ELECTRONIC COMPONENT FOR A CELL-CONTACTING SYSTEM AND METHODS FOR PRODUCING A CELL-CONTACTING SYSTEM AND A BATTERY MODULE

Abstract

An electronics component for a cell-contacting system with cell connectors for a battery contains a printed circuit board of a measuring and/or management arrangement for the battery with a communication interface. The printed circuit board can be electrically connected to precisely two of the cell connectors and, for this purpose, has at least one soldering area for each of the cell connectors. At least one electrical connecting element is provided which is areally of strip-like form and can be soldered onto the soldering areas. Wherein a first connecting element for mechanical fastening and/or thermal transfer being of comparatively mechanically rigid and comparatively short design, and a second connecting element for thermal and/or mechanical length compensation being of comparatively mechanically flexible and long design, are provided. A cell-contacting system with cell connectors contains at least one electronics component.

Claims

1. An electronic component for a cell-contacting system, the cell-contacting system having a plurality of cell connectors which serve for a power contacting of battery cells of a battery, the electronic component comprising: a printed circuit board of a measuring and/or management configuration for the battery, said printed circuit board being connected electrically to precisely two of the cell connectors and for this purpose has at least one soldering surface for each of the cell connectors; a plurality of electrical connecting elements, at least one of said electrical connecting elements being soldered to said at least one soldering surface for each of the cell connectors for a respective electrical connection of said at least one soldering surface to a cell connector of the cell connectors, at least one of said electrical connecting elements configured as a flat strip; at least a first one of said electrical connecting elements provided for connecting to a first one of the cell connectors for a mechanical fastening and/or thermal transmission between the first cell connector and said printed circuit board is configured so that said first electrical connecting element is relatively mechanically rigid and relatively short; at least a second one of said electrical connecting elements provided for connecting to a second one of the cell connectors for thermal and/or mechanical length compensation between the cell connectors and/or between the second cell connector and said printed circuit board is configured so that said second electrical connecting element is relatively mechanically flexible or more flexible and long than said first electrical connecting element; and said printed circuit board has at least one communications interface for a data exchange of information with a remote station.

2. The electronic component according to claim 1, wherein at least one of said electrical connecting elements has a selective coating in a soldering region to be soldered to said at least one soldering surface.

3. The electronic component according to claim 2, wherein: said electrical connecting elements are formed of a base material; and at least one transition region between said base material of one of said electrical connecting elements and said selective coating is sealed against corrosion.

4. The electronic component according to claim 1, wherein at least one of said electrical connecting elements: is made from aluminum; and/or has a tin coating.

5. The electronic component according to claim 1, wherein at least one of said electrical connecting elements is a stamped part from a piece of sheet metal.

6. The electronic component according to claim 1, further comprising a temperature sensor being rigidly attached to said printed circuit board, said temperature sensor being coupled thermally to said at least one soldering surface for said first electrical connecting element.

7. The electronic component according to claim 1, wherein at least said first electrical connecting element has a rectangular shape.

8. The electronic component according to claim 1, wherein said second electrical connecting element is configured S-shaped with a straight central limb, and adjoining said straight central limb on both sides in each case one sub-limb parallel thereto, and in each case one right-angled lead-in limb branching off from said sub-limb on both sides.

9. The electronic component according to claim 1, further comprising a communications interface which has at least one holding means for a wire as at least part of a communications channel.

10. The electronic component according to claim 1, wherein at least one of said electrical connecting elements is a one-piece direct connector between said printed circuit board and the cell connectors.

11. The electronic component according to claim 1, wherein in a mounted state in the cell-contacting system, said printed circuit board is fastened mechanically to the cell connectors and consequently in the cell-contacting system only by means of said electrical connecting elements.

12. A cell-contacting system, comprising: a plurality of cell connectors which serve for power contacting battery cells; and at least one electronic component according to claim 1.

13. A method for producing a cell-contacting system, which comprises the steps of: providing a plurality of cell connectors which serve for power contacting battery cells; providing an electronic component according to claim 1; first connecting the electrical connecting elements to the printed circuit board by soldering; and subsequently connecting the electrical connecting elements to the cell connectors.

14. A method for producing a battery module, which comprises the steps of: providing a battery having battery cells; providing an electronic component according to claim 1; providing a cell-contacting system having a plurality of cell connectors which serve for power contacting the battery cells; first connecting the cell-contacting system to the battery without the electronic component; and subsequently electrically connecting the printed circuit board to the cell connectors by means of the connecting elements.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0054] FIG. 1 is a diagrammatic, perspective view of an electronic component according to the invention; and

[0055] FIG. 2 is a plan view of a cell-contacting system with four electronic components according to FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

[0056] Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown an electronic component 2 for a cell-contacting system 4.

[0057] FIG. 2 shows four (n−1, see below) of the electronic components 2 from FIG. 1 in their mounted state in the cell-contacting system 4. The cell-contacting system 4 contains a plurality n of cell connectors 6, in this case five. The cell connectors 6a-e serve for power contacting battery cells (not illustrated in the figures) of a battery. In the final mounting process (not illustrated) of a battery system, the cell-contacting system 4 is mounted on the battery by, inter alia, the cell connectors 6a-i being welded to the battery poles.

[0058] The electronic component 2 contains a printed circuit board 8. This is part of a management arrangement (not illustrated in detail in the figures) for implementing battery management at the battery whilst it is operating. The printed circuit board 8 contains in the example two soldering surfaces 10a,b, in this case in the form of copper (Cu) surfaces. The soldering surfaces 10a,b serve to electrically connect the printed circuit boards 8 to the cell connectors 6a-e via in this case two respective connecting elements 12a,b. The two connecting elements 12a,b are also part of the respective electronic component 2.

[0059] Each of the connecting elements 12a,b here has a single-pole configuration and, at its respective end facing the printed circuit board 8 in the mounted state, a soldering region 18a,b which is only indicated in dashed lines and cannot be seen because it is situated on the underside, pointing downward in the illustration, of the connecting elements 12a,b and is already soldered to the soldering surfaces 10a,b.

[0060] The connecting elements 12a,b are configured as flat, namely as aluminum pieces of sheet metal which are relatively thin relative to their flat transverse extent and are configured as strips. The connecting elements 12a are straight rectangular strips and the connecting elements 12b are strips which run with an S-shape and have a respective widened portion at their ends.

[0061] The connecting elements 12a to each of the first cell connectors (6b,d) are configured so that they are mechanically relatively rigid (compared with the connecting elements 12b) and relatively short for mechanical fastening and thermal transfer between the cell connectors 6b,d and the printed circuit board 8.

[0062] The connecting elements 12b to each of the second cell connectors (6a,c,e) are configured so that they are mechanically relatively flexible (compared with the connecting elements 12a) and long for thermal and/or mechanical 3D length compensation between the cell connectors 6a-e and/or between the second cell connector (6a,c,e) and the printed circuit board 8. In the example, this is achieved by the length being increased by the S-shaped profile of the strip, i.e. with two 90° changes in direction and two 180° changes in direction. Thus, a straight central limb 36, adjoining with a 180° change in direction on both sides a half-length sub-limb 38a,b parallel thereto, and a lead-in limb 40a,b, branching off from the sub-limb at right angles (with a 90° change in direction) on both sides, are provided.

[0063] The flexibility of the structure is achieved by the length of the strip and the bendability of the structure at the respective four angles/changes in direction which, inter alia, are moreover provided with round free cuts 42.

[0064] In the example, the printed circuit board 8 moreover has a communications interface 22 which is also part of the electronic component 2. Each of the communications interfaces 22 is here configured in the form of two holding means 24, joined to the printed circuit board 8, for wire 28 in the form of tuning fork contacts. The tuning fork contacts are joined to the printed circuit board or mechanically rigidly connected thereto. Each of the holding means 24 serves to hold a wire 28, in this case a copper enameled wire, so that it is electrically contacted and mechanically fastened. Communication then takes place via the corresponding wires 28 as a communications line/communications medium or bus system 44 for data exchange with a remote station 26, in this case a communications interface 22 of a further printed circuit board 8. The wires 28 thus form a communications channel 30 of the bus system 44.

[0065] In the example, the connecting elements 12a,b are one-piece direct connectors between the printed circuit board 8 and the respective cell connector 6a-e.

[0066] In the example, the printed circuit board 8 is retained mechanically in the cell-contacting system 4 only via the connecting elements 12a-e and only on the cell connectors 6a-i.

[0067] In the exemplary embodiment, the printed circuit board 8 is configured as a single-cell chip PCB, i.e. it is designed for precisely two cell connectors (FIG. 2: 6a,b/6b,c/6c,d/6d,e), and can thus detect their two, possibly different potentials or other parameters. For a battery system with, for example, n=five cell connectors, thus only n−1=four electronic components 2 with such printed circuit boards 8 are required.

[0068] In the final mounted state (not illustrated), the CCS 4 is mounted on the battery. The signal lines (in this case implemented by the connecting elements 12a,b) of the individual potential level (for example, potentials of the contacted cell connectors 6a-e) of the battery system are then combined on the individual printed circuit boards 8 as a processing system (in this case a PCB, alternatively also a flex/rigid-flex PCB). The potential levels, converted into a digital signal, are relayed there, in this case to the remote station 26, by means of the communications interfaces 22 via a data transmission system (BUS, bus system 44, in this case the wires 28). The electronic components required for this are situated on the printed circuit board 8.

[0069] A single-cell chip printed circuit board 8 taps the signals between two successive potentials (cell connectors 6a,b/6b,c/6c,d/6d,e) and for this purpose is located between in each case two cell connectors 6. Two successive potentials are routed to the next potential via selectively coated connecting elements 12a,b (12b with 3D resiliency or strain relief) which are configured as long. The coating 14 which is selective (because it is not applied over the whole of the connecting elements 12) is situated on the connecting element 12a,b (selectively only) in the respective soldering region 18a,b and is also not visible in the figures and is indicated only by dashed lines.

[0070] Impedance can be measured because the connecting elements 12a,b can be reproduced with a high degree of accuracy. The connecting elements 12a,b can be or are configured here as stamped parts and can be situated on a stamped band and automatic fitting is thus possible (not illustrated). The selective coating 14 simplifies the welding of the connecting elements 12 at the locations 13 to the cell connectors 6 because the material is the same (uncoated aluminum of the connecting element 12 and aluminum of the cell connector 6) and also fulfills the claimed corrosion protection. The expansion in length due to heat and the vibration compensation are achieved by the stamping geometry of the connecting elements 12b. The attachment to the printed circuit board 8 is effected by a soldering process, wherein the PCBs can consequently be configured as rigid, flex, or rigid-flex PCBs. The soldering takes place between the soldering surface 10 and the soldering region 18.

[0071] The data transmission is effected by special copper pins (tuning fork contacts, holding means 24) which serve for the application of a laser welding process for producing a standard aluminum/copper welded connection. These pins enable the transmission of digital signals between individual printed circuit boards 8 or between individual battery systems.

[0072] A plurality of (single-cell chip) printed circuit boards 8 are provided which are each located between two successive potentials (see FIG. 2).

[0073] Data transmission is effected by the communications interfaces 22 via BUS links.

[0074] The welding between the connecting elements 12 and the cell connectors 6 takes place in each case at the location 13 of the connecting elements 12.

[0075] The electronic component 2 is configured as a “single-cell chip” variant (contacts only two cell connectors 6 in each case) and rests on one of the cell connectors 6b,d via the connecting elements 12a in each case mechanically rigidly and sufficiently well coupled thermally and taps the temperature of the cell connector 6b,d via an integrated temperature sensor 34 (NTC, part of the chip illustrated, indicated only symbolically). Two successive potentials (of second cell connectors 6a,c to 6b, 6c,e to 6d) are routed via connecting elements 12b (configured as long and flexible with 3D resiliency and strain relief) to the next potential (cell connectors 6b,d). It is thus also possible to measure the impedance.

[0076] The temperature sensor 34 is attached directly to the soldering surface 10a such that it is also located as closely as possible to the connecting element 12a in the mounted state. It is thus optimally thermally linked to the temperature transmission from the cell connector 6 via the connecting element 12a to the soldering surface 10a.

[0077] According to FIG. 2, there is a single-cell control system for a cell-contacting system 4 completed correspondingly by a battery (not illustrated): an electrical connection (link/control link logic) is effected by a bus system 44 (connection to the communications interface 22) to the respective next single-cell chip (printed circuit board 8) via in this case a copper enameled wire (welding forks, holding means 24, etc), in the example a two-core bus or a bus system 44 consisting of two wires 28.

[0078] The cell-contacting system 4 is produced as follows: first, the electrical connecting elements 12a,b are connected to the printed circuit board 8 by soldering (soldering surfaces 10 and soldering regions 18). Next, the electrical connecting elements 12a,b are connected, in this case welded, to the cell connectors 6.

[0079] A battery module which contains a battery and a cell-contacting system 4 contacting the battery is produced as follows: the electronic component 2 and, separately therefrom, the remainder of the cell-contacting system 4 are supplied. First, the cell-contacting system 4 is connected to the battery without the electronic component, i.e. the cell connectors 6 are welded to the battery poles. Next, the printed circuit board 8 is electrically connected to the cell connectors 6 by means of the connecting elements 12, in particular in accordance with the abovementioned method, i.e. the cell-contacting system is produced and completed.

[0080] When reading the claim language, the following definitions apply. When the claim language recites A and/or B it means A alone, B alone or A and B. When the claim language recites at least one of A and B it means A alone, B alone or A and B. When the claim language recites at least one of A or B it means A alone, B alone or A and B.

[0081] The following is a summary list of reference numerals and the corresponding structure used in the above description of the invention.

LIST OF REFERENCE SIGNS

[0082] 2 electronic component [0083] 4 cell-contacting system [0084] 6a-e cell connector [0085] 8 printed circuit board [0086] 10a,b soldering surface [0087] 12a,b connecting element [0088] 13 location [0089] 14 coating [0090] 18a,b soldering region [0091] 22 communications interface [0092] 24 holding means [0093] 26 remote station [0094] 28 wire [0095] 30 communications channel [0096] 34 temperature sensor [0097] 36 central limb [0098] 38a,b sub-limb [0099] 40a,b lead-in limb [0100] 42 free cut [0101] 44 bus system