ELECTRIC-SHOCK-PROTECTED BATTERY CONNECTOR, BATTERY MODULE AND SYSTEM COMPRISING BATTERY CONNECTORS AND BATTERY MODULES

Abstract

A battery connector (1) is provided for electrically contact-connecting a first pole pin (19) of a first battery module (10) to a second pole pin (20) of a second battery module (10). The battery connector (1) has a busbar (1) with a first contact region (2), a second contact region (3) and a connecting region (4) arranged between the first contact region (2) and the second contact region (3) in a main direction of extent (H) of the busbar (1). The connecting region (4) has an electrically insulating coating. The first contact region (2) and the second contact region (3) each have a cutout (5). The cutouts (5) are open in an insertion direction (E) that is parallel to a main plane of extent (HE) of the busbar (1) and orthogonal to the main direction of extent (H).

Claims

1. A battery system comprising: first and second battery modules, each of the first and second battery modules having an end and first and second pole pins projecting up from the respective battery module at positions in proximity to the end of the respective battery module, the first and second battery modules being adjacent to one another with the ends of the first and second battery modules being aligned with one another; first and second covers mounted respectively on the first and second battery modules, each of the covers having an end edge adjacent the end of the respective battery module and opposite first and second side edges extending away from the end edge of the respective cover so that the first side edge of the first cover is opposed to the second side edge of the second cover, first and second openings extending through each of the covers at positions in proximity to the end edge of the respective cover so that the first and second openings expose the first and second pole pins of the battery module on which respective cover is mounted; first and second pole pin coverings connected to each of the covers and being at positions spaced above the first and second pole pins of the battery module to which the respective cover is mounted, the first and second pole pin coverings being connected to the respective cover at positions between the first and second openings of the respective cover, a first gap being defined between the first pole pin covering and the respective cover, the first gap extending along a side of the first pole pin covering closest to the first side edge of the respective cover and continuing along a side of the first pole pin covering farthest from the end edge of the respective cover, and a second gap being defined between the second pole pin covering and the respective cover, the second gap extending along a side of the second pole pin covering closest to the second side edge of the respective cover and continuing along a side of the second pole pin covering farthest from the end edge of the respective cover, wherein the first gap between the first cover and the first pole pin covering faces the second gap between the second cover and the second pole pin covering.

2. The battery system of claim 1, further comprising a battery connector for connecting the first pole pin of the first battery module to the second pole pin of the second battery module, the battery connector comprising: a busbar with a first contact region, a second contact region and a connecting region between the first contact region and the second contact region in a main direction of extent of the busbar, the connecting region having an electrically insulating coating, the first contact region and the second contact region being provided respectively with first and second cutouts that are open in an insertion direction that is parallel to a main plane of extent of the busbar and orthogonal to the main direction of extent, the first cutout being connectable to the first pole pin of the first battery module and the second cutout being connectable to the second pole pin of the second battery module with the connecting region being between the first pole pin covering of the first cover and the second pole pin covering of the second covering.

3. The battery system of claim 2, wherein each of the first and second covers has an upper surface facing away from the respective first and second battery modules, the first gap and the second gap each defining an insertion height extending from the upper surface of the respective cover to the respective first or second pole pin covering, the insertion height corresponding to a thickness of the first contact region and the second contact region as measured orthogonal to the main plane of extent of the first contact region and/or of the second contact region.

4. The battery system of claim 2, wherein the upper surface of each of the covers has a first recess between the first side edge and the first opening and a second recess between the second side edge and the second opening, a lower part of the connecting region of the battery connector being slidably inserted into the first recess of the first cover and the second recess of the second cover.

5. The battery system of claim 2, wherein the connecting region has a thickened portion orthogonal to the main plane of extent, the thickened portion being thicker than the first contact region and the second contact region as measured orthogonal to the main plane of extent of the first contact region and/or of the second contact region.

6. The battery system of claim 5, wherein the connecting region has a lug that extends over an entire extent of the busbar in the insertion direction, the lug being electrically insulating and spacing apart the first battery module from the second battery module.

7. The battery system of claim 2, further comprising a first captive nut engaged in each of the first pole pin coverings and being screw connected to the respective first pole pin and a second captive nut engaged in each of the second pole pin coverings and being configured for being screwed onto the respective second pole pin, the first captive nuts being configured for screw tightening against the respective first contact region and the second captive nuts being configured for screw tightening against the respective second contact region.

8. The battery system of claim 2, wherein the first contact region and the second contact region each have a further cutout, the further cutouts being open in the insertion direction.

9. The battery connector of claim 8, wherein the cutouts and the further cutouts are U-shaped.

10. The battery system of claim 1, wherein the first and second pole pin coverings further are connected to the respective cover in regions facing the end edge of the respective cover.

11. A motor vehicle having the battery system of claim 1.

12. A battery connector for electrically contact-connecting a first pole pin of a first battery module to a second pole pin of a second battery module, the battery connector comprising: a busbar with a first contact region, a second contact region and a connecting region between the first contact region and the second contact region in a main direction of extent of the busbar, the connecting region having an electrically insulating coating, the first contact region and the second contact region being provided respectively with cutouts, wherein the cutouts are open in an insertion direction that is parallel to a main plane of extent of the busbar and orthogonal to the main direction of extent.

13. The battery connector of claim 12, wherein the first contact region and the second contact region each have a further cutout, the further cutouts being open in the insertion direction.

14. The battery connector of claim 13, wherein the cutouts and the further cutouts are U-shaped.

15. The battery connector of claim 13, wherein the first contact region and the second contact region each have a recessed region, the recessed regions being arranged offset relative to the connecting region in a z-direction that is orthogonal to the main plane of extent, the cutouts and the further cutouts being arranged in the recessed regions.

16. The battery connector of claim 12, wherein the connecting region has a thickened portion orthogonal to the main plane of extent.

17. The battery connector of claim 12, wherein the connecting region has a lug that extends over an entire extent of the busbar in the insertion direction, the lug being electrically insulating and spacing apart the first battery module from the second battery module.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 schematically illustrates a system according to an exemplary embodiment of the invention having two battery connectors and two battery modules according to an embodiment of the invention.

[0028] FIG. 2 schematically illustrates a battery connector according to an exemplary embodiment of the present invention.

[0029] FIG. 3 schematically illustrates a section through a battery module according to an embodiment of the invention with an inserted battery connector according to an embodiment of the present invention.

[0030] FIG. 4 schematically illustrates a section through a battery module according to an embodiment of the invention with an inserted battery connector, which is exposed in the drawing, according to an embodiment of the invention.

[0031] FIG. 5 schematically illustrates a motor vehicle according to an exemplary embodiment of the invention.

[0032] FIG. 6 is a schematic end elevational view of the two battery modules shown in FIG. 1 without the battery connectors.

[0033] FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 6.

[0034] FIG. 8 is a schematic end elevational view similar to FIG. 6, but showing the battery connectors.

[0035] FIG. 9 is a cross-sectional view taken along line 9-9 of FIG. 8.

DETAILED DESCRIPTION

[0036] FIGS. 1-4 and 6-9 schematically illustrate a system 100 according to an exemplary embodiment of the present invention. The system 100 has two battery connectors 1, a first battery module 10 and a second battery module 10. Each of the first and second battery modules 10 and 10 has a cover 11. Each cover 11 has an end edge 14 and opposite first and second side edges 15, 15 that extend away from the end edge 14. Additionally, each cover 11 has a first opening 17 in proximity to the end edge 14 and the first side edge 15. Each cover 11 further has a second opening 18 in proximity to the end edge 14 and the second side edge 15. A first pole pin covering 12 covers the first opening 17, and a second pole pin covering 13 covers the second opening 18. The first pole pin coverings 12 have the gaps 21 that extend along their sides that face the respective first side edge 15 and continue to extend without interruption or support along their end edges that are averted from the end edge 14 of the respective cover 11. Similarly, the second pole pin coverings 13 have the gaps 21 that extend along their sides that face the respective second side edge 15 and continue to extend without interruption or support along their end edges that are averted from the end edge 14 of the respective cover 11.

[0037] To electrically connect the first battery module 10 to the second battery module 10, a battery connector 1 is inserted into the first opening 17 of the second battery module 10 and the second opening 18 of the first battery module 10, centrally in FIGS. 1, 8 and 9. Only the connecting region 4, which is coated with an insulating coating, with the thickened portion 4 is visible in FIG. 1. The non-electrically-insulated first contact region 2 and the non-electrically-insulated second contact region 3 are covered respectively by the first pole pin covering 12 of the second battery module 10 and the second pole pin covering 13 of the first battery module 10, as shown in FIG. 8. Here, the first and second pole pin coverings 12, 13 act as an electric-shock protection and prevent, together with the insulating coating of the connecting region 4, a live part, from being touched.

[0038] FIGS. 1, 8 and 9 furthermore show, on the left-hand side of FIG. 1 and the right-hand-side of FIGS. 8 and 9, a battery connector 1 that has not been inserted yet. The battery connector 1 has, as can be clearly seen in FIGS. 1, 8 and 9, the busbar 1 which is manufactured from an electrically conductive material, preferably copper, aluminum or soft iron. FIGS. 1, 8, and 9 furthermore show the regions that are arranged adjacent in the main direction of extent H of the battery connector 1, namely, the second contact region 3, the connecting region 4 and the first contact region 2. The first contact region 2 and the second contact region 3 each have recessed regions 2, 3 that are recessed in the z-direction Z. The U-shaped cutouts 5 and the U-shaped further cutouts 6 are each open in the insertion direction E and are arranged in the recessed regions 2, 3. If the battery connector 1 is inserted into the openings 17, 18 of the cover 11, the battery connector 1 is centered by way of the thickened portion 4 of the connecting region 4 sliding into the first thinned portion 16 or the second thinned portion 16 of the cover 11. In the inserted state of the battery connector 1, the lug 7 is arranged between the first battery module 10 and the second battery module 10 and spaces the battery modules 10, 10 apart from one another. Forces generated while pushing the connecting region 4 in the insertion direction E are not sufficient to deform the first and second contact regions 2, 3 about axes extending perpendicular to the main direction of extent H.

[0039] Owing to the flat shape of the busbar 1 arranged along the main plane of extent HE and the low structural height of the first covering 12 and of the second covering 13, a very flat construction of the system 200 is possible.

[0040] FIG. 2 schematically illustrates a battery connector 1 according to an exemplary embodiment of the present invention. The figure clearly shows the busbar 1, which is arranged along the main direction of extent H in the main plane of extent HE, with the first contact region 2, the second contact region 3, the insulated connecting region 4, the thickened portion 4 and the lug 7. The U-shaped cutouts 5, 6 are open in the insertion direction E and are arranged in the recessed regions 2, 3, 2, 3. The busbar 1 has the thickness D.

[0041] FIG. 3 schematically illustrates a section through a battery module 10 with an inserted battery connector 1. More particularly, FIG. 3 shows details relating to securing the fit of the battery connector 1 in the second opening 18 and contact-connecting the first contact region 2 to the first pole pin 19 (here hidden by the first captive nut 12) and the further first pole pin 19. The first contact region 2 is arranged in the first opening 18 and covered in an electric-shock-protected manner by the first covering 12. The first pole pin covering 12 is connected to the cover 11 at the end edge 14, as is clearly shown here. In order to position the battery connector 1 in the manner shown in FIGS. 3 and 9, said battery connector is inserted through the gap 21 into the first opening 17 until the cutout 5 surrounds the first pole pin 19 and the further cutout 6 surrounds the further first pole pin 19. To save structural height, the insertion height EH of the gap 21 corresponds to 1.2 times the thickness of the busbar 1 (see FIG. 2). To electrically contact-connect and secure the battery connector 1, the first captive nut 12 and the further first captive nut 12 are screwed onto the first pole pin 19 and, respectively, the further first pole pin 19 until the captive nuts 12, 12 are seated fixedly on the first contact region 2 by way of a ring 32 that is arranged at the end averted from the cover 11. The captive nuts 12, 12 are manufactured from a conductive material and establish the electrical contact between the first pole pin 19, the further first pole pin 19 and the first contact region 2. The captive nuts 12, 12 are secured against becoming lost in the non-fixedly-screwed state by way of being clamped between the cover 11 and the pole pins 19, 19. To this end, an upper part of the captive nuts 12, 12 is located in a nut housing 33 of the cover 11. Overall, the captive nuts 12, 12 are so long that they cannot be removed by being lifted away from the pole pins 19, 19 and tilted and/or moved out of the nut housing 33. For convenient screwing-in, the nut housing 33 has, above the captive nuts 12, 12, a respective screw opening 34 for inserting a tool in order to turn the respective captive nut 12, 12. For being screwed onto the pole pins 19, 19, the captive nuts 12, 12 are provided with an internal thread, not shown, and the pole pins 19, 19 are provided with an external thread, not shown.

[0042] FIG. 4 schematically illustrates a section through a battery module 10 according to an embodiment of the invention with an inserted battery connector 1, which is exposed in the drawing. For reasons of clarity, parts of the battery module 10 that would block the view of the battery connector 1 and in particular of the first contact region 2 have been removed in FIG. 4. FIG. 4 clearly shows the first captive nut 12 and the second captive nut 12 that can be screwed onto the first pole pin 19 (hidden by the first captive nut 12 here) and, respectively, the further pole pin 19. A cap 30 is arranged on that end side of the captive nuts 12, 12 that is averted from the contact region 2. The cap 30 closes the end and has a driving profile 31 for a screw head drive. A ring 32 is arranged on that end of the captive nuts 12, 12 that faces the contact region 2. The driving profile 31 ensures convenient screwing of the captive nuts 12, 12 onto the first pole pin 19 and the further first pole pin 19. The rings 32 increase the size of the area over which the electrical contact between the captive nuts 12, 12 and the contact region 2 is established.

[0043] FIG. 5 schematically illustrates a motor vehicle 200 according to an embodiment of the invention. The motor vehicle 200 has the system 100 according to the invention with a large number of battery modules 10 according to the invention and battery connectors 1 that connect the battery modules 10 (see FIG. 1).