Verbindungselement, Kontaktierungssystem und Batteriemodul sowie Verfahren zur Herstellung derselben

Abstract

The invention relates to a connecting element of a battery module or of a contacting system for a battery module, realized to connect a cell connector, designed for electrically conductive connection of voltage taps of two battery cells of the battery module, or a voltage tap of a battery cell of the battery module, to at least one conductor of a signal line of a monitoring system of the battery module in an electrically conductive manner, the connecting element having a first connection region, which is realized for materially bonded connection to the cell connector or to the voltage tap, and the connecting element furthermore having a second connection region, which is realized to accommodate at least one conductor of the signal line of the monitoring system of the battery module in a force-fitting and/or form-fitting manner.

Claims

1. A connecting element of a battery module or of a contacting system for a battery module, the connecting element being configured to connect a cell connector, to at least one conductor of a signal line of a monitoring system of the battery module in an electrically conductive manner, wherein the cell connector is configured for electrically conductive connection of voltage taps of two battery cells of the battery module, or a voltage tap of a battery cell of the battery module, the connecting element having a first connection region for materially bonded connection to the cell connector or to the voltage tap, and the connecting element furthermore having a second connection region configured to accommodate at least one conductor of the signal line of the monitoring system of the battery module in a force-fitting and/or form-fitting manner.

2. The connecting element according to claim 1, characterized in that the connecting element comprises at least one electrically conductive material, such that the first connection region and the second connection region are connected to each other in an electrically conductive manner.

3. The connecting element according to claim 1, characterized in that the first connection region is connectable to the cell connector or to the voltage tap by welding, ultrasonic welding, soldering or adhesive bonding.

4. The connecting element according to claim 1, characterized in that the second connection region is deformable such that the second connection region can accommodate at least one conductor of the signal line in a force-fitting and/or form-fitting manner.

5. The connecting element according to claim 4, characterized in that the second connection region has at least one deformation region made of a metallic material, which is irreversibly deformable, such that the second connection region can accommodate at least one conductor of the signal line, such that the deformation region surrounds the at least one conductor in an at least partially contacting manner.

6. A contacting system for a battery module, the battery module comprising a plurality of battery cells, which each have at least one voltage tap, and the contacting system having at least one cell connector configured to connect the voltage taps of two battery cells of the battery module in an electrically conductive manner, and the contacting system having at least one signal line, having at least one conductor configured for electrically conductive connection between one of the cell connector and the voltage tap, and a monitoring system, the at least one cell connector and the at least one signal line being disposed on a support element, wherein the contacting system has a connecting element according to claim 1.

7. The contacting system according to claim 6, characterized in that the connecting element connects the cell connector and the at least one conductor of the signal line to each other in an electrically conductive manner, the first connection region being connected to the cell connector in a materially bonded manner, and the second connection region accommodating the at least one conductor in a force-fitting and/or form-fitting manner.

8. A method for producing a contacting system, the method comprising in a first step, providing a connecting element according to claim 1, in a second step, positioning at least one cell connector and at least one signal line on a support element and, in a third step, positioning the connecting element on the support element.

9. The method according to claim 8, wherein in the third step, the first connection region is connected to the cell connector in a materially bonded manner.

10. A method for producing a battery module, the method comprising in a first step, providing a connecting element according to claim 1, in a second step, connecting the voltage taps of two battery cells to each other in an electrically conductive manner with at least one cell connector, and providing a signal line that is connectable to a monitoring unit, and in a third step, connecting the first connection region to the cell connector in a materially bonded manner.

11. (canceled)

12. Battery module having a connecting element according to claim 1.

13. The connecting element according to claim 1, characterized in that the connecting element comprises copper, aluminum or nickel, such that the first connection region and the second connection region are connected to each other in an electrically conductive manner.

14. The connecting element according to claim 1, characterized in that the second connection region is deformable such that the second connection region can accommodate at least one conductor of the signal line by crimping.

15. The contacting system according to claim 6, wherein the at least one cell connector and the at least one signal line are connected to the support element.

16. The method according to claim 8, wherein in the third step, at least one conductor of the at least one signal line is accommodated by the second connection region.

17. The method according to claim 16, wherein in the third step, the first connection region is connected to the cell connector in a materially bonded manner.

18. A method for producing a battery module, the method comprising in a first step, providing a connecting element according to claim 1, in a second step, connecting the voltage taps of two battery cells to each other in an electrically conductive manner with at least one cell connector, and providing a signal line that is connectable to a monitoring unit, and in a third step, accommodating at least one conductor of the at least one signal line by the second connection region in a force-fitting and/or form-fitting manner.

19. The method according to claim 18, wherein, in the third step, the first connection region is connected to the cell connector in a materially bonded manner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Exemplary embodiments of the invention are represented in the drawings and explained in greater detail in the description that follows.

[0024] FIG. 1 is a schematic top view of a connecting element according to the invention that connects at least one conductor of a signal line to a cell connector or to a voltage tap in an electrically conductive manner,

[0025] FIG. 2a is a cross section, along line A-A shown in FIG. 1, of a second connection region that accommodates at least one conductor of a signal line in a force-fitting manner,

[0026] FIG. 2b is a cross section similar to FIG. 2a of a second connection region before accommodating at least one conductor of a signal line,

[0027] FIG. 3 is a schematic side view of a battery module having a connecting element according to the invention, and

[0028] FIG. 4 is a top view of a battery module having a contacting system according to the invention.

DETAILED DESCRIPTION

[0029] FIG. 1 shows a schematic top view of a connecting element 1 of a battery module 8 or of a contacting system 13 for a battery module 8, which connecting element connects at least one conductor 5 of a signal line 4 to a cell connector 2 and/or to a voltage tap 3 in an electrically conductive manner.

[0030] A portion of a cell connector 2 or of a voltage tap 3 of a battery cell 9 can be seen in FIG. 1. Furthermore, FIG. 1 also shows a signal line 4 of a monitoring system, not shown in FIG. 1, of the battery module 8. The signal line 4 has a plurality of conductors 5. Furthermore, the plurality of conductors 5 is surrounded, at least partially, by an electrical insulation 6, in order to prevent unwanted current flows.

[0031] The connecting element 1 has a first connection region 11 and a second connection region 12, each respectively indicated by the boxes drawn in broken lines. The first connection region 11 in this case is realized for materially bonded connection to the cell connector 2 or to the voltage tap 3. Furthermore, the second connection region 12 is realized to accommodate at least one conductor 5 of the signal line 4 of the monitoring system of the battery module in a force-fitting and/or form-fitting manner.

[0032] FIG. 1 shows that the first connection region 11 is materially connected to the cell connector 2, or to the voltage tap 3. In this case, the first connection region 11 is connected by welding to the cell connector 2, or to the voltage tap 3, indicted by the exemplarily drawn weld points 7. As a result of the materially bonded connection of the first connection region 11 to the cell connector 2 or to the voltage tap 3, the first connection region 11 is connected to the cell connector 2, or to the voltage tap 3, in an electrically conductive manner.

[0033] Furthermore, FIG. 1 also shows that the second connection region 12 accommodates the plurality of conductors 5 of the signal line 4 in a force-fitting manner. As a result of the plurality of conductors 5 being accommodated by the second connection region 12 in a force-fitting manner, the second connection region 12 is connected to the plurality of conductors 5 in an electrically conductive manner.

[0034] In addition, the connecting element 1 is made of an electrically conductive material, or the first connection region 11 and the second connection region 12 are connected to each other in an electrically conductive manner by an electrically conductive material.

[0035] The connecting element 1 shown in FIG. 1 thus connects the plurality of conductors 5 of the signal line 4 to the cell connector 2 or to the voltage tap 3 in an electrically conductive manner. In this case, the first connection region 11 and the second connection region 12 are disposed separately from each other, such that it is possible for the first connection region 11 to be connected to the cell connector 2 or to the voltage tap 3 independently of the connection of the second connection region 12 in the plurality of conductors 5 of the signal line 4.

[0036] FIG. 2a shows a cross section through the second connection region 12 according to the section A-A shown in FIG. 1. In this case the second connection region 12 accommodates a plurality of conductors 5 of the signal line 4 in a force-fitting manner.

[0037] FIG. 2b shows a cross section through the second connection region 12. Unlike FIG. 2a, the plurality of conductors 5 of the signal line 4 have not yet been received in a force-fitting manner by the second connection region 12.

[0038] Furthermore, the second connection region 12 has at least one deformation region 121, which can be deformed for the purpose of accommodating the conductors 5 of the signal line 4. Preferably, the deformation region 121 is made of a metallic material. Furthermore, preferably, the deformation region 121 is irreversibly deformable for the purpose of accommodating the at least one conductor 5 of the signal line 4, such that the deformation region 121 surrounds the at least one conductor, in an at least partially contacting manner. FIG. 2b thus shows a deformation region 121 that is not yet completely irreversibly deformed, whereas FIG. 2a shows an irreversibly deformed deformation region 121. In this case, the deformation region 121 shown in FIG. 2a surrounds the plurality of conductors 5, at least partially, and also effects contacting of the latter. Since the deformation region 121 and the conductors 5 of the signal line 4 are preferably made of a metallic material, an electrically conductive connection can thus be produced.

[0039] In particular, the connection of the second connection region 12 to conductors 5 of the signal line 4 is realized as a crimp connection, which can therefore be evaluated according to a standard.

[0040] A representation of a battery module 8 having a plurality of battery cells 9 is shown schematically, in a side view, in FIG. 3. The battery cells 9 each have voltage taps 3. The voltage taps 3 of two battery cells 9 are connected to each other in an electrically conductive manner by means of a cell connector 2. The battery cells 9 each have two voltage taps 3, the representation according to FIG. 3 showing in each case only the front voltage tap 3 that faces toward the plane of the drawing, and not showing the rear voltage tap 3 that faces away from the plane of the drawing. The battery cells 9 shown in FIG. 3 are interconnected serially to each other, the front voltage taps 3 being connected to each other in an electrically conductive manner by non-hatched cell connectors 2, 101, and the rear voltage taps 3, which are not visible in the figure, being connected to each other in an electrically conductive manner by the hatched cell connectors 2, 102.

[0041] Furthermore, as described above, a connecting element 1 in each case connects a signal line 4 to the cell connector 2, 101 or 2, 102 in an electrically conductive manner and also mechanically. Furthermore, a connecting element 1 also connects a voltage tap 3 to the signal line 4 of a monitoring system of the battery module 8 in an electrically conductive manner and also mechanically, the battery cell 9 having such a connection, at the far right in the figure.

[0042] FIG. 4 shows a top view of a battery module 8 having a contacting system 13.

[0043] The contacting system 13 has a plurality of cell connectors 2, which connect the voltage taps 3 of two battery cells 9 to each other in an electrically conductive manner. For this purpose, the cell connectors 2 are each connected to the voltage taps 3 of the battery cells 9, in particular by welding, this being indicated here by weld points 7.

[0044] Furthermore, the contacting system 13 has openings 31, through which the voltage tap 3 of a battery cell 9 of the battery module 8 can be routed. In particular, the entire voltage of the battery module 8 can be tapped at the voltage taps 3 routed through the opening 31.

[0045] As can be seen from FIG. 4, a connecting element 1 in each case connects at least one conductor 5 of the signal lines 4 to a cell connector 2 or to the voltage tap 3 of a battery cell 9 in an electrically conductive manner.