CELL-CONTACTING SYSTEM FOR A BATTERY MODULE AND BATTERY MODULE WITH SUCH A CELL-CONTACTING SYSTEM

Abstract

A cell-contacting system for a battery module having a plurality of battery cells includes a plurality of cell connectors for electrically conductively connecting cell terminals of different battery cells, and a printed circuit board having a plurality of signal lines each configured for connecting a signal source of one of the plurality of cell connectors to a signal management circuit or a connection interface. The signal sources of the cell connectors are electrically conductively connected to the signal lines of the printed circuit board through connection elements. At least one of the connection elements is configured in the form of a press-fit connection element. A battery module having the cell-contacting system is also provided.

Claims

1. A cell-contacting system for a battery module having a plurality of battery cells, the cell-contacting system comprising: a plurality of cell connectors for electrically conductively connecting cell terminals of different battery cells, said plurality of cell connectors having signal sources; a printed circuit board having a plurality of signal lines each configured to connect said signal source of a respective one of said plurality of cell connectors to a signal management circuit or a connection interface; and connection elements, at least one of said connection elements electrically conductively connecting each of said signal sources of said plurality of cell connectors to a respective one of said plurality of signal lines of said printed circuit board; at least one of said connection elements configured as a press-fit connection element having a first press-in portion to be pressed into a hole in said printed circuit board, a second press-in portion to be pressed into a hole in one of said signal sources, and a connection portion connected between said first and second press-in portions.

2. The cell-contacting system according to claim 1, wherein said signal sources have at least one of: at least one voltage tap point provided on one of said plurality of cell connectors, or at least one temperature-measuring device mounted on one of said plurality of cell connectors.

3. The cell-contacting system according to claim 2, wherein: said temperature-measuring device has a sensor printed circuit board with a temperature-sensing element; a contact element connects said sensor printed circuit board to a corresponding one of said plurality of cell connectors; and said sensor printed circuit board is connected to one of said plurality of signal lines of said printed circuit board by one of said connection elements.

4. The cell-contacting system according to claim 3, wherein one of said connection elements for said temperature-measuring device is configured as a press-fit connection element having a first press-in portion for pressing into a hole in said printed circuit board, a second press-in portion for pressing into a hole in said sensor printed circuit board, and a connection portion connected between said first and second press-in portions.

5. The cell-contacting system according to claim 3, wherein said contact element for said temperature-measuring device is configured as a press-fit contact element having a first press-in portion for pressing into a hole in one of said plurality of cell connectors, a second press-in portion for pressing into a hole in said sensor printed circuit board, and a connection portion connected between the first and second press-in portions.

6. The cell-contacting system according to claim 5, wherein said first and second press-in portions of said press-fit contact element for said temperature-measuring device are disposed one behind another with a common longitudinal axis, and said connection portion of said press-fit contact element extends along said common longitudinal axis between said press-in portions.

7. The cell-contacting system according to claim 2, wherein: said voltage tap point is formed by a corresponding one of said plurality of cell connectors; and said connection element for said voltage tap point is configured as a press-fit connection element having a first press-in portion for pressing into a hole in said printed circuit board, a second press-in portion for pressing into a hole in one of said plurality of cell connectors, and a connection portion connected between said first and second press-in portions.

8. The cell-contacting system according to claim 4, wherein said first and second press-in portions of at least one of said press-fit connection elements are disposed one behind another with a common longitudinal axis, and said connection portion runs along said common longitudinal axis between said press-in portions.

9. The cell-contacting system according to claim 4, wherein said first and second press-in portions of at least one of said press-fit connection elements are disposed side by side with parallel longitudinal axes, and said connection portion runs transversely to said longitudinal axes of said press-in portions between said press-in portions.

10. The cell-contacting system according to claim 5, wherein said first and second press-in portions of at least one of said press-fit connection elements are disposed side by side with parallel longitudinal axes, and said connection portion runs transversely to said longitudinal axes of said press-in portions between said press-in portions.

11. The cell-contacting system according to claim 10, wherein said connection portion of said press-fit connection element is configured to position said first and second press-in portions of said press-fit connection element at identical or different heights.

12. The cell-contacting system according to claim 4, wherein said connection portion of at least one of said press-fit connection elements is at least partially elastic and allows movement of a corresponding one of said plurality of cell connectors relative to said printed circuit board in a plane parallel to a plane of said printed circuit board.

13. The cell-contacting system according to claim 5, wherein said connection portion of at least one of said press-fit connection elements is at least partially elastic and allows movement of a corresponding one of said plurality of cell connectors relative to said printed circuit board in a plane parallel to a plane of said printed circuit board.

14. The cell-contacting system according to claim 4, wherein said connection portion of at least one of said press-fit connection elements is rigid and prevents movement of a corresponding one of said plurality of cell connectors relative to said printed circuit board.

15. The cell-contacting system according to claim 5, wherein said connection portion of at least one of said press-fit connection elements is rigid and prevents movement of a corresponding one of said plurality of cell connectors relative to said printed circuit board.

16. The cell-contacting system according to claim 1, wherein said printed circuit board has at least one ventilation opening formed therein.

17. A battery module comprising: a plurality of battery cells; and a cell-contacting system according to claim 1.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0027] FIG. 1 is a diagrammatic, perspective plan view of a battery module according to an exemplary embodiment of the invention;

[0028] FIG. 2 is a plan view of a cell-contacting system according to an exemplary embodiment of the invention for the battery module of FIG. 1;

[0029] FIG. 3 is an enlarged partial view of the cell-contacting system of FIG. 2;

[0030] FIG. 4A is a partial perspective view of a connector of a voltage tap point according to an exemplary embodiment of the invention;

[0031] FIG. 4B is a partial perspective view of the exemplary embodiment of FIG. 4A before pressing in the press-fit connection elements;

[0032] FIG. 5A is a partial perspective view of a connector of a temperature-sensing element according to an exemplary embodiment of the invention;

[0033] FIG. 5B is a partial perspective view of the exemplary embodiment of FIG. 5A before pressing in the press-fit connection elements;

[0034] FIG. 6A is a partial perspective view of a connector of a temperature-sensing element according to a further exemplary embodiment of the invention;

[0035] FIG. 6B is a partial perspective view of the exemplary embodiment of FIG. 6A before pressing in the press-fit connection elements; and

[0036] FIGS. 7A-7D are perspective views of press-fit connection elements and/or press-fit contact elements according to various exemplary embodiments of the invention for the connections of the voltage tap points or temperature-sensing elements.

DETAILED DESCRIPTION OF THE INVENTION

[0037] Referring now to the figures of the drawings in detail and first, particularly, to FIGS. 1-3 thereof, there is seen an exemplary embodiment of a battery module with a cell-contacting system according to the invention.

[0038] The battery module 10 has a plurality of battery cells (for example Li-ion battery cells) 12. In this exemplary embodiment, the battery cells 12 are disposed side by side in the right-left direction of FIG. 1 and each have a negative terminal in the upper or lower end region shown in FIG. 1 and a positive terminal in the lower or upper end region shown in FIG. 1, the negative and positive terminals of the battery cells 12 being disposed alternately so that a negative terminal of one battery cell is next to a positive terminal of an adjacent battery cell.

[0039] The battery module 10 further has a cell-contacting system 20 disposed above the battery cells 12. The battery cells 12 together with the cell-contacting system 20 are usually disposed in a module housing (not shown).

[0040] The cell-contacting system 20 has a plurality of cell connectors 22 forming a power supply line system. In this exemplary embodiment, the cell connectors 22 each have two contact regions 22a, 22b and a (preferably elastic) compensation region 22c between the two contact regions 22a, 22b and are mounted on the battery cells 12 in such a way that they each couple the negative terminal of a battery cell 12 to the positive terminal of an adjacent battery cell 12 through their two contact regions 22a, 22b, resulting in a series connection of the battery cells 12 in the battery module 10. The battery cells 12 are additionally connectable to a consumer or a charging system through an electrical connection of the battery module 10.

[0041] The cell-contacting system 20 further includes a preferably rigid printed circuit board 24 forming the signal conduction system and being disposed over the battery cells 12 in the region between the two rows of cell connectors 22 along the entire length of the battery cell array. The shape and size of the printed circuit board 24 can, in principle, be adapted to any construction of battery modules, in particular to any arrangements, sizes or numbers of battery cells.

[0042] As shown in FIGS. 1 and 2, the printed circuit board 24 has a plurality of ventilation holes acting as ventilation openings 38 for supporting a cooling process of the battery cells 12 located thereunder.

[0043] As indicated only schematically in FIGS. 2 and 3, the printed circuit board 24 has a plurality of signal lines 30 each connecting a signal source 32, 34 of a cell connector 22 to an electronic signal management circuit 26. The signal management circuit 26 is configured, for example, to perform the voltage measurement process and to evaluate the measurement signals obtained from the signal sources of the cell connectors 22. In this exemplary embodiment, the signal management circuit 26 is integrated on the printed circuit board 24 and connected to a connection interface 28, through which the signal management circuit 26 can be connected to a battery module controller. This battery module controller serves, for example, to perform charging processes, balancing of the voltages and the states of charge, temperature-control processes such as, in particular, cooling processes, etc., these processes being performed at least partially depending on the measurement signals obtained by the cell-contacting system 20 or the measurement values obtained by the signal management circuit 26 thereof. In an alternative embodiment of the invention, the signal management circuit 26 can also be configured externally to the printed circuit board 24. In this case, the signal lines 30 of the printed circuit board 24 are directly connected to the connection interface 28 and the external signal management circuit is coupled to the connection interface 28 of the printed circuit board 24 and is additionally coupled to the battery module controller through a further connection interface.

[0044] As indicated in FIGS. 1 to 3, there are two types of signal sources in this cell-contacting system 20. Firstly, all (optionally only a majority) of the cell connectors 22 have a voltage tap point 32 as a first signal source type for measuring the voltage of the battery cells 12. In addition, a few (optionally also all) of the cell connectors 22 have a temperature-measuring device 34 as a second signal source type for measuring the temperature of the battery cells 12.

[0045] The voltage tap points 32 can each be formed directly by a contact region 22a, 22b of a cell connector 22. At least one (in this exemplary embodiment, two) connection element 40 in the form of a press-fit connection element is provided in each case for connecting the voltage tap points 32 to the signal lines 30 of the printed circuit board 24. The structures and modes of operation of these press-fit connection elements 40 are illustrated in FIGS. 4A-4B and 7A-C.

[0046] The temperature-measuring devices 34 are each mounted on a cell connector 22. In order to connect the temperature-measuring devices 34 to the signal lines 30 of the printed circuit board 24, at least one (in this exemplary embodiment, two) connection element 44 is provided in each case and is also in the form of a press-fit connection element. The structures and modes of operation of these press-fit connection elements 44 are illustrated in FIGS. 5A-B, 6A-B and 7A-D.

[0047] Referring now to FIGS. 4A-4B and 7A-7C, the press-fit connection elements 40 for connecting the voltage tap points 32 to the signal lines 30 of the printed circuit board 24 will be explained in greater detail in an exemplary manner. These press-fit connection elements 40 each have a first press-in portion 46 pressed into a defined hole 51 in the printed circuit board 24, a second press-in portion 47 pressed into a defined hole 52 in a contact region 22a, 22b of a cell connector 22, and a connection portion 48 between these two press-in portions 46, 47. The press-fit connection elements 40 are formed of metal and form an electrical and mechanical connection between the voltage tap point 32 or the cell connector 22 and the signal line 30 or the printed circuit board 24. The connection is made simply by pressing the press-in portions 46, 47 into the holes 51, 52, for example automatically, without the need for a soldering or welding process. The press-in portions 46, 47 are at least partially dimensionally elastic and in their initial state have a somewhat larger diameter than the holes 51, 52, so that, when pressed in, the press-in portions and/or the holes are somewhat deformed and form a secure mechanical and electrical contact. The two press-in portions 46, 47 are disposed side by side with substantially parallel longitudinal axes 49a, 49b and the connection portion 48 runs substantially perpendicular to the longitudinal axes 49a, 49b of the two press-in portions 46, 47. When the upper side of the printed circuit board 24 and the upper side of the cell connector 22 (or its contact region 22a, 22b) are positioned at substantially the same level in the battery module or are oriented in substantially the same plane (as can be roughly seen in FIGS. 4A-4B), then the connection portion 47 is additionally configured in such a way that the two press-in portions 46, 47 are positioned at (approximately) the same level, as shown in FIG. 7A. On the other hand, if the upper side of the printed circuit board 24 and the upper side of the cell connector 22 (or its contact region 22a, 22b) are positioned at different levels in the battery module 10 or are oriented in different planes, then the connection portion 47 can be configured in such a way that the two press-in portions 46, 47 are positioned at different heights, as illustrated by way of example in FIG. 7B. Depending on the relative positioning of the printed circuit board and the cell connectors 22, in this embodiment the second press-in portion 47 can optionally be positioned lower than the first press-in portion 46 (see FIG. 7B) or the first press-in portion 46 can be positioned lower than the second press-in portion 47 (not shown). It is additionally possible to make the connection portion 48 of the press-fit connection element 40 at least partially elastic, as indicated in FIG. 7C, so that the connection element 40 can allow movement of the corresponding cell connector 22 relative to the printed circuit board 24 in a plane parallel to the plane of the printed circuit board. This flexibility allows the connection element to compensate for movement and swelling of the battery cells 12 that may occur, for example, during charging and discharging cycles. This variant with an elastic connection portion 48 can be used both for connection elements 40 with press-in portions 46, 47 positioned at the same height (see FIG. 7C) and for connection elements 40 with press-in portions 46, 47 positioned at different heights (combination of FIGS. 7B and 7C, not shown). Alternatively, the connection portion 48 can also be configured to be rigid in such a way that it prevents movement of the corresponding cell connector 22 relative to the printed circuit board 24, if desired for any reason.

[0048] Since the press-fit technology is basically known to the person skilled in the art, there is no need to explain further details and modes of operation. In addition, various embodiments of the press-fit technology can, in principle, be used for the cell-contacting system according to the invention.

[0049] Referring now to FIGS. 5A-5B and 7A-7D, a first variant of the temperature-measuring device 34 and its press-fit connection elements 44 for connection to the signal lines 30 of the printed circuit board 24 will be explained in more detail. The temperature-measuring device 34 has a small sensor printed circuit board 35 with an integrated temperature-sensing element 36. The temperature-sensing element 36 is, for example, an NTC resistor or an NTC thermistor. The sensor printed circuit board 35 is connected to the corresponding cell connector 22 through at least one (in this exemplary embodiment, two) contact element 37 in order to transmit and sense thermal energy from the cell connector 22 to the temperature-sensing element 36. The contact element 37 is likewise configured using press-fit technology. This press-fit contact element 37 has a first press-in portion 46 that is pressed into a defined hole 56 in the cell connector 22, a second press-in portion 47 that is pressed into a defined hole 55 in the sensor printed circuit board 35, and a connection portion 48 between these two press-in portions 46, 47. The press-fit contact element 37 forms a thermal and mechanical connection between the temperature-measuring device 34 and the cell connector 22. The connection is made simply by pressing the press-in portions 46, 47 into the holes 51, 52, for example automatically, without the need for a soldering or welding process. In this exemplary embodiment, the sensor printed circuit board 35 is positioned relative to the cell connector 22 in such a way that the two holes 55, 56 are opposite each other. For this reason, the two press-in portions 46, 47 are disposed one behind the other with a substantially common longitudinal axis 50, and the connection portion 48 runs substantially along the common longitudinal axis 50 between the two press-in portions 46, 47, as shown in FIG. 7D. If, on the other hand, the sensor printed circuit board 35 is positioned differently relative to the cell connector 22, the press-fit contact element 37 can also be configured analogously to the press-fit connection element shown in FIG. 7B with press-in portions 46, 47 disposed side by side.

[0050] In this first variant of the temperature-measuring device 34, the press-fit connection element 44 for connecting the temperature-measuring device 34 to a signal line 30 of the printed circuit board 24 is configured analogously to FIG. 7B, since the cell connectors 22 are positioned at the same level as the printed circuit board 24, but the sensor printed circuit board 35 is positioned higher than the printed circuit board 24 by being attached to the cell connector 22. In other words, this press-fit connection element 44 has a first, lower press-in portion 46, which is pressed into a defined hole 53 in the printed circuit board 24, a second, higher press-in portion 47, which is pressed into a defined hole 54 in the sensor printed circuit board 35, and a connection portion 48 between these two press-in portions 46, 47. In all other respects, the press-fit connection element 44 for the temperature-measuring device 34 corresponds to the press-fit connection element 40 for the voltage tap point 32 and can also adopt any other variants (for example, FIG. 7A and/or FIG. 7C) as required.

[0051] Referring now to FIGS. 6A-B and 7D, a second variant of the temperature-measuring device 34 and its press-fit connection elements 44 for connecting to the signal lines 30 of the printed circuit board 24 are explained in more detail in an exemplary manner. The temperature-measuring device 34 is basically configured as in the first variant of FIGS. 5A-5B, but is positioned on the cell connector 22 in such a way that it also extends somewhat above the printed circuit board 24. As in the first variant, the press-fit contact elements 37 correspond to the configuration shown in FIG. 7D. The press-fit connection elements 44 for connection to a signal line 30 of the printed circuit board 24 are also of the same construction as shown in FIG. 7D, unlike in the first variant. That is to say, these press-fit connection elements 44 have a first press-in portion 46 that is pressed into a defined hole 51 in the printed circuit board 24, a second press-in portion 47 that is pressed into a defined hole 54 in the sensor printed circuit board 35, and a connection portion 48 between these two press-in portions 46, 47, the two press-in portions 46, 47 being disposed one behind the other with a substantially common longitudinal axis 50 and the connection portion 48 running substantially along the common longitudinal axis 50 between the two press-in portions 46, 47.

[0052] With reference to FIGS. 4A to 7D, several specific exemplary embodiments of the press-fit connection elements 40, 44 and the temperature measuring device 34 have been explained. Within the scope of the invention defined in the appended claims, further embodiments are also possible in which individual features of these figures are omitted, features are added to these figures, or features from different figures are combined.

[0053] The described battery modules 10 with the cell-contacting systems 20 according to the invention can be used, for example, for vehicles, in particular electric vehicles and hybrid vehicles and in particular motor vehicles and motorcycles, or for energy storage systems or for other electrical appliances (for example electronic household appliances).

[0054] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention.

LIST OF REFERENCE NUMERALS

[0055] 10 battery module [0056] 12 battery cells [0057] 20 cell-contacting system [0058] 22 cell connectors (power supply line system) [0059] 22a, b contact regions of the cell connectors [0060] 22c compensation regions of the cell connectors [0061] 24 printed circuit board (signal line system) [0062] 26 signal management circuit [0063] 28 connection interface [0064] 30 signal lines [0065] 32 voltage tap point (signal source) [0066] 34 temperature-measuring device (signal source) [0067] 35 sensor printed circuit board [0068] 36 temperature-sensing element [0069] 37 press-fit contact element [0070] 38 ventilation openings [0071] 40 press-fit connection element to 32 [0072] 44 press-fit connection element to 34 [0073] 46 first press-in portion [0074] 47 second press-in portion [0075] 48 connection portion between 46 and 47 [0076] 51 hole in the printed circuit board for 40 [0077] 52 hole in the cell connector for 40 [0078] 53 hole in the printed circuit board for 44 [0079] 54 hole in the sensor printed circuit board for 44 [0080] 55 hole in the sensor printed circuit board for 37 [0081] 56 hole in the cell connector for 37