ELECTRONIC COMPONENT FOR A CELL-CONTACTING SYSTEM, CELL CONTACTING SYSTEM, AND METHOD FOR PRODUCING THE CELL CONTACTING SYSTEM OR A BATTERY MODULE

Abstract

An electronic component for a cell-contacting system with cell connectors is used for power contacting of battery cells of a battery. The component contains a circuit board of a measurement and/or management assembly for the battery, and has plug receptacles for connection to the cell connectors, a support frame with receptacle for the circuit board, electrical connection elements for connection of the circuit board and the cell connectors to plug contacts, embedded in the support frame, for the plug receptacles. The circuit board is insertable into the receptacle by plugging the plug receptacles with the plug contacts and has a communication interface. A cell-contacting system with cell connectors contains at least one electronic component. When producing a cell-contacting system, the electrical connection elements are firstly connected to the cell connectors and the circuit board is then inserted into the receptacle.

Claims

1. An electronic component for a cell-contacting system, the cell-contacting system having a plurality of cell connectors serving for 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 having plug-in sockets for electrical connection to the cell connectors; at least one support frame having a holder for said printed circuit board; a plurality of electrical connecting elements for a respective electrical connection of said printed circuit board to the cell connectors, each of said electrical connecting elements having a plug-in contact being plugged in an electrically contacting manner to one of said plug-in sockets; each said plug-in contact being embedded in said at least one support frame and consequently fastened thereto; said printed circuit board being inserted into said holder by plugging said plug-in sockets to said plug-in contacts; and said printed circuit board having 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 said plug-in contact is a press-fit pin or a plated through hole pin.

3. 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 a cell connector of the cell connectors.

4. The electronic component according to claim 1, further comprising a connecting wire; and wherein at least one of said electrical connecting elements is configured with multiple parts and contains a fixed section, facing said printed circuit board, with said plug-in contact, and a wire section facing a cell connector and contains at least one wire holder, connected to said fixed section, for said connecting wire and said connecting wire leading from said at least one wire holder to the cell connector.

5. The electronic component according to claim 1, wherein said at least one support frame is fastened in a mounted state in the cell-contacting system only by means of said electrical connecting elements mechanically on the cell connectors and/or on a support structure which supports the cell connectors, and consequently is fastened in the cell-contacting system.

6. The electronic component according to claim 1, wherein said at least one support frame contains, in addition to said electrical connecting elements, a mechanical interface, and in a mounted state in the cell-contacting system said at least one support frame is fastened at least partially by means of said mechanical interface mechanically on the cell connectors and consequently in the cell-contacting system.

7. The electronic component according to claim 6, wherein said mechanical interface is configured for fastening to a cell connector of the cell connectors for an intended purpose and/or a support structure supporting the cell connectors.

8. The electronic component according to claim 7, wherein said mechanical interface is configured for fastening to a cell connector of the cell connecters for an intended purpose and/or the support structure by it being configured as a plug-on holder for plugging said at least one support frame onto a mating structure for the intended purpose on the cell connector.

9. The electronic component according to claim 1, further comprising a temperature sensor being attached firmly to said printed circuit board.

10. The electronic component according to claim 1, further comprising a temperature sensor configured as a unit which is separate from said printed circuit board and is connected electrically to said printed circuit board.

11. The electronic component according to claim 1, wherein a number of said electrical connecting elements is provided for precisely two said cell connectors.

12. The electronic component according to claim 1, wherein a number of said electrical connecting elements is provided for precisely three said cell connectors.

13. 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.

14. 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 with the printed circuit board not yet inserted into the holder; electrically connecting the electrical connecting elements to the cell connectors; and subsequently inserting the printed circuit board into the holder with the plug-in sockets contacting the plug-in contacts.

15. A method for producing a battery module, which comprises the steps of: providing a battery having battery cells; providing a cell-contacting system having a plurality of cell connectors which serve for power contacting the battery cells; providing an electronic component according to claim 1 with the printed circuit board not yet inserted into the holder; electrically connecting the electrical connecting elements to the cell connectors; connecting the cell-contacting system to the battery; and subsequently inserting the printed circuit board into the holder with the plug-in sockets contacting the plug-in contacts.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0053] FIG. 1 is a diagrammatic, perspective view of an electronic component;

[0054] FIG. 2 is a perspective view showing a cell-contacting system with two electronic components according to FIG. 1;

[0055] FIG. 3 is a plan view of an alternative electronic component;

[0056] FIG. 4 is a perspective view of the electronic component from FIG. 3; and

[0057] FIG. 5 is a plan view of an alternative cell-contacting system with three electronic components according to FIGS. 3 and 4.

DETAILED DESCRIPTION OF THE INVENTION

[0058] 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.

[0059] FIG. 2 shows two 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 of cell connectors 6, nine (6a-i) of which can be seen in FIG. 2. The cell connectors 6a-i 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.

[0060] 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 five plug-in sockets 10a-e (not visible in more detail in the figures), in this case in the form of PTHs, i.e. metal-plated through bores. The plug-in sockets 10a-e serve to electrically connect the printed circuit board 8 to the cell connectors 6a-i via in this case five respective connecting elements 12a-e. The connecting elements 12a-e are also part of the electronic component 2.

[0061] The electronic component 2 moreover contains a support frame 14, in this case a plastic frame, which has a holder 16 for the printed circuit board 8. The holder 16 is here a trough-shaped or shell-like holding space which is surrounded or formed by the plastic frame. The printed circuit board 8 is already inserted into the holder 16 in FIGS. 1 and 2.

[0062] Each of the connecting elements 12a-e is here configured as unipolar and has a plug-in contact 18a-e at its respective end facing the printed circuit board 8 in the mounted state. The plug-in contacts 18a-e are also not visible in FIGS. 1 and 2 because they have already been plugged completely into the plug-in sockets 10a-e. The plug-in contacts 18a-e are press-fit pins in the exemplary embodiment. The combination of press-fit pins and PTHs enables both electrical contacting and also mechanically firm retention between the connecting element 12a-e and the printed circuit board 8. All of the plug-in contacts 18a-e are in each case mechanically firmly embedded in the support frame 14, this not being illustrated in FIGS. 1 and 2 for the sake of clarity.

[0063] The following is thus possible: the printed circuit board 8 is mounted in the support frame 14 or in the holder 16 or is introduced therein by it being inserted into the support frame 14/the holder 16 in the direction of the arrow 20. Because the connecting elements 12a-e and hence also their ends configured as plug-in contacts 18a-e are fastened firmly to the support frame 14, they are thus simultaneously pushed into the plug-in sockets 10a-e of the printed circuit board 8 and thus establish a respective electrical contact and a mechanical connection. In other words, the printed circuit board 8 can thus be inserted into the support frame 14 or the holder 16 in the direction of the arrow 20, wherein the introduction takes place with simultaneous plugging or plugging-in or insertion of the plug-in contacts 18a-e into the plug-in sockets 10a-e.

[0064] In the example, the printed circuit board 8 moreover has two communications interfaces 22a-b which are likewise part of the electronic component 2. Each of the communications interfaces 22a,b is here configured in the form of four wire holders 24, in this case tuning fork contacts or clamping forks, connected to the printed circuit board 8. The tuning fork contacts are also encapsulated in the support frame 14 or held mechanically firmly therein and have plug-in contacts for corresponding plug-in sockets in the printed circuit board 8. Each of the wire holders 24 serves to hold an only symbolically indicated connecting wire 28, in this case, for example, a copper enameled wire, so that it is electrically contacted and mechanically fastened. Communication then takes place via the corresponding connecting wire 28 as an electrical communication line/communications medium for data exchange with a remote station 26 which is indicated only symbolically in the figures and in this case is an external management unit for the battery.

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

[0066] In the example, the support frame 14 is mechanically retained in the cell-contacting system 4 only via the connecting elements 12a-e and only on the cell connectors 6a-i and/or a support structure (not illustrated) supporting the cell connectors 6a-i. The printed circuit board 8 is also mechanically fixed in the holder 16 via the connection of the plug-in sockets 10a-e to the plug-in contacts 18a-e. Additional positive retention is moreover effected by the printed circuit board 8 being bordered by the support frame 14.

[0067] In the exemplary embodiment, the printed circuit board 8 is configured as a multiple printed circuit board (multi-cell chip), i.e. it is designed for more than two, in this case namely five cell connectors 6d,e,g,h,i (for the printed circuit board 8 visible “at the front of the drawing) and can thus detect its five, possibly different potentials or other parameters. For a battery system with, for example, fifteen cell connectors, thus only three electronic components 2 with such printed circuit boards 8 would be 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-e) of the individual potential level (for example, potentials of the contacted cell connectors 6d,e,g,h,i) of the battery system are then combined on the individual printed circuit board 8 (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 22a,b via a data transmission system (BUS, bus system 44, in this case the connecting wires 28). The electronic components required for this are situated on the printed circuit board 8. The printed circuit board 8 is inserted into a plastic frame, namely the support frame 14, in which the connecting elements 12a-e or the plug-in contacts 18a-e, in this case press-fit pins (or PTH pins) are embedded. These pins (plug-in contacts 18a-e) are directly connected to the cell connectors 6d,e,g,h,i via the one-part connecting elements 12a-e.

[0069] In an alternative embodiment which is not illustrated, the connecting elements 12a-e are configured with multiple parts. The plug-in contacts 18a-e are then connected indirectly to the cell connectors 6d,e,g,h,i via forks and copper enameled wiring, as indicated in the example for the communications interfaces 22a,b.

[0070] The method for producing the cell-contacting system 4 is configured such that the holder 16 of the printed circuit board 8/support frame 14 in the form of the plastic frame is mounted first. Next, the connections in the CCS are established by connecting the connecting elements 12a-e, alternatively the said wiring (not illustrated), to the embedded press-fit pins (plug-in contacts 18a-e). Finally, the printed circuit board 8 is connected mechanically and electrically in one step to the holder 16 or the support frame 14 by being pushed onto the press-fit pins, i.e. the plug-in contacts 18a-e.

[0071] A distinction is made between a plurality of printed circuit boards (single-cell chip) which are in each case situated between two successive potentials (see FIGS. 3-5) and a multiple printed circuit board or printed circuit board panel (multi-cell chip) which detect more than two or all of the potentials present in the battery system (see FIGS. 1-2).

[0072] The “multi-cell chip” variant taps the signal for temperature measurement via a separately configured sensor 30, in this case an NTC PCB (NTC: temperature sensor, negative temperature coefficient), and relays it to the printed circuit board 8 via a supply line 32, in this case a copper enameled wire. Data transmission is effected for both variants by the communications interfaces 22a,b via BUS links. Contacting of the printed circuit board 8 by plug-in contacts 18a-e in the form of special copper pins enables the application of a laser welding process in order (in the case of aluminum cell connectors 6) to produce a standard aluminum/copper welded connection at the connection point between the cell connector 6 and the connecting element 12.

[0073] According to FIGS. 1 and 2, multi-cell/(FIGS. 3-5: single-cell) electronics (electronic component 2 and printed circuit board 8) with temperature/voltage measurement and balancing on the cell connector 6 thus result.

[0074] The tuning fork contacts of the communications interfaces 22a,b are also formed on the printed circuit board 8 as plug-in contacts. Here too, the printed circuit board 8 is contacted only when it is plugged onto corresponding plug-in contacts (not labeled separately in the figures).

[0075] The welding between the connecting elements 12 and the cell connectors 6 is effected in each case at the location 13, widened in the manner of a plate, of the connecting elements 12.

[0076] FIGS. 3 to 5 show an alternative embodiment of an electronic component 2 and a cell-contacting system 4 (FIG. 5, battery once again not illustrated). A total of four cell connectors 6a-d and three electronic components 2 are contained here.

[0077] The electronic component 2 is configured here as a “single-cell chip” variant (contacts only two cell connectors 6 in each case) and rests directly against one of the cell connectors 6a,c,d and taps the temperature of the cell connector 6a,c,d via an integrated temperature sensor 34 (NTC, indicated symbolically). Two successive potentials (of second cell connectors 6b to 6a, 6a to 6c, and 6c to 6d) are routed via connecting elements 12a,b (configured as long press-fit pins) to the next potential (cell connectors 6a,c,d). It is thus also possible to measure the impedance. The connecting elements here have the resiliency explained above, caused here (see in particular FIG. 4) because they run in an S-shape between the locations 13 and the support frame 14.

[0078] Visible and illustrated here in particular in FIGS. 3 and 4, in contrast to FIGS. 1 and 2, is the mechanically firm embedding of the connecting elements 12 and the corresponding structures of the communications interfaces 22a,b in the support frame 14. Firm embedding forms a suitable starting point for successfully plugging the plug-in sockets 10 onto the plug-in contacts 18 when the printed circuit board 8 is introduced into the holder 16.

[0079] The arrangement is explained here by way of example with the aid of one electronic component 2 between the cell connectors 6a,b.

[0080] Here too, the electronic component comprises the support frame 14 with a holder 16, wherein four connecting elements 12a-d are mechanically firmly embedded in the support frame 14. Just one communications interface 22a with a total of four tuning fork contacts for wire connections is included here per printed circuit board 8. The printed circuit board is also plugged into the holder 16 of the support frame 14 in the direction of the arrow 20.

[0081] However, the support frame 14 here includes a mechanical interface 36. In the mounted state in FIG. 5, the support frame 14 is mechanically fastened to the cell connectors 6, and consequently in the whole cell-contacting system 4, by means of the interface 36. For this purpose, the interface 36 has a total of four tabs 38 which engage around a mating structure 40, in this case a tab of the cell connector 6, and consequently effect mechanical fastening. The support frame 14 is pushed onto the mating structure 40 in the direction of the arrow 42 in order to mount it.

[0082] The temperature sensor 34 here also comes into contact with the mating structure 40, i.e. the metal tab as an extension of the cell connector 6, such that the temperature of the cell connector 6 can be measured directly.

[0083] According to FIGS. 3-5, a printed circuit board 8 thus results in the form of a rigid PCB with a single-cell chip with integrated temperature measurement and impedance measurement.

[0084] The arrangement of the temperature sensor (chip) is situated below the cell connector 6a. The temperature of the cell connector 6a is detected by the temperature sensor 34 (actual sensor integrated into the chip) via a medium (not illustrated, adhesive or paste or rubber, with or without improved thermal conductivity). A hole (not visible in the figures) in the printed circuit board 8 is situated below the temperature sensor 34 (chip) in order to reduce the dissipation of heat via the metallization of the printed circuit board 8. The actual temperature measurement is effected via the chip surface (facing the underside of the cell connector 6a) of the temperature sensor 34.

[0085] It is possible to measure the impedance via the two connecting elements 12a,b and 12c,d per cell connector 6a and 6b.

[0086] According to FIG. 5, 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 22a) to the respective next single-cell chip (printed circuit board 8) via in this case a copper enameled wire (welding forks, etc), in the example a four-core bus consisting of four connecting wires 28.

[0087] 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

[0088] 2 electronic component [0089] 4 cell-contacting system [0090] 6a-i cell connector [0091] 8 printed circuit board [0092] 10a-e plug-in socket [0093] 12a-e connecting element [0094] 13 location [0095] 14 support frame [0096] 16 holder [0097] 18a-e plug-in contact [0098] 20 arrow [0099] 22a,b communications interface [0100] 24 wire holder [0101] 26 remote station [0102] 28 connecting wire [0103] 30 sensor [0104] 32 supply line [0105] 34 temperature sensor [0106] 36 interface (mechanical) [0107] 38 tab [0108] 40 mating structure [0109] 42 arrow [0110] 44 bus system