a first battery terminal (101) and the second fastening section having a second through opening for receiving a second battery terminal (102). The first fastening section and the second fastening section are arranged within an arrangement plane (201), at least the first fastening section having a clamping section (160) with at least one elastically deformable clamping element (161) at the through opening, which is bent out of the arrangement plane (201) and protrudes into the first through opening in such a way that when the first battery terminal (101) is introduced, the clamping element (161) can be prestressed to generate a clamping force and a clamping connection between the first fastening section (111) and at least one side wall (203) of the first battery terminal (101) can be provided.

Description

Technical area

The present invention relates to a system for connecting battery terminals of individual prismatic battery cells of a battery module, which provides more than 30A, wherein fastening sections of the individual cell connectors can be fastened to battery terminals with a clamp connection. The invention also relates to the battery module and a method for connecting battery poles of individual prismatic battery cells of a battery module.

Background of the invention

In the case of high-performance battery modules, in particular in the case of traction batteries, a large number of individual prismatic battery cells are combined to form a battery pack or battery module. The respective battery poles of the battery cells are connected with conductive cell connectors.

Various fastening methods are used to connect battery cells using a cell connector for batteries with loads over 30A. These are based on contacting processes using screw technology, vibration-induced ultrasonic welding or thermal (especially laser) welding. The usual methods for high-current contacting of cell pole and cell connector are either a load on the cell (heat or vibration) or represent increased manufacturing or material costs (material costs for screws, positioning robots for wrenches, time for screwing, etc.).

The cell connectors can partially have pointed ends and sharp-edged side surfaces. The increasing high voltage to which batteries are serially chained, especially in the automotive and domestic storage sectors, leads to a potential field that is able to have negative effects (e.g. dendrite growth, corona burn, hillock formation, etc.) on the affected conductor paths. Especially prismatic battery cells, which are combined to form a battery module, show these effects in the high performance class (from 500 Wh per battery module). In the order of magnitude from 500 Wh, which are more and more often built into an aluminum housing for better temperature dissipation, a high electrical potential can build up between the pole and the cell housing. On the one hand, the interlinked voltage rises in the range of e.g. 400V to 800V compared to ground and, on the other hand, with liquid cooling, the coolant is also ground potential. Isolators are also used here. Depending on where the greater insulation value is (between coolant and aluminum housing or between cell connector and aluminum housing), a large voltage difference develops despite the high-resistance insulation and thus a large potential field. This high potential field favors the negative effects on the cell connectors and sensor cables.

In addition, it must be taken into account that batteries experience a change in volume both with temperature changes and depending on the state of charge. Especially when battery cells age, these expand. This means that the connection systems must be flexible enough to accommodate these changes in distance. However, this flexibility is problematic precisely in production.

In the case of high-current cell connectors (especially for cell connectors that have a 10-minute current load capacity of over 30A or 50 A, in particular over 90A or 170 A), difficulties can arise with screw-free, vibration and heating-free contact between the cell connector and the battery terminal. The cell pole should be mechanically only slightly stressed. The battery pole is not suitable for a mechanically high pressure load in the z-direction, i. H. on a battery pole in the direction of the base body of a battery cell. Furthermore, with increasing current-carrying capacity, the thermal problems increase non-linearly. With increasing current load, high contact resistances have more serious effects (local eruptions, which can cause oxide layers to form during cold / warm changes).

Screw-based contacts for a prismatic accumulator have some disadvantages with regard to the construction height in the Z-direction, material fits and the resulting micro-corrosion.

Friction welding (ultrasonic bonding) is technically possible, but contains extremely strong vibrations that are transmitted from the battery terminal into the battery cell. Depending on the type of battery, this can have negative effects on the service life or performance of the battery.

Presentation of the invention

It is an object of the present invention to provide a gentle and technically simple connection system between the cell connector and the battery terminals.

This object is achieved with a system for connecting battery poles of prismatic battery cells of a battery module, the battery module and a method for connecting battery poles of battery cells of a battery module solved according to the subjects of the independent claims.

According to a first aspect of the present invention, a system for connecting battery posts of individual prismatic battery cells of a battery module providing more than 30A is described. The system has an electrically conductive cell connector with a first fastening section and a second fastening section. The first fastening section has a first through opening for receiving a first battery terminal and the second fastening section has a second through opening for receiving a second battery terminal. The first fastening section and the second fastening section are arranged within an arrangement plane.

At least the first fastening section has a clamping section at the through opening with at least one elastically deformable clamping element (e.g. an elastic clamping bracket), which is bent out of the plane of arrangement and protrudes into the first through opening in such a way that when the first battery terminal is introduced, the clamping element for generating a clamping force can be preloaded and a clamping connection can be provided between the first fastening section and at least one side wall of the first battery terminal.

According to a further aspect of the present invention, a battery module is described which provides more than 30A. The battery module has the system described above, a first battery terminal and a second battery terminal. The first battery post is clamped in the first through-opening and the second battery post is clamped in the second through-opening.

According to a further aspect, a method is described for connecting battery poles of individual prismatic battery cells of a battery module which provides more than 30A. According to the method, an electrically conductive cell connector with a first fastening section and a second fastening section is provided, wherein the first fastening section has a first through opening for receiving a first battery terminal and wherein the second fastening section has a second through opening for receiving a second battery terminal. The first fastening section and the second fastening section are arranged within an arrangement plane. At least the first fastening section has a clamping section with at least one elastically deformable clamping element at the through opening, which is bent out of the arrangement plane and protrudes into the first through opening in such a way that when the first battery terminal is introduced, the clamping element can be prestressed to generate a clamping force and a clamping connection between the first fastening section and at least one side wall of the first battery terminal can be provided. According to the method, the first battery terminal is inserted into the first through opening to produce the clamp connection.

The battery module defines an assembly which combines several prismatic battery cells and provides a mechanical connection for them, and at least enables an electrical series connection or parallel connection of the battery cells by means of the cell connector. The individual battery cells can, for example, be arranged next to one another along one spatial direction or next to one another and / or one above the other (i.e. along two spatial directions) in a battery module.

A prismatic battery cell defines an electrical energy storage device with a fixed housing in, for example, a prismatic or cuboid design. The battery cells are, for example, lithium-ion accumulators. Each battery cell has in particular two battery poles, one + pole and one - pole. These two poles can be attached to the same side surface of the battery cell. The cell connectors according to the invention are designed or dimensioned in particular so that they can be used to connect battery cells with a nominal voltage of less than 5.5 V. The adjacent second battery cell accordingly also has two battery poles, one + pole and one - pole. A cell connector is used in particular to connect the + pole (or - pole) of a battery cell to the corresponding - pole (or + pole) of the adjacent battery cell. The prismatic battery cells are individual. This means that each battery cell forms a self-contained unit and therefore does not have any common components and has no fluidic coupling (e.g. via the battery fluid) with another battery cell.

A cell connector thus represents a high-current-resistant connection between the battery poles of two adjacent prismatic battery cells. In particular, when the battery module is heavily used, the cell connectors must withstand a strong voltage drop when loaded. The cell connectors are made of a robust and electrically conductive material, such as a metallic material such as aluminum or copper. The cell connectors also consist of a flat or plate-like material, for example sheet metal. The cell connectors are accordingly self-supporting compared to wire-like material.

The cell connectors have, for example, corresponding through openings as fastening sections for a respective battery pole. A battery pole can accordingly be fixed in a through opening, for example by means of clamping forces.

At least the first fastening section and / or the second fastening section has, at its through opening, a corresponding clamping section which has an elastically deformable clamping element. In particular, the clamping element is bent out of the plane of arrangement.

The clamping element can be configured on the basis of its dimensions and the choice of material in such a way that the restoring force or clamping force is so great that a displacement of the battery pole in the insertion direction, i.e. H. perpendicular to the arrangement plane. It is therefore not necessary to use additional fastening measures, such as welding or gluing, for example, in order to achieve a fixation of the battery pole in the through-opening.

The clamping element can, for example, be fastened to the through opening or be formed integrally with the cell connector. The cell connector can be punched out of sheet metal, for example. Correspondingly, the clamping element can be formed integrally in the fastening section in that the clamping element is cut out of the cell connector on at least three edges and is fastened integrally with the cell connector on a bending edge. The clamping element can then be bent out of the plane of arrangement by bending around the bending edge. The clamping element can for example be bent out of the arrangement plane in the direction of a battery cell. Alternatively, the clamping element can be bent out onto an opposite side with respect to the battery cell.

A rigid counterpart, e.g. H. a non-elastically deformable stop can be formed so that the clamping element in the fastening pole presses against this stop and thus creates a clamping connection. Alternatively, as described in detail below, an opposing further elastically deformable clamping element can be arranged so that the battery pole is clamped between two elastically deformable clamping elements.

Due to the side wall contact of the clamping element on the side wall of the battery pole, in particular the free end faces or surface of the battery pole remains free, so that, for example, good thermal dissipation, for example to the environment or to a coupled to the cooling system, is made possible.

The curved lateral contacting zones or contact elements are designed in such a way that the heating of the contact resistance at the maximum current strength is kept sufficiently small and this does not lead to any disruptive corrosive phenomena in the transition between the contacts. Optionally, the top of the cell connector can be provided with an additional coating after contacting, which prevents further corrosion progress in the event of microcracks at the bending points and also compensates for surface unevenness for the thermal coupling.

The described clamp connection according to the invention thus allows the production of cell connectors which have only a small voltage drop in the high load range. With a suitable choice of material and correspondingly careful construction, voltage drops across the cell connectors at a load of 1C of less than 0.5 V, in particular less than 0.2 V, and in special cases less than 0.1 V are achieved. A 10-minute current load capacity of the cell connectors is over 30A, in particular over 50 A, further in particular over 90A, even further in particular over 170 A.

In addition to the advantages already mentioned, the clamp connection according to the invention allows, due to its design, a simple release of cell connectors in the case of service or recycling. Either through the use of relief mechanisms, through mechanical forces or by cutting open the cell connector, the cell connector can be removed again without damaging the battery.

In a further particularly preferred embodiment variant, the spring forces or the clamping force of the clamping elements in the clamping connection between the cell connector and the battery pole are designed to be greater or significantly greater than the tensile forces on the pole connection resulting from the expansion compensation. This prevents the high-current connections from being loosened and any cold welds being torn open by the expansion behavior of the cell connectors or the battery cells. The clamping element can be configured in such a way that the clamping force is twice as large or more than five times greater than the tensile forces of the expansion compensation of the battery cells.

In a further preferred embodiment, the contact zone between the cell connector and the battery terminal is structured. This increases the point pressure during assembly and, when the cell connector is pushed on, tears up any oxide layers over the battery pole, which promotes the formation of a cold weld. The same effect can also be achieved by a cell connector which has several sheet metal layers, the contacting then being designed in such a way that the sheet metal ends hit the surface of the battery terminal with sharp edges and thus achieve the mentioned contact improvement.

According to a further exemplary embodiment, at least the first through opening and / or the second through opening has a predominantly round, elliptical or rectangular opening cross section. In particular, the opening cross section of the through opening can be adapted to the shape of the battery terminal.

According to a further exemplary embodiment, the clamping section is designed to exclusively contact side walls of the first battery terminal. Correspondingly, the free surface or end face of a battery pole can be used for further coupling of external systems, for example with a cooling system, or generally for thermal heat dissipation.

According to a further exemplary embodiment, the clamping element protrudes at least in regions into the through opening and can be preloaded by introducing the first battery terminal. In the arrangement plane, the through opening has a corresponding opening cross section with a central axis which runs perpendicular to the arrangement plane (or parallel to a normal to the arrangement plane). The clamping element is bent out of the arrangement plane in such a way that the clamping element runs in a direction of extent out of the arrangement plane in the direction of the central axis. In other words, the clamping element, which is spaced from the fastening section of the cell connector and correspondingly spaced from the plane of arrangement, protrudes into the through opening. This leads to the fact that when a battery terminal is inserted into the through opening, the clamping element moves outwards, i. H. away from the central axis, so that a restoring force is generated due to the elasticity of the clamping element. This restoring force acts as a clamping force against the side wall of the battery terminal.

According to a further exemplary embodiment, the clamping element has a bending section and a contact section, the bending section being integrally connected to the first fastening section and having a bend out of the plane of arrangement, the bending section being integrally connected to the contact section. The contact section has a clamping surface which can be coupled in a force-transmitting manner to the side wall of the first battery terminal. The larger the clamping surface, the better the current can be transmitted between the clamping element and the battery terminal. For example, the contact section or its clamping surface can nestle against the battery terminal in order to generate surface contact with the battery terminal.

According to a further exemplary embodiment, the contact section is designed in such a way that the clamping surface of the contact section in the unstressed state extends from an edge of the through opening, in particular pyramidal or conical, in the direction of the center of the through opening. This supports, accelerates and / or simplifies the positioning (in the sense of self-alignment) in the context of automated assembly.

According to a further exemplary embodiment, the clamping element has an end section with a free end, the contact section being arranged between the bending section and the end section. The end section extends opposite the clamping surface of the contact section in such a way that the end section is free of contact with the side wall of the first battery terminal when the clamping surface is coupled in a force-transmitting manner to the side wall of the first battery terminal. Since the free end is bent away from the side wall, assembly aids, for example, can more easily grip the clamping element at the free end and move it away in order to provide an assembly aid accordingly.

According to a further exemplary embodiment, the cell connector has an assembly opening. The end section accordingly has a receiving opening. The assembly opening and the coupling point are arranged in such a way that a relief spike can be inserted through the assembly opening and can be coupled to the coupling point in such a way that the end section and the contact section can be bent away against the clamping direction for decoupling with the first battery terminal.

The battery poles of a battery cell may only be exposed to limited mechanical loads so that the battery cell is not damaged. A corresponding assembly aid temporarily reduces the clamping force of the cell connectors so that they can be pushed over the battery poles.

According to a further exemplary embodiment, the clamping section has at least one further elastically deformable clamping element, which is arranged at the through opening opposite the clamping element and is bent out of the plane of arrangement so that the first battery pole can be inserted between the clamping element and the further clamping element in order to provide the clamping connection. The further clamping element can be designed in accordance with the clamping element described above.

The clamping forces of the clamping elements are configured in such a way that the clamping force on at least two opposite side walls of a battery terminal is approximately the same. This creates a force-neutral and therefore largely distortion-free connection between the cell connector and the battery terminal.

Correspondingly, according to a further exemplary embodiment, the clamping section can furthermore have further elastically deformable clamping elements which are arranged opposite one another at the through opening and are bent out of the plane of arrangement so that the first battery terminal can be pushed between the clamping elements and a force-symmetrical clamping force can be provided around the first battery terminal is.

The clamping section can thus generate a clamping force around the battery pole with a multiplicity of circumferential clamping elements, which clamping force acts symmetrically, in particular force symmetrically, around the battery pole.

According to a further exemplary embodiment, the system has a clamping ring which is arranged around the clamping elements in order to prevent the clamping connection from being released. The clamping ring is in particular releasably braced around the clamping elements and presses them evenly into the center of the through opening and thus against the side walls of an inserted battery terminal. The clamping ring is designed in particular to be elastically deformable in order to better adjust a clamping force effect. The clamping ring can for example consist of an electrically insulating plastic material. Furthermore, the clamping ring can also consist of the same or a different material with respect to the cell connector and, for example, have an iron alloy.

The cell connectors can be made of aluminum, for example. The crystal structure of aluminum tends to flow. For this reason, the clamping ring is attached around the clamping contact. This can only act on the corners of the clamps or on their entire length. The choice of a spring material with long-term stability, such as corrosion-proof or corrosion-protected iron material or similar, is particularly advantageous. This also prevents the long-term tearing of the corrosion layer typical of aluminum and the associated oxidation problems.

According to a further exemplary embodiment, the first fastening section and the second fastening section are connected to one another by means of a conductive connection. The conductive connection can be formed integrally and monolithically with the first and second attachment portions. In particular, the cell connector can be produced together with the fastening sections and the conductive connection in a stamping process.

According to an exemplary embodiment, the conductive connection has a conductor, in particular a strip-shaped conductor. The strip-shaped conductor runs in particular within the arrangement plane in which the first fastening section and the second fastening section are also arranged. The course described above is designed in such a way that the rigidity in the x-direction is smaller than in the y-direction and / or z-direction. In this way, expansions or contractions in the x direction can be compensated for without tension and corresponding defects occurring in the conductive connection or in the cell connection.

According to a further exemplary embodiment, the conductor has a loop-shaped, curved or wave-shaped, in particular meander-shaped, course to compensate for a change in distance between the first fastening section and the second fastening section. The course described above is designed in such a way that the rigidity in the x-direction is smaller than in the y-direction and / or z-direction. In this way, expansion or contraction in the x-direction can be compensated for without tension and corresponding defects occurring.

According to a further exemplary embodiment, the clamping connection is designed such that the elastically deformable clamping element is designed to be more rigid than the conductive connection between the first fastening section and the second fastening section. It can thus be ensured that in the event of a relative movement between the fastening sections, which are not prevented by the conductor due to its deformability, the clamping connection, i. H. in particular the clamping elements, which are designed to be more rigid with respect to the conductor, do not come loose.

According to a further exemplary embodiment, the cell connector is a first cell connector. The system also has a second electrically conductive cell connector which is used for fastening and electrically connecting two further spaced apart battery posts is formed.

The system furthermore has an electrically insulating carrier element, to which the first cell connector and the second cell connector are fastened, in order to provide a supporting structure for the first cell connector and the second cell connector (for fastening the first cell connector and the second cell connector by means of the carrier element the carrier element, the first cell connector and the second cell connector are exclusively embedded in regions in the carrier element, so that surface areas of the first cell connector and the second cell connector are free of a cover with the carrier element.

The carrier material of the carrier element consists of an electrically insulating material, such as, for example, a (in particular injection-mouldable) plastic material. The first cell connector and the second cell connector are attached to the carrier material. The carrier material is firmly connected to the first cell connector and the second cell connector in such a way that a self-supporting unit is created together. This corresponding self-supporting unit can, in particular, facilitate assembly, since simple handling is possible, in particular when connecting the corresponding battery poles.

According to the invention, the first cell connector and the second cell connector are partially embedded in the carrier element. The term “embedding” is understood below to mean that a cell connector is at least partially surrounded by the material of the carrier element and, so to speak, is partially immersed in a body of the carrier element, so that the carrier material at least partially encloses the cell connector. In other words, the carrier material has, for example, a receiving slot in which a region of the cell connector is present, so that the carrier material encloses two opposing surfaces and the end face of the cell connector connecting the surfaces and is embedded accordingly. A corresponding embedding is preferably implemented in an injection molding process, so that no machining, for example to form the receiving slot in the carrier element, is necessary.

The definition of “exclusively region-wise embedding” is understood to mean that the cell connectors are not completely embedded in the carrier element and are encased by the carrier element. In particular, the contact areas on the cell connector, in particular in the corresponding through-openings into which the battery terminals can be inserted, remain free from covering the carrier material in order to provide electrical contact capability. Furthermore, surface areas of the cell connectors remain free of the material of the carrier element in order to provide better heat dissipation in particular. For example, the carrier element covers less than 50%, in particular less than 10% and further in particular less than 5% of a surface of a cell connector. Correspondingly, the carrier element can cover an opposing surface area.

The carrier element can embed a cell connector in such a way that, for example, the carrier element surrounds the cell connector along one side length. For example, the carrier element can run circumferentially around the cell connector, a center of the cell connector, in particular in which the through-opening of the fastening area is provided, being free from embedding or covering with the carrier area.

In particular, a surface of a cell connector facing away from the battery cell can be covered by the carrier element only less than 50%, in particular less than 10% and further in particular less than 5%, so that a sufficiently stable embedding is created and at the same time sufficient Free space on the surface to enable thermal heat dissipation and, for example, the coupling of a heat sink. At the same time, the surface facing the battery cell can be more than 10%, in particular more than 50%, in particular completely covered by the carrier element in order to thus provide good potential shielding.

According to a further exemplary embodiment, the first cell connector, the second cell connector and the carrier element are arranged within the common arrangement plane. In other words, the cell connectors and the carrier element are arranged next to one another within the common arrangement plane.

According to a further exemplary embodiment, the first cell connector and the second cell connector form punched-out flat components. According to a further exemplary embodiment, the first cell connector and / or the second cell connector each consist, for example, of a sheet metal, in particular a multilayer sheet. In the case of a punched-out flat component or a sheet metal, the width and length of which are very much greater than their thickness. The first and second cell connectors can for example consist of a sheet made of aluminum or copper. Furthermore, different layers of different materials can form a cell connector. For example, different materials can be used in different layers.

According to a further exemplary embodiment, the carrier element has a first carrier section which at least partially embeds the first cell connector, and a second carrier section which at least partially embeds the second cell connector. The first carrier section and the second carrier section are connected by means of an electrically insulating connection structure. The connection structure can consist of the same material as the first carrier section or the second carrier section. In particular, the first carrier section, the second carrier section and the connection structure can be created in a common injection molding step. The first support section, the second support section and the connecting structure form a self-supporting unit and can be manufactured robustly.

According to a further exemplary embodiment, the connection structure is designed to be deformable in order to compensate for a change in distance between the first cell connector and the second cell connector. The connection structure can for example be made of an elastically deformable material in order to compensate for a corresponding change in distance between two cell connectors without breaking. Typically, the carrier element connects two cell connectors which connect battery poles of a common battery cell to at least one fastening area. Due to thermal expansion or due to aging, battery cells expand or reduce their size. In order not to cause the two cell connectors to become wedged due to a carrier element that is too rigid, the connection structure between two carrier sections can advantageously be designed to be elastically deformable.

The connection structure can be designed in such a way that elastic deformation is possible along a predetermined spatial direction. The individual battery cells are arranged next to one another along a first spatial direction (for example the x-axis) and connected accordingly with the cell connectors. A second spatial direction (for example y-axis) which is orthogonal to the first spatial direction describes an extension of the battery cell in the arrangement plane. A third spatial direction (z-axis), which is, for example, parallel to the normal of the arrangement plane and along which the battery poles of a cell connector extend, is in particular orthogonal to the first spatial direction and the second spatial direction.

The length changes relevant for the contacting of battery cells, which are based on the problem of the volume change of rechargeable batteries mentioned in the problem, are of particular importance in the assembly of battery modules in the x-direction. Correspondingly, the connection structure can be designed in such a way that it is non-destructive or elastically deformable along the first spatial direction (X direction). Because the length changes not only taking place in the x-direction, a rigid movement restriction in the x-direction is not selected, but a system with different elasticity constants (dependent on the direction of the coordinate). This means that in the y- and z-direction the movement compensation with stiffer movement mechanisms than in the x-direction. In the y and z directions, for example, due to the choice of material and design concept, a relatively stiff behavior can be achieved compared to a possibility of deformation in the x direction. A mechanical sliding system can also be proposed in the x direction, which preferably deflects the resulting change forces in this direction.

According to a further exemplary embodiment, the connection structure has a loop-shaped, curved or wave-shaped, in particular meander-shaped, course. The connection structure can for example be produced together with the first cell connector and the second cell connector from a common base material, such as a plate-like material or sheet metal, by means of cutting or punching. The course of the connection structure described above runs in particular within the arrangement plane in which the first cell connector and the second cell connector are also arranged. The course described above is designed in such a way that the rigidity in the x-direction is smaller than in the y-direction and / or z-direction. In this way, expansions or contractions in the x direction can be compensated for without tension and corresponding defects occurring in the connection structure or in the cell connection.

According to a further exemplary embodiment, at least the first carrier section and / or the second carrier section has at least one receiving groove for receiving a signal line.

The signal line can thus be coupled to the first cell connector or the second connector. The signal line is attached to the corresponding cell connector and can also be arranged on the cell connector in an electrically conductive manner. Signals can thus be transmitted via the signal line, either from the cell connector itself or from a sensor additionally arranged there. The signal lines can thus in particular represent sensor lines, which represent connecting lines in the interior of a battery module and are used to monitor measured values. The measured values included for example cell voltage and temperature. In the case of certain battery modules, these lines can be used to actively balance the charge / load. Charging and discharging of individual cells can also be made possible.

The signal lines in the component carrier can be electrically insulated in such a way that they are suitable for a test voltage of over 400V, in particular over 800 V, in particular over 1600 V. The mean cross section of the sensor lines can be over 0.1 mm ^ 2 (square millimeters), in particular over 0.5 mm ^ 2, further in particular over 1.2 mm ^ 2. The system can in particular contain a strain relief for a sensor assembly to which the signal lines are connected.

In particular, each cell connector connects corresponding battery poles of two different battery cells. The first cell connector can connect a - pole of a first battery cell to a + pole of an adjacent second battery cell. The second cell connector can correspondingly connect a + pole of the first battery cell to a - pole of a third adjacent battery cell. The two electrically conductive cell connectors are connected by the electrically insulating carrier element, so that a robust, rigid and, in particular, self-supporting unit of cell connector and carrier element is provided. In this way, in particular in the case of automated production of large battery modules with a large number of battery cells, easier handling of the cell connectors and, correspondingly, faster and more secure connection of the cell connectors to the battery poles can be provided. In this regard, the system according to the invention can have a multiplicity of cell connectors, two cell connectors each being mechanically coupled to a corresponding carrier element. Accordingly, a large number of battery poles can be connected simultaneously in one work step. In comparison to a conventional individual attachment of the respective cell connectors to two battery poles, the system according to the invention brings about a significantly faster and more robust connection of a large number of battery cells.

With the formation of the receiving groove in the carrier element, the carrier element has the additional function of stable and protected guidance of the signal line. In particular, the signal line can be preinstalled in the receiving groove before the system is installed on the battery poles or can be installed subsequently after the system has been installed on the battery poles. In particular, the first and / or second carrier section can have a multiplicity of receiving grooves for corresponding signal lines.

Due to the mechanical relief of the clamping elements during assembly according to the invention, a particularly high contact pressure can be built up between the clamping elements and the battery terminal later, after assembly, which would lead to mechanical overload or damage to the battery terminal without force relief during assembly. In this way, such a high clamping force can be generated at the battery pole that this leads to a particularly high level of impact resistance (without detaching the cell connector) of the entire battery module (e.g. in the event of minor accidents). Particularly in the case of short impacts, which can lead to short accelerations of the cell connectors of over 2 G or over 4 G to over 9 G, the risk of detachment and / or of cold welds tearing open at contact zones can be reduced due to the lower mass.

According to a further exemplary embodiment, the system furthermore has a coupling element which is fastened, in particular releasably, between the first carrier section and the second carrier section. The coupling element is arranged with the first carrier section and the second carrier section one after the other along an arrangement direction, in particular within an arrangement plane, so that the first carrier element, the coupling element and the second carrier element are arranged one after the other along the arrangement direction (x-direction). The coupling element couples the first carrier section and the second carrier section, so that a more robust structure of the system is provided. The coupling element consists of an electrically insulating material such as plastic, for example, and can also be produced, for example, by means of an injection molding process.

According to a further exemplary embodiment, the coupling element has a further receiving groove for receiving the signal line. The coupling element thus has the additional function of stable and protected routing of the signal line or another signal line. In particular, the coupling element and the signal line can be preinstalled in the further receiving groove before the system is installed on the battery terminals. For example, the coupling element can be coupled to the carrier sections before the system is installed on the battery posts. Alternatively, the carrier sections can first be attached to the battery terminals. Subsequently, the coupling elements (for example together with the signal lines) can be attached to the carrier sections. After the coupling sections have been installed, the first carrier section, the coupling element and then the second carrier section are present in the x direction and within the arrangement plane. Consequently When installed, the system can form a load-bearing structure that carries the signal lines on the one hand and the cell connectors on the other.

The construction creates a mechanically predetermined movement path for the signal lines. Dodging / deviating from this path, which is specified by the receiving groove, due to the higher forces required for this, is unlikely. This increases the safety of the live signal lines (e.g. sensor and load balancing lines).

In a preferred embodiment variant, the cell connectors and the coupling element are joined to one another prior to assembly on the prismatic cells and the signal or sensor lines are connected to the cell connectors. This allows full testing of the system prior to mounting on the battery cells.

In a further exemplary embodiment, the carrier element and / or the coupling element can be designed in such a way that a large creepage distance can be formed between the signal lines even for higher voltages and a test voltage of over 400V, preferably over 800V and in special cases over 1600V is sufficient. This allows battery modules according to the invention to be operated using the relevant provisions for energy systems with operating voltages above the electrical protective extra-low voltage of below 50V.

In a further sub-variant, contact protection is achieved by increasing the height of the insulators compared to conductors. This can be achieved in particular in that the receiving grooves in the carrier element or the coupling element are deeper than a height or a cross section of a signal line.

The cell connectors but also the sensor lines can be punched out of a flat material and then embedded. By creating meanders, loops or bends that lie in the arrangement plane (x-y plane), both expansion compensation and cost-effective production can be achieved.

The production of cell connectors from punched sheet metal brings with it a good starting position in terms of manufacturing technology, because punching is a proven, inexpensive, stable and large-volume process. On the technical side, stamped sheets have a high degree of accuracy. Other bending or embossing processes reduce these accuracies, which is why the solution according to the invention only processes small or very small parts of an entire cell connector accordingly, i.e. performs deformations in the Z-plane.

In a further exemplary embodiment, the signal lines are implemented with a larger cross section than would be necessary for pure voltage monitoring of the individual cell voltage. This higher cross-section allows a higher current carrying capacity on these lines. As a result, the difference between individual cells can be at least partially compensated for by means of a BMS (battery management system) via these lines (reloading, additional charging, partial charging, etc. of individual cells).

According to a further exemplary embodiment, the signal line has an integrated current fuse, in particular a fuse, the signal line being designed in particular with a fuse area with a defined cross-sectional reduction in such a way that the cross-sectional reduction provides the fuse.

The cross-section reduction can be produced, for example, by means of a notch (e.g. made during a stamping process), thinning by bending (in the sense of deep-drawing, which reduces the cross-section) or drawing. A notch can be advantageous in terms of keeping to measure.

This reduction is placed in a place where overheating does not lead to ignition of the insulation material. This cross-sectional reduction can serve as a fuse in the event of a short circuit in the sensor line. Because the sensor line is in a defined (and safe with respect to the surrounding components) position, overheating of the sensor line can be avoided along its entire length. Alternatively, a securing element can also be used instead of a cross-section reduction. To ensure the thermal integrity of the component carrier and / or to visualize a trip, this safety mechanism can be built into the non-embedded part of the system. In an exemplary embodiment, the securing element can be designed to be non-reversible so that, in the event of a response, a service activity has to check whether the response of the securing element has led to greater damage.

The securing function or the cross-section reduction can in particular lie at least partially in a non-embedded part of the component carrier.

According to a further exemplary embodiment, the system has a sensor, in particular a temperature sensor, a voltage sensor or a power sensor, which is arranged on the first cell connector or on the second cell connector or is integrated therein. In particular, the sensor is coupled to one of the signal lines in order to receive or forward signals. The system thus has an integrated status control of the system itself or of the connected battery cells.

The sensor can, for example, be firmly attached to a cell connector. In particular, since the connection system and the plug-in connection intercepts expansion of the battery cells, for example via sliding components or meandering connection mechanisms, it is possible, for example, to better thermally couple a temperature sensor to a single cell. This allows a more precise, more reliable and long-term stable temperature measurement than with a normal pressure-based (frictional) coupling of the thermocouple to the battery cell. The contacting of this sensor can in turn take place via the inventive concept of the sensor lines. The same mechanism also applies to the coupling of other sensors to a single battery cell, for example with local intelligence (e.g. bus systems for sensor data transmission, active charge / load balancing).

The carrier element can also integrate additional electrical sensors (e.g. heat sensor) and / or electronic components (e.g. local intelligence or active charging / load balancing).

Furthermore, in a further exemplary embodiment, the carrier element and / or the coupling element can have externally applied or integrated cooling lines through which a cooling medium can read. For example, the cooling lines are connected to an external cooling mechanism. The cooling mechanism can, for example, have the heat sink described below, which is in thermal contact with the cell connectors and, furthermore, in particular in direct contact with the battery terminals.

According to a further exemplary embodiment of the battery module, at least one of the first battery terminals has a free terminal surface. The first battery terminal protrudes from a base body of a battery cell, the first battery terminal being arranged in the first through opening in such a way that a first surface of the first cell connector directed towards the base body of the battery cell is closer to the base body than the terminal surface. In particular, the first battery terminal is arranged in the first through-opening in such a way that the terminal surface is coplanar with a second surface of the first cell connector opposite the first surface, so that a common coupling surface can be provided. The coupling surface extends and lies, for example, within the arrangement plane. A homogeneous coupling surface is thus formed on which external components, such as the heat sink described below, can be arranged in a simple manner, so that a large surface contact is provided between the pole surface and the cell connector on the one hand and the external component on the other.

According to a further exemplary embodiment, the battery module has a heat sink of a cooling system, which is arranged on the pole surface for thermal coupling. In particular, the heat sink rests flat on the coupling surface for thermal coupling. The cooling body can for example have cooling lines through which a cooling medium, for example a liquid fluid, flows. The cooling lines of the cooling body can, for example, be coupled to cooling lines which are integrated in the carrier element and / or the coupling element.

The contact clips or the clamping elements, which rest on the side walls of the battery poles, can be designed with a very small structural height (in the z-direction). As a result, the cell connector can be applied to the battery pole in such a way that the free surface of the cell connector facing away from the battery cell lies in the same plane as the pole surface of a battery pole, or the free surface of the cell connector is at least not higher than the battery pole itself or around the battery pole protrudes less than the sheet metal thickness of the cell connector itself. As a result, the coolant flow can take place within the arrangement plane (x-y plane) along the pole surface and the cell connector with little or no flow disturbances in the direct vicinity of the battery pole. In particular, the clamping element has an extension length parallel to a side wall of the battery pole, which is equal to the pole extension in the z-direction or is smaller than the pole extension of the battery pole in the z-direction by the thickness of the cell connector.

According to a further exemplary embodiment, the first fastening section is welded to the first battery terminal and / or the second fastening section is welded to the second battery terminal. In this way, for example, higher currents can be transmitted compared to an exclusive clamping connection. The clamp connection according to the invention allows, for example, initially in a first assembly step Force-neutral positioning of the cell connectors on the battery cells. In a second step, for example, due to the exact positioning, a robust and precisely positioned welding can be carried out. According to an exemplary embodiment of the method, before the first battery terminal is inserted, the clamping element is pretensioned against the clamping force by means of a mounting element.

The clamping element is bent in a direction opposite to the central axis of the through-opening and, for example, out of the through-opening by means of the mounting element, before and while the cell connector is plugged onto the battery terminal. During assembly, the clamping force is, so to speak, reduced by means of the assembly element. The assembly element for reducing the clamping force can have a wedge system, a mandrel / punch system and / or relief pins.

As explained above in an exemplary embodiment, the cell connector has an assembly opening through which, for example, a relief mandrel can be inserted and coupled to the end section of the clamping element. The relief mandrel can then be pivoted or displaced in such a way that the end section and thus the entire clamping element is bent out from the center of the through opening in order to reduce the clamping force and enable simple assembly.

According to a further exemplary embodiment, the mounting element has a stamp which is inserted from an upper side (which is directed away from the battery cell) of the cell connector into the first through opening (in particular in the direction of the battery cell) in order to preload the clamping element (and correspondingly out of the To bend out the center of the through opening). The first battery pole is inserted from the underside (which is closest to the battery cell) of the cell connector into the first through opening until a predetermined position is reached in the first through opening. The stamp is then pulled out of the through opening and the clamping element clamps the side wall of the first battery terminal.

In summary, with the system according to the invention, a simpler and faster assembly of cell connectors on corresponding battery cells can be made possible. The signal lines (sensor lines) can be prefabricated in a self-supporting unit on the carrier element and the coupling elements (and also for attachment to the cell connector) and, if necessary, tested. In particular, the conductive connection between the corresponding fastening sections of a cell connector and the connection structure between the carrier sections can create tension and pressure relief systems for assembly and for operational (for example due to aging) expansion. Expansion compensation can also be provided for the different elasticities between the clamping elements and, for example, the conductive connection between the fastening sections.

Furthermore, it has been found that punched cell connectors with minimal edge bends in the area of the battery terminal have a number of advantages. The minimal edge bends allow, on the one hand, the compensation of the mechanical scattering of the mass of the battery pole and, on the other hand, allow a suitable contact pressure to be built up. The contact pressure should be high enough to achieve low contact resistance over the long term (e.g. through micro-welds) and, on the other hand, sufficiently small in terms of elasticity of the conductor material relationship between the clamping element, so that the system remains within the permanent elasticity of the components involved. In the case of aluminum as a conductor material in particular, the area of flow (limit of the linear expansion area and transition to plastic deformation) can be avoided.

The cell connectors are plugged onto the battery pole, whereby the insertion forces may well require mechanical support or mechanical aids for force reduction (i.e. assembly elements) can be used for this purpose.

According to the present invention, the battery poles are laterally contacted by means of the clamping elements, so that a force symmetry of the contacting forces arises, which avoids mechanical loading (in the sense of spring contact in the Z direction) on the battery pole or the area around the cell connector. In order to prevent any vibration-related separation of the pole connector, a corresponding mechanical inhibition can be added from the outer housing or the cooling system (not shown).

It is pointed out that the embodiments described here only represent a limited selection of possible embodiment variants of the invention. It is thus possible to combine the features of individual embodiments with one another in a suitable manner, so that for a person skilled in the art, with the embodiment variants explicitly shown here, a large number of different embodiments are to be seen as obviously disclosed. In particular, there are some embodiments of the invention with device claims and other embodiments of the invention with method claims. However, when reading this application, it will immediately become clear to the person skilled in the art that, unless explicitly stated otherwise, in addition to a combination of features belonging to one type of subject matter of the invention, any combination of features relating to different types of Subjects of the invention belong.

Figure list

• 1 eine schematische Darstellung eines Systems zum Verbinden von Batteriepolen eines Batteriemoduls gemäß einer beispielhaften Ausführungsform.
• 2 eine schematische Schnittdarstellung eines Systems zum Verbinden von Batteriepolen eines Batteriemoduls gemäß einer beispielhaften Ausführungsform.
• 3 eine schematische Darstellung eines Systems zum Verbinden von Batteriepolen mit einem Versteifungselement gemäß einer beispielhaften Ausführungsform.
• 4 eine schematische Darstellung von Kopplungselementen mit Signalleitungen gemäß einer beispielhaften Ausführungsform.
• 5 eine schematische Darstellung einer mechanischen Steckverbindung gemäß einer beispielhaften Ausführungsform.
• 6 eine schematische Darstellung eines Systems zum Verbinden einer Vielzahl von Batteriezellen eines Batteriemoduls gemäß einer beispielhaften Ausführungsform.
• 7 eine schematische Darstellung einer Befestigung eines Zellverbinders an einen Batteriepol gemäß einer beispielhaften Ausführungsform.
• 8 eine schematische Darstellung eines Zellverbinders mit einem Isolationselement gemäß einer beispielhaften Ausführungsform.
• 9 eine schematische Darstellung eines Trägerbands für Kopplungselemente gemäß einer beispielhaften Ausführungsform.
• 10 eine schematische Darstellung einer Befestigung eines Zellverbinders an einen Batteriepol gemäß einer beispielhaften Ausführungsform.
• 11 eine schematische Darstellung einer Montagehilfe mit einem Entlastungsdorn gemäß einer beispielhaften Ausführungsform.
• 12 eine schematische Darstellung einer Montagehilfe mit einem Stempel gemäß einer beispielhaften Ausführungsform.

In the following, for further explanation and for a better understanding of the present invention, exemplary embodiments are described in more detail with reference to the accompanying drawings. Show it:

• 1 a schematic representation of a system for connecting battery terminals of a battery module according to an exemplary embodiment.
• 2 a schematic sectional illustration of a system for connecting battery terminals of a battery module according to an exemplary embodiment.
• 3 a schematic representation of a system for connecting battery terminals to a stiffening element according to an exemplary embodiment.
• 4th a schematic representation of coupling elements with signal lines according to an exemplary embodiment.
• 5 a schematic representation of a mechanical plug connection according to an exemplary embodiment.
• 6th a schematic illustration of a system for connecting a plurality of battery cells of a battery module according to an exemplary embodiment.
• 7th a schematic representation of a fastening of a cell connector to a battery pole according to an exemplary embodiment.
• 8th a schematic representation of a cell connector with an insulation element according to an exemplary embodiment.
• 9 a schematic representation of a carrier tape for coupling elements according to an exemplary embodiment.
• 10 a schematic representation of a fastening of a cell connector to a battery pole according to an exemplary embodiment.
• 11 a schematic representation of an assembly aid with a relief mandrel according to an exemplary embodiment.
• 12th a schematic representation of an assembly aid with a stamp according to an exemplary embodiment.

Detailed description of exemplary embodiments

Identical or similar components in different figures are provided with the same reference numbers. The representations in the figures are schematic.

1 a schematic representation of a system 100 for connecting battery poles 101 , 102 a battery module 100 according to an exemplary embodiment. 2 illustrates the embedding of the cell connector in a step display 110 of the system 100 the end 1 .

The system 100 has a first electrically conductive cell connector 110 , which is used to attach and electrically connect two spaced apart battery poles 101 , 102 is formed, and a second electrically conductive cell connector 120 , which is used to attach and electrically connect two further spaced apart battery poles 101 , 102 is trained on. Furthermore, the system 100 an electrically insulating support element 130 on which the first cell connector 110 and the second cell connector 120 are attached to by means of the support element 130 a supporting structure for the first cell connector 110 and the second cell connector 120 to provide, wherein for fastening the first cell connector 110 and the second cell connector 120 on the carrier element 130 the first cell connector 110 and the second cell connector 120 only in certain areas in the carrier element 130 are embedded, so that surface areas of the first cell connector 110 and the second cell connector 120 free of a cover with the carrier element 130 are. A signal line 105 is at least one of the first and second cell connectors 120 coupled.

The electrically conductive cell connector 110 is with a first attachment portion 111 and a second attachment portion 112 formed, wherein the first fastening portion has a first through opening for receiving the first battery terminal 101 and wherein the second fastening section has a second through opening for receiving the second battery terminal 102 having. The first fastening section and the second fastening section are within an arrangement plane 201 (please refer 2 ), wherein at least the first fastening section has a clamping section on the through opening 160 with at least one elastically deformable clamping element 161 has, which from the arrangement level 201 (in the direction of the battery cell 151 ) is bent out and protrudes into the first through opening in such a way that when the first battery terminal is introduced 101 the clamping element 161 can be preloaded to generate a clamping force and a clamping connection between the first fastening section 111 and at least one side wall 203 of the first battery pole 101 can be provided.

The battery module 150 defines an assembly that contains multiple prismatic battery cells 151 summarizes, as well as at least by means of the cell connector 110 , 120 an electrical series connection or parallel connection of the battery cells 151 is achieved. The individual battery cells 151 are arranged next to one another, for example, along one spatial direction (x-axis). Every battery cell 151 in particular has two battery poles 101 , 102 , each one + pole 102 and one - pole 101 , on. The adjacent second battery cell 151 accordingly also has two battery poles 101 , 102 on. The cell connectors 110 , 120 are used to connect the + pole (or - pole) 101 , 102 a battery cell 151 with the corresponding - pole (or + pole) 101 , 102 the neighboring battery cell 151 connect to.

The carrier material of the carrier element 130 consists of an electrically insulating material, such as a (in particular injection-mouldable) plastic material. On the carrier material 130 is the first cell connector 110 and the second cell connector 120 attached. The carrier material is so fixed to the first cell connector 110 and the second cell connector 120 connected so that together a self-supporting unit is created.

According to the invention, the first cell connector is thereby used 110 and the second cell connector 120 partially in an embedded area 104 in the carrier element 130 embedded. The term “embedding” is understood below to mean that the cell connectors 110 , 120 at least partially from the material of the carrier element 130 are surrounded so that the carrier material is the cell connector 110 , 120 at least partially encloses. As in 2 shown has the carrier material 130 for example a receiving slot in which a region of the cell connector 110 , 120 is present so that the carrier material has two opposing surfaces 206 , 207 and the face of the cell connector connecting the surfaces 110 , 120 encloses and embedded accordingly. A corresponding embedding is preferably implemented in an injection molding process.

In particular, stay on the cell connector 110 , 120 the contact areas in particular in the corresponding through openings in which the battery poles 101 , 102 can be inserted, free from an overlap of the carrier material of the carrier element 130 to provide electrical contact capability.

Beam sections 131 , 132 of the carrier element 130 are formed, for example, with a U-shaped section in which the cell connectors 110 , 120 are embedded. Thus only a small surface area, for example between 10% and 30% of a total area of a cell connector 110 , 120 , with the carrier element 130 covered and embedded.

There is also a signal line 105 to the first cell connector 110 or the second cell connector 120 coupled. The signal line 105 is on the corresponding cell connector 110 , 120 attached and can also be electrically conductive to the cell connector 110 , 120 be arranged.

The first cell connector 110 , the second cell connector 120 and the support element 130 are within the common arrangement level 201 arranged. In other words, the cell connectors are 110 , 120 and the support element 130 next to each other within the common arrangement level 201 arranged.

The first cell connector 110 and the second cell connector 120 form punched flat components.

The first beam section 131 and the second support section 132 are by means of an electrically insulating connection structure 103 tied together. The first beam section 131 , the second beam section 132 and the connection structure 103 form a self-supporting unit.

The connection structure 130 is to compensate for a change in distance (in particular along the x-axis) between the first cell connector 110 and the second cell connector 120 deformable. The connection structure 103 consists of an elastically deformable material to allow for a corresponding change in distance between two cell connectors 110 , 120 balance without breaking. The connection structure 103 be designed in such a way that elastic deformation is possible along a predetermined spatial direction. The individual battery cells are positioned along a first spatial direction (for example the x-axis) 151 arranged next to each other and correspondingly with the cell connectors 110 , 120 tied together. A second spatial direction (for example y-axis) which is orthogonal to the first spatial direction describes an extension of the battery cell in the arrangement plane 201 . A third spatial direction (z-axis) which, for example, is parallel to the normal of the Arrangement level 201 and along which the battery pole is 101 , 102 from a cell connector 110 , 120 extend, is in particular orthogonal to the first spatial direction (x-axis) and the second spatial direction (y-axis).

The connection structure 103 has a loop-shaped, curved or wave-shaped, in particular meander-shaped, course. The course of the connection structure 103 runs in particular within the arrangement level 201 , in which also the first cell connector 110 and the second cell connector 120 are arranged. The course is designed in such a way that the rigidity in the x-direction is smaller than in the y-direction and / or z-direction. In this way, expansions or contractions in the x-direction can be compensated without causing tension and corresponding defects in the connection structure 102 or in the cell connectors 110 , 120 comes.

For temporary stiffening of the first carrier section 131 or the second carrier section 132 is a stiffening element 109 releasably attachable. The stiffening element 109 leads to that during the assembly of the system 100 on battery poles 101 , 102 the cell connectors 110 , 120 and the support element 130 are stiffened and thus more robust, so that handling is easier, in particular using automated tools, and leads to less damage to the system 100 during assembly.

For example, along the plane of arrangement 201 a reinforcement bar 109 on the carrier element 130 be attached to bring about a stiffening. After the system 100 at the battery terminals 101 , 102 is attached, the reinforcement beam 109 removed. In particular, a predetermined breaking point between the carrier element can be used for this purpose 130 one hand and the reinforcement beam 109 on the other hand are provided, so that a simple removal by breaking away the reinforcing bar 109 can be provided. The reinforcement element 109 leads in particular to a stiffening of the system in the x-direction.

The first beam section 131 and / or the second carrier section 132 have several grooves 202 for receiving signal lines 105 on. Thus, the carrier element receives 130 the additional function for stable and protected routing of the signal line 105 .

Furthermore, the signal line 105 a meandering course with a U-shaped section, wherein the carrier element 130 a strain relief structure 113 having. The strain relief structure 113 is designed such that the strain relief structure 113 engages in the U-shaped section to the signal line 105 to fix. The strain relief structure 113 forms, for example, a projection from the carrier element 130 along a first direction (for example y-direction), which in the U-shaped section of the signal line 105 intervenes. Thus, for example, in the case of a tensile force perpendicular to the first direction (for example in the x direction), the U-shaped section can be pressed against the projection, so that the projection brings about a strain relief.

The system 100 furthermore has a coupling element 140 on, which is between the first carrier section 131 and the second support section 132 , in particular releasably, is attached. The coupling element 140 is with the first support section 131 and the second support section 131 one after the other along an arrangement direction, in particular within an arrangement plane 201 , arranged so that the first carrier element along the arrangement direction (x-direction) 130 , the coupling element 140 and the second support element 130 are arranged one after the other. The coupling element 140 couples, for example, the first carrier section 131 and the second support section 132 a carrier element 130 or a first support section 131 a first carrier element 130 with a second support section 132 a second support element 130 so that a more robust structure of the system 100 provided.

The coupling element 140 has a further receiving groove (for example an open groove or a closed groove designed as a bore) for receiving the signal line 105 on.

The coupling element 140 also has, for example, an electrical connector device 141 on for coupling a signal component, in particular a further signal line. The electrical connector device 141 is designed in particular as a plug socket.

The first fastening section 111 and the second attachment portion 112 are by means of a conductive connection 106 connected with each other. The conductive connection 106 may be integral and monolithic with the first and second attachment portions 111 , 112 be trained. In particular, the cell connector can be used in a stamping process 110 , 120 together with the fastening sections 111 , 112 and the conductive connection 106 getting produced.

The conductive connection 106 is designed as a ribbon-shaped conductor. The strip-shaped conductor runs in particular within the arrangement plane 202 , in which also the first fastening section 111 and the second attachment portion 112 are arranged. The course is like this designed that the rigidity in the x-direction is smaller than in the y-direction and / or z-direction. In this way, expansion or contraction in the x direction can be compensated for without causing tension and corresponding defects in the conductive connection 106 or in the cell connectors 110 , 120 comes. The head 106 has to compensate for a change in distance between the first fastening section 111 and the second attachment portion 112 a loop-shaped, curved or undulating, in particular meander-shaped, course.

At least the first fastening section 111 and the second attachment portion 112 have the corresponding clamping section at their rectangular through openings 160 on, which in the exemplary embodiment four opposing elastically deformable clamping elements 161 having. As in 2 the clamping elements can be seen 161 from the arrangement level 201 bent out.

The core elements 161 can be configured due to their dimensioning and the choice of material in such a way that the restoring force or clamping force is so great that a displacement of the battery pole 101 , 102 in the insertion direction (in the z-direction), ie perpendicular to the arrangement plane 201 , is prevented.

The clamping forces of the clamping elements 161 are configured in such a way that the clamping force is applied to at least two opposite side walls 203 of a battery pole 101 , 102 is roughly the same. This creates a force-neutral and therefore largely distortion-free connection between the cell connectors 110 , 120 and battery pole 101 , 102 .

Correspondingly, the clamping section can have further elastically deformable clamping elements 161 have, which are arranged opposite one another at the through opening and out of the arrangement plane 201 are bent out so that the battery post 101 , 102 between the clamping elements 161 can be pushed in and a force-symmetrical clamping force around the battery pole 101 , 102 can be provided.

Through the side wall contact of the clamping element 161 on the side wall 203 of the battery pole 101 , 102 In particular, the free end face or pole surface remains 204 of the battery pole 101 , 102 free, so that, for example, good thermal dissipation, for example to the environment or to a connected heat sink 208 a cooling system.

Furthermore, the system 100 a sensor 107 , in particular a temperature sensor, a voltage sensor or a power sensor, which is on the first cell connector 110 or on the second cell connector 120 is arranged or is integrated in this. The sensor 107 is particularly to one of the signal lines 105 paired to receive or relay signals.

As in 2 is made clear, the battery terminal points 101 , 102 a free pole surface 204 on. The first battery pole 101 protrudes from a base body, for example 205 a battery cell 151 out, the first battery pole 101 is arranged in the first through opening in such a way that one to the base body 205 the battery cell 151 directed first surface 206 of the first cell connector 110 closer to the main body 205 is present as the pole surface 204 .

In particular the first battery terminal 101 is arranged in the first through opening in such a way that the pole surface 204 coplanar with one, the first surface 206 opposite second surface 207 of the first cell connector 110 is, so that a common coupling surface can be provided. The coupling surface extends and lies, for example, within the arrangement plane 201 . A homogeneous coupling surface is thus formed on which external components, such as the heat sink, for example, are formed in a simple manner 208 , can be arranged so that a large area contact between the pole surface 204 and the cell connector 110 on the one hand and the external component on the other.

The heat sink 208 is in particular flat on the coupling surface for thermal coupling. The heat sink 208 can, for example, cooling lines 209 have through which a cooling medium, for example a liquid fluid, flows.

3 shows a schematic representation of a system 100 for connecting battery poles 101 , 102 with a stiffening element 109 before attaching to the corresponding battery poles 101 , 102 .

4 shows a schematic representation of coupling elements 140 with signal lines 105 according to an exemplary embodiment. The signal lines 105 are in corresponding grooves of the coupling elements 140 arranged. There are also sensors 107 at one end of corresponding signal lines 105 arranged. The arrangement in 4th can for example be prefabricated and on a suitable carrier tape 901 (please refer 9 ) can be rolled up.

Parallel to the production of the in 4th illustrated arrangement can, for example, the Cell connector 110 , 120 together with the carrier element 130 getting produced. First, for example, the cell connectors 110 , 120 punched and then with the carrier element 130 embedded in an injection molding process. At the same time, the stiffening element can also be used in the injection molding process 109 on the carrier element 130 to be ordered.

Before mounting on a battery module 150 can the in 4th illustrated arrangement consisting of the coupling elements 140 together with the signal lines 105 and sensors 107 to the support elements 130 according to the arrangement 3 be attached. The system made in this way 100 is with the stiffener 109 reinforced and can therefore be used in a robust manner on a large number of battery poles 101 , 102 of battery cells 151 a battery module 150 can be attached in one process step.

5 shows a schematic representation of a mechanical plug connection according to an exemplary embodiment. The coupling element 140 has with a carrier element 131 , 132 a mechanical connector, the mechanical connector having at least one guide rail 502 and a complementary one, in the guide rail 502 pluggable sliding element 501 is trained. The guide rail 502 and the complementary sliding element 501 (for example a slide pin) extend in particular along a sliding direction, for example the x-axis, along which expansion compensations are desired. The coupling element 140 is with the beam sections 131 , 132 thus slidably mounted along a plug-in direction.

A corresponding support section 131 , 132 can, for example, have a large number of sliding elements protruding in the x direction 501 have and between the sliding elements 501 corresponding grooves, which act as guide rails 502 act. The coupling element 140 has corresponding complementary grooves and excellent sliding elements 501 on, so that a corresponding plug-in coupling between the coupling elements 140 and the support sections 131 , 132 is implemented.

The mechanical plug connection is also configured in such a way that along a direction (for example along the z-axis) perpendicular to the arrangement plane 201 the mechanical plug connection has one degree of freedom and has no degree of freedom along a direction opposite to the direction (for example along the z-axis). This can be implemented, for example, by the guide rails 502 have an open U-profile, so that the corresponding sliding elements through the open side of the U-profile 501 from the guide rails 502 can be taken.

6th shows a schematic representation of a system 100 for connecting a large number of battery cells 151 a battery module 150 according to an exemplary embodiment. It becomes clear that a variety of battery cells 151 which are arranged in particular along an arrangement direction (for example x-axis) can be provided. Furthermore, for example, battery cells connected in parallel can also be used 151 to be ordered. The system 100 can also have a first system contact at the edge areas 601 and a second system contact 602 have, at which the corresponding battery power of the battery module 150 can be taken.

In 6th in particular are two rows of cell connectors 110 , 120 shown. In a further exemplary embodiment, these can also be reinforced by means of electrically insulating frame elements 603, 604 in order to form a robust support or assembly frame. The frame elements 603 are, for example, on the carrier sections 131 attached to a stiffening frame structure with two opposing rows of cell connectors 110 , 120 to accomplish. Furthermore, as an alternative or in addition, further frame elements 604 can be arranged which are attached to the connection structures 103 the opposite cell connector 110 , 120 are attached. The frame elements 603, 604 can be used together with the carrier elements in a common injection molding process 130 getting produced. Correspondingly, the frame elements 603, 604 can be made of the same material as the carrier elements 130 getting produced. Alternatively, the frame elements 603, 604 can be made from a different material than the carrier elements 130 getting produced.

Thus, a sturdy and self-supporting frame structure is formed with which two or more rows of battery posts 101 , 102 in one assembly step with the cell connectors 110 , 120 can be electrically and mechanically coupled.

7th shows a schematic representation of a fastening of a cell connector 110 to a battery pole 101 according to an exemplary embodiment. The clamping elements 161 each have a bending section 162 and a contact portion 163 on, the bending section 162 is integrally connected to the first fastening portion and a bend out of the plane of arrangement 201 having. The bending section 162 is with the contact portion 163 integrally connected. The contact section 163 has a clamping surface that connects to the side wall 203 of the first battery pole 101 Can be coupled in a force-transmitting manner. The larger the clamping surface, the better the current can between the clamping element 161 and the battery pole 101 be transmitted.

The contact section 163 is designed such that the clamping surface of the contact section 163 in the unstressed state from an edge of the through opening, in particular pyramidal or conical, in the direction of the center of the through opening. The clamping element 161 has an end portion 164 with a free end, the contact portion 163 between the bending section 162 and the end section 164 is arranged. The end section 164 runs opposite the clamping surface of the contact section 163 such that the end portion 164 without contact with the side wall 203 of the first battery pole 101 is when the clamping surface with the side wall 203 of the first battery pole 101 Is coupled force-transmitting. Because the free end from the side wall 203 is bent away, for example, assembly aids can simpler the clamping element 161 Grab the free end and move it away to provide an assembly aid accordingly.

Furthermore, a clamping ring 165 around the clamping elements 161 be arranged to prevent loosening of the clamp connection. The tension ring 165 is particularly releasable around the clamping elements 161 braces and presses it evenly in the center of the through opening and thus against the side walls 203 an inserted battery pole 101 .

8th shows a schematic representation of a cell connector 110 with an isolation element 801 according to an exemplary embodiment. The isolation element 801 consists in particular of an electrically insulating material such as plastic. Furthermore, the insulation element 801 integral and monolithic to the coupling element 140 or the carrier element 130 be coupled. The isolation element 801 is particularly at the conductive connection 106 a cell connector 110 arranged. In particular, the insulation element 801 between the cell connector 110 and the main body 205 a battery cell 105 with a sufficiently large distance 802 arranged.

9 shows a schematic representation of a rollable carrier tape 901 for coupling elements 140 according to an exemplary embodiment. A variety of coupling elements 140 (or support elements 130 ) are detachable, in particular by means of an adhesive connection, on the carrier tape 901 are temporarily attached.

10 shows a schematic representation of a fastening of a cell connector 110 to a battery pole 101 , 102 according to an exemplary embodiment. In this embodiment, the clamping elements are 161 bent outwards. The cell connector 110 for example, has the first surface 206 on. The clamping elements 161 are towards a second surface 207 of the cell connector 110 curved which is the first surface 206 opposite. The cell connector, for example 110 closer to the battery cell 151 to be ordered. At the same time form the clamping elements 161 a sufficient clamping surface with the corresponding side walls 203 the battery poles 101 , 102 the end.

11 shows a schematic representation of an assembly aid with a relief mandrel 1103 according to an exemplary embodiment.

The cell connector 110 has a mounting opening 1101 on. The end section 164 accordingly has a receiving opening 1102 on. The assembly opening 1101 and the coupling point or receiving opening 1102 are arranged in such a way that the relief mandrel 1103 through the mounting opening 1101 can be plugged in and can be coupled to the coupling point in such a way that the end section 164 and the contact section 163 for decoupling with the first battery pole 110 can be bent away against the clamping direction. The clamping element 161 is in particular by means of the relief mandrel 1103 in a direction opposite to the central axis of the through-opening and, for example, bent out of the through-opening before and during the cell connector 110 on the battery pole 101 is attached. During the assembly, the clamping force is so to speak by means of the assembly element or relief mandrel 1103 reduced.

12th shows a schematic representation of an assembly aid with a stamp 1201 according to an exemplary embodiment. The Stamp 1201 is from a top 207 (which from the battery cell 151 away) of the cell connector 110 into the first through opening (in particular in the direction of the battery cell 151 ) inserted to the clamping element 161 pretensioning (and bending accordingly out of the center of the through opening). The first battery pole 101 is from the bottom 206 (which of the battery cell 151 closest) of the cell connector 110 inserted into the first through opening until a predetermined position is reached in the first through opening. Then the stamp 1201 pulled out of the through opening and the clamping element 161 clamps the side wall 203 of the first battery pole 101 a.

In addition, it should be pointed out that “comprehensive” does not exclude any other elements or steps and “one” or “one” does not exclude a large number. It should also be pointed out that features or steps that have been described with reference to one of the above exemplary embodiments can also be used in combination with other features or steps of other exemplary embodiments described above. Reference signs in the claims are not to be regarded as a restriction.

List of reference symbols

100

system

101

Battery pole

102

Battery pole

103

Connection structure

104

embedded area

105

Signal line

106

conductive connection

107

sensor

108

further connection structure

109

Stiffening element

110

first cell connector

111

first fastening section

112

second fastening section

113

Strain relief structure

120

second cell connector

130

Support element

131

first carrier section

132

second carrier section

140

Coupling element

141

Connector device

150

Battery module

151

Battery cell

160

Clamping section

161

Clamping element

162

Bending section

163

Contact section

164

End section

165

Tension ring

201

Arrangement level

202

Receiving groove

203

Side wall

204

Pole surface

205

Base body

206

first surface

207

second surface

208

Heat sink

209

Cooling duct

501

Sliding element

502

Guide rail

601

first system contact

602

second system contact

801

Isolation element

802

Distance between base body and insulation element

901

rollable carrier tape

1101

Assembly opening

1102

Receiving opening

1103

Relief mandrel

1201

rubber stamp

Claims (32)

A system (100) for connecting battery poles (101, 102) of individual prismatic battery cells of a battery module which provides more than 30A, comprising the system (100) an electrically conductive cell connector (110) with a first fastening section (111) and a second fastening section (112), wherein the first fastening section has a first through opening for receiving a first battery terminal (101) and wherein the second fastening section has a second through opening for receiving a second Has battery poles (102), wherein the first fastening section and the second fastening section are arranged within an arrangement plane (201), wherein at least the first fastening section at the through opening has a clamping section (160) with at least one elastically deformable clamping element (161) which is bent out of the arrangement plane (201) and protrudes into the first through opening in such a way that when the first battery terminal (101) is introduced the clamping element (161) can be preloaded to generate a clamping force and a clamping connection can be provided between the first fastening section (111) and at least one side wall (203) of the first battery terminal (101). System (100) according to Claim 1 , wherein at least the first through opening has a predominantly round, elliptical or rectangular opening cross section. System (100) according to Claim 1 or 2 , wherein the clamping section (160) is designed to exclusively contact side walls of the first battery terminal (101). System (100) according to one of the Claims 1 until 3 , wherein the clamping element (161) protrudes at least in some areas into the through opening and can be pretensioned by introducing the first battery terminal (101). System (100) according to one of the Claims 1 until 4th , wherein the clamping element (161) has a bending section (162) and a contact section (163), the bending section (162) being integrally connected to the first fastening section (111) and having a bend out of the arrangement plane (201), the bending section (162) is integrally connected to the contact section (163), the contact section (163) having a clamping surface which can be coupled in a force-transmitting manner to the side wall (203) of the first battery terminal (101). System (100) according to Claim 5 , wherein the contact section (163) is designed such that the clamping surface of the contact section (163) in the unstressed state extends from an edge of the through opening, in particular pyramidal or conical, in the direction of the center of the through opening. System (100) according to Claim 5 or 6th , wherein the clamping element (161) has an end section (164) with a free end, wherein the contact section (163) is arranged between the bending section (162) and the end section (164), the end section (164) opposite the clamping surface of the contact section (163) extends in such a way that the end section (164) is free of contact with the side wall (203) of the first battery terminal (101) when the clamping surface is coupled in a force-transmitting manner to the side wall (203) of the first battery terminal (101). System (100) according to Claim 7 wherein the cell connector (110) has a mounting opening (1101), the end section (164) having a receiving opening (1102), the mounting opening (1101) and the coupling point being arranged in such a way that a relief mandrel (1103) passes through the mounting opening ( 1101) can be plugged in and can be coupled to the coupling point in such a way that the end section (164) and the contact section (163) can be bent away against the clamping direction for decoupling with the first battery terminal. System (100) according to one of the Claims 1 until 8th , wherein the clamping portion (160) has at least one further elastically deformable clamping element (161) which is arranged at the through opening opposite the clamping element (161) and is bent out of the plane of arrangement (201) so that the first battery terminal (101) between the clamping element (161) and the further clamping element (161) can be pushed in in order to provide the clamping connection. System (100) according to Claim 9 , wherein the clamping section (160) also has further elastically deformable clamping elements (161) which are arranged opposite one another at the through opening and are bent out of the arrangement plane (201) so that the first battery pole (101) can be inserted between the clamping elements (161) and a force-symmetrical clamping force around the first battery terminal (101) can be provided. System (100) according to Claim 10 , further comprising a clamping ring (165) which is arranged around the clamping elements (161) in order to prevent the clamping connection from becoming detached. System (100) according to one of the Claims 1 until 11 wherein the first fastening section and the second fastening section are connected to one another by means of a conductive connection (106). System (100) according to Claim 12 , wherein the conductive connection (106) has a conductor, in particular a band-shaped conductor. System (100) according to Claim 13 wherein the conductor has a loop-shaped, curved or wave-shaped, in particular meander-shaped, course to compensate for a change in distance between the first fastening section (111) and the second fastening section (112). System (100) according to one of the Claims 12 until 14th , wherein the clamping connection is designed such that the elastically deformable clamping element (161) is designed to be more rigid than the conductive connection (106) between the first fastening section (111) and the second fastening section (112). System (100) according to one of the Claims 1 until 15th , wherein the cell connector (110) is a first cell connector (110) and the system (100) further comprises a second electrically conductive cell connector (120) which is designed for fastening and electrically connecting two further spaced apart battery poles (101, 102), and an electrically insulating carrier element (130), to which the first cell connector (110) and the second cell connector (120) are attached, in order to create a supporting structure for the first cell connector (110) and the second cell connector (120) by means of the carrier element (130) ), wherein for fastening the first cell connector (110) and the second Cell connector (120) on the carrier element (130), the first cell connector (110) and the second cell connector (120) are exclusively embedded in certain areas in the carrier element (130), so that surface areas of the first cell connector (110) and of the second cell connector (120) are free from a cover with the carrier element (130). System (100) according to Claim 16 , wherein the first cell connector (110), the second cell connector (120) and the carrier element (130) are arranged within the common arrangement plane (201). System (100) according to Claim 16 or 17th , wherein the first cell connector (110) and the second cell connector (120) form punched-out flat components. System (100) according to one of the Claims 16 until 18th , wherein the carrier element (130) has a first carrier section (131) which at least partially embeds the first cell connector (110), and a second carrier section (132) which at least partially embeds the second cell connector (120), the first carrier section (131) and the second carrier section (132) are connected by means of an electrically insulating connection structure (103). System (100) according to Claim 19 wherein the connection structure (103) is designed to be deformable to compensate for a change in distance between the first cell connector (110) and the second cell connector (120). System (100) according to Claim 20 wherein the connection structure (103) has a loop-shaped, curved or undulating, in particular meandering, course. System (100) according to one of the Claims 19 until 21 wherein at least the first carrier section (131) or the second carrier section (132) has at least one receiving groove (202) for receiving a signal line (105). System (100) according to one of the Claims 19 until 22nd , further comprising a coupling element (140) which is fastened, in particular releasably, between the first carrier section (131) and the second carrier section (132), wherein the coupling element (140) with the first carrier section (131) and the second carrier section (132 ) are arranged one after the other along an arrangement direction, in particular within an arrangement plane (201), so that the first carrier element (130), the coupling element (140) and the second carrier element (130) are arranged one after the other along the arrangement direction. System (100) according to Claim 23 , wherein the coupling element (140) has a further receiving groove for receiving a signal line (105). System (100) according to one of the Claims 1 until 24 , further comprising a sensor (107), in particular a temperature sensor, a voltage sensor or a power sensor, which is arranged on the cell connector (110). A battery module that provides more than 30A, the battery module having a system (100) according to one of the Claims 1 until 25th , a first battery post (101), a second battery post (102), wherein the first battery post (101) is clamped in the first through opening and the second battery post (102) is clamped in the second through opening. Battery module Claim 26 , wherein at least the first battery pole (101) has a free pole surface (204) and the first battery pole (101) protrudes from a base body (205) of a battery cell, the first battery pole (101) being arranged in the first through-opening in such a way that a the first surface (206) of the first cell connector (110) directed towards the base body (205) of the battery cell is closer to the base body (205) than the pole surface (204), in particular the first battery pole (101) being arranged in the first through opening in such a way that that the pole surface (204) is coplanar with a second surface (207) of the first cell connector (110) opposite the first surface (206), so that a common coupling surface can be provided. Battery module according to Claim 27 , further comprising a cooling body (208) of a cooling system, which is arranged on the pole surface (204) for thermal coupling, the cooling body (208) in particular resting flat on the coupling surface for thermal coupling. Battery module according to one of the Claims 26 until 28 , wherein the first fastening section (111) is welded to the first battery terminal (101) and / or the second fastening section (112) is welded to the second battery terminal (112). A method for connecting battery poles (101, 102) of individual prismatic battery cells of a battery module which provides more than 30A, the method comprising providing an electrically conductive cell connector (110) with a first fastening section (111) and a second fastening section (112), wherein the first fastening section a first Having a through opening for receiving a first battery terminal (101) and wherein the second fastening section has a second through opening for receiving a second battery terminal (102), wherein the first fastening section and the second fastening section are arranged within an arrangement plane (201), with at least the first fastening section at the through opening has a clamping section (160) with at least one elastically deformable clamping element (161) which is bent out of the arrangement plane (201) and protrudes into the first through opening in such a way that when the first battery terminal (101) is introduced the clamping element (161) can be preloaded to generate a clamping force and a clamping connection can be provided between the first fastening section (111) and at least one side wall (203) of the first battery terminal (101), inserting the first battery terminal (101) into the first through opening to produce the clamping connection . Procedure according to Claim 30 , the clamping element (161) being pretensioned against the clamping force by means of a mounting element before the first battery terminal (101) is inserted. Procedure according to Claim 31 , wherein the mounting element is a stamp (1201) which is inserted from an upper side of the cell connector (110) into the first through opening in order to preload the clamping element (161), the first battery pole (101) from the underside of the cell connector (110) is inserted into the first through-opening until a predetermined position is reached in the first through-opening, and then the stamp (1201) is pulled out of the through-opening and the clamping element (161) clamps the side wall (203) of the first battery terminal (101).

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