Assembly kit, battery cell stack including the same, and method of assembling a battery cell stack

Abstract

The present invention relates to an assembly kit, a battery cell stack including the same, and a method of assembling the battery cell stack. The present invention relates to an assembly kit for assembling a carrier frame for stacking battery cell blocks, wherein the assembly kit includes a Z-shaped bus bar. The present invention also relates to an assembly kit for assembling a stack of battery cells, which includes the assembly kit for assembling a carrier frame for stacking battery cell blocks according to the present invention. In addition, the present invention relates to a battery cell stack composed of the assembly kit for assembling a stack of battery cells and a method of manufacturing such a battery cell stack.

Description

Technical Field

[0001] The present invention relates to an assembly kit for assembling a carrier frame for stacking battery cell blocks, wherein the assembly kit includes a Z-shaped bus bar. The present invention also relates to an assembly kit for assembling a stack of battery cells, which includes the assembly kit for assembling a carrier frame for stacking battery cells according to the present invention. In addition, the present invention relates to a battery cell stack composed of the assembly kit for assembling a stack of battery cells and a method for manufacturing such a battery cell stack. Background Art

[0002] In recent years, vehicles for transporting goods and people using electric power as a motive source have been developed. Such electric vehicles are automobiles driven by an electric motor using energy stored in a rechargeable battery. The electric vehicle can be powered only by the battery, or can be in the form of a hybrid vehicle additionally powered by, for example, a gasoline generator. In addition, the vehicle can include a combination of an electric motor and a conventional internal combustion engine. Generally, an electric vehicle battery (EVB) or traction battery is a battery for providing electric power for the propulsion of a pure electric vehicle (BEV). Electric vehicle batteries are different from starting batteries, lighting batteries, and ignition batteries because they are designed to provide electric power over a sustained period of time. A rechargeable battery or secondary battery is different from a primary battery because it can be repeatedly charged and discharged, while the latter only provides an irreversible conversion of chemical energy to electrical energy. Low-capacity rechargeable batteries are used as power sources for small electronic devices such as cellular phones, laptop computers, and video cameras, while high-capacity rechargeable batteries are used as power sources for hybrid vehicles and the like.

[0003] Generally, a rechargeable battery includes an electrode assembly, a case accommodating the electrode assembly, and electrode terminals electrically connected to the electrode assembly. The electrode assembly includes a positive electrode, a negative electrode, and a separator interposed between the positive electrode and the negative electrode. An electrolyte solution is injected into the case so that the battery can be charged and discharged via an electrochemical reaction of the positive electrode, the negative electrode, and the electrolyte solution. The shape of the case (e.g., cylindrical or rectangular) depends on the intended use of the battery. Lithium-ion (and similar lithium polymer) batteries, well-known for their use in laptop computers and consumer electronics, dominate the latest batch of electric vehicles under development.

[0004] Rechargeable batteries can be used as battery modules formed by a plurality of unit battery cells connected in series and / or in parallel, thereby providing a high energy density, especially for driving the electric motor of a hybrid vehicle. That is, the electrode terminals of a plurality of unit battery cells are interconnected depending on the required amount of electric power, and a battery module is formed to achieve a high-power rechargeable battery.

[0005] A battery pack is a set of any number of (preferably, identical) battery modules. They can be configured in series, in parallel, or a combination of both to provide the desired voltage, capacity, or power density. The components of a battery pack include the individual battery modules and the interconnections that provide electrical conductivity between the individual battery modules.

[0006] The mechanical integration of such a battery pack requires appropriate mechanical connections between the individual components, such as the battery modules, and between the individual components and the vehicle's support structure. These connections must remain functional and safe during the average service life of the battery system. In addition, installation space and interchangeability requirements must be met, especially in mobile applications.

[0007] The mechanical integration of the battery modules can be achieved by providing a carrier frame and placing the battery modules thereon. Fixing the battery cells or battery modules can be achieved by mating recesses in the frame or by mechanical interconnectors such as bolts or screws. Alternatively, the battery modules are restricted by fastening side plates to the sides of the carrier frame. In addition, a cover plate can be fixed on top of and below the battery module.

[0008] The carrier frame of the battery pack is mounted to the vehicle's load-bearing structure. In the case where the battery pack is to be fixed to the vehicle floor, the mechanical connection can be established from the underside, for example, by bolts passing through the carrier frame of the battery pack. The frame is typically made of aluminum or an aluminum alloy to reduce the overall weight of the structure.

[0009] Despite any modular structure, battery systems according to the prior art typically include a battery housing that serves as an enclosure for sealing the battery system against environmental influences and providing structural protection for the components of the battery system. The battery systems housed in the housing are typically installed as a whole into their application environment (e.g., an electric vehicle). Thus, replacing a defective system component (e.g., a defective battery sub-module) requires first disassembling the entire battery system and removing its housing. Even a defect in a small and / or inexpensive system component can result in the disassembly and replacement of the entire battery system and its individual repair. Since high-capacity battery systems are expensive, large, and heavy, the process appears to be burdensome, and it becomes difficult to store the bulky battery systems, for example, in a mechanic's workshop.

[0010] The design of prior art battery cell stacks (especially cylindrical battery cells) mainly includes one or more structural components (such as injection-molded plastic components) shaped like an egg box and components for electrical connection between cells. The components for electrical connection between cells are often referred to as "busbars" and are made of simple conductive sheet metal plates. The joining technique of cells can be implemented in several ways. However, these techniques often require an alternating orientation of serially connected cells or cell bricks (parallel-connected cell blocks). This alternating assembly is mainly due to the fact that the gap between the main terminals (e.g., PLUS-terminals) and the opposite potential (e.g., MINUS-terminals) of the cells rather than the cell cans themselves is quite small on the main side of the cells, so there is no highly efficient possibility of encapsulating the sheet metal busbars by joining them only on a single side of the cells. Currently, one of the industry standards is to use wire bonding as the joining technique or to generally increase the space between each cell and especially between serially connected cell bricks. However, in the case of an alternating orientation, the behavior in the case of an exhaust event (e.g., thermal runaway) is always crucial. Therefore, implementing an appropriate cooling system for the battery cell stack can also become complex because it often requires two cooling plates on both the top and bottom sides of the cells.

[0011] Accordingly, an object of the present invention is to overcome or reduce at least some of the disadvantages of the prior art and to provide a battery cell stack, an assembly kit for assembling a battery cell stack, a method for assembling a battery cell stack, and an assembly kit for assembling a carrier frame for stacking battery cell blocks. Summary of the Invention

[0012] Embodiments of the present disclosure attempt to solve at least one of the problems existing in the prior art to at least some extent. In particular, an assembly kit for assembling a carrier frame for stacking battery cell blocks is provided, the assembly kit including: one or more Z-shaped busbars; a first frame beam and a second frame beam; wherein each Z-shaped busbar includes: a positive plate configured to be connected to the positive terminals of the battery cells of a battery cell block; a negative plate configured to be connected to the negative terminals of the battery cells of another battery cell block; and a connecting plate connecting the positive plate and the negative plate; wherein each Z-shaped busbar further includes: a first fastening device configured to be fastened to the first frame beam; and a second fastening device configured to be fastened to the second frame beam; and wherein the first frame beam includes one or more first fastening elements such that all of the one or more Z-shaped busbars can be simultaneously connected to the first frame beam through the respective first fastening devices of the Z-shaped busbars; wherein the second frame beam includes one or more second fastening elements such that all of the one or more Z-shaped busbars can be simultaneously connected to the second frame beam through the corresponding second fastening devices of the Z-shaped busbars.

[0013] The expression "Z-shaped" in this context means that the Z-shaped busbar presents at least approximately a contour or cross-section similar to the letter Z, where the lower bar and the upper bar of the letter Z correspond to the cross-section of the positive plate and the cross-section of the negative plate respectively, and the line connecting the lower bar and the upper bar in the letter Z corresponds to the cross-section of the connecting plate. However, it should be noted that the expression "Z-shaped" used in this context should also cover or encompass the following cases, where in the said contour or cross-section of the Z-shaped busbar, the cross-section of the positive plate and the cross-section of the connecting plate are positioned at an angle of 90° or greater (however, in any case at an angle less than 180°) relative to each other, and / or where in the said contour or cross-section of the Z-shaped busbar, the cross-section of the negative plate and the cross-section of the connecting plate are positioned at an angle of 90° or greater (however, in any case at an angle less than 180°) relative to each other. Specifically, in the context of the present invention, the expression "Z-shaped" with respect to the busbar shall mean a busbar formed such that the positive plate and the negative plate protrude away from the connecting plate in opposite directions.

[0014] In a preferred embodiment of the assembly kit according to the present invention, the positive plate, the negative plate, and / or the connecting plate have a rectangular shape. Preferably, the Z-shaped busbar is formed such that the positive plate and the negative plate are positioned parallel to each other. In an embodiment where the positive plate and the negative plate of the Z-shaped busbar are positioned parallel to each other, the connecting plate can be positioned perpendicular to each of the positive plate and the negative plate. Thus, one edge of the rectangular connecting plate can be connected to one edge of the equally rectangular positive plate, and the opposite edge of the connecting plate can be connected to one edge of the rectangular negative plate, such that the positive plate protrudes from the connecting plate in a direction opposite to the direction in which the negative plate protrudes from the connecting plate.

[0015] In a preferred embodiment, the Z-shaped busbars have the same shape.

[0016] Each battery cell block (which is not part of the above-mentioned assembly kit) includes a bundle of battery cells. Each of the battery cells in the battery cell block is oriented in the same direction, i.e., there is a predetermined direction such that for all the battery cells in the battery cell block, both the positive terminal and the negative terminal of the battery cell lie on a straight line parallel to this direction, and when observed in this direction, the negative terminal lies behind the positive terminal. In addition, the positive terminals of the battery cells in the battery cell block can all abut against the same (virtual) plane perpendicular to the said direction. In addition, the negative terminals of the battery cells in the battery cell block can all abut against the same (virtual) plane perpendicular to the said direction. Of course, the plane against which the positive terminals abut is different from the plane against which the negative terminals abut; the body of each battery cell extends between these two planes.

[0017] Hereinafter, one side where all the positive electrodes of the battery cells of the battery cell block are arranged will be referred to as the "positive electrode side of the battery cell block". Correspondingly, hereinafter, one side where all the negative electrodes of the battery cells of the battery cell block are arranged will be referred to as the "negative electrode side of the battery cell block".

[0018] The body of each battery cell in the battery cell block may have a cylindrical shape; the cylindrical surface surrounds a central axis parallel to a predetermined direction. The shape and size (dimensions) of the battery cells of the battery cell block may be the same. The cylindrical battery cells of the battery cell block may be arranged such that each battery cell (except those at the edge of the battery cell block) is surrounded by six other cylindrical battery cells. These six other battery cells may be arranged in six-fold symmetry around the battery cell centered between these six other battery cells. These six other battery cells may each contact the battery cell centered between these six other battery cells, or alternatively, may each be spaced apart from the battery cell centered between these six other battery cells.

[0019] The Z-shaped bus bar included in the assembly kit according to the present invention may be adapted such that, together with a suitable set of battery cell blocks, where the number of battery cell blocks corresponds to the number of Z-shaped bus bars in the assembly kit, the Z-shaped bus bar and the battery cell blocks may be assembled such that each Z-shaped bus bar is connected to the positive electrode side of one of the battery cell blocks through the positive electrode plate of the Z-shaped bus bar, and is also connected to the negative electrode side of one of the battery cell blocks through the negative electrode plate of the Z-shaped bus bar.

[0020] Herein and hereinafter, expressions such as "being connected" or "being connectable" etc. mean mechanical and electrical connection or connectability, as long as they refer to the connection between the terminals of the battery and the bus bar. The mechanical connectability between the terminal of the battery and the plate of the bus bar may only mean that the terminal contacts the plate of the bus bar; however, a permanent connection between the terminal of the battery and the plate of the bus bar may be provided by additional fixing elements; see below.

[0021] In one embodiment of the assembly kit, at least one Z-shaped bus bar is integrally formed. Preferably, each Z-shaped bus bar included in the assembly kit according to the present invention is integrally formed. The expression "integrally formed" should mean in this context that the Z-shaped bus bar is formed as one piece in the present context. Preferably, at least one of the integrally formed Z-shaped bus bars is manufactured by bending a single piece of metal.

[0022] At least one of the Z-shaped busbars can be made of metal. Preferably, each Z-shaped busbar is made of metal. The metal can be aluminum, copper or iron. The metal can be an alloy including copper and / or iron. The metal can be an aluminum alloy. Preferably, the metal is a high-strength aluminum alloy. In this way, the Z-shaped busbar provides the appropriate structural stiffness required for the mechanical stability of the assembled carrier frame.

[0023] Preferably, the wall thickness of each Z-shaped busbar is at least 1 mm, preferably at least 1.5 mm, and most preferably 1.5 mm.

[0024] In one embodiment of the assembly kit, the connecting plate of each Z-shaped busbar is configured to separate a pair of battery cell blocks when one battery cell block in the pair is connected to the positive plate of the Z-shaped busbar and the other battery cell block in the pair is connected to the negative plate of the Z-shaped busbar.

[0025] In a preferred embodiment of the assembly kit according to the present invention, when one battery cell block in a pair of battery cell blocks is connected to the positive plate of the Z-shaped busbar and the other battery cell block in the pair is connected to the negative plate of the Z-shaped busbar, the connecting plate extends between the battery cell blocks in the pair of battery cell blocks such that for each battery cell block in the pair of battery cell blocks, the connecting plate completely covers the side of the battery cell block facing the other battery cell block.

[0026] In an embodiment of the present invention, the separation of the two battery cell blocks connected to the Z-shaped busbar by the above-mentioned connecting plate helps to prevent a thermal event (e.g., thermal runaway) from being transmitted from one battery cell block connected to the busbar to the other battery cell block connected to the busbar in the event that one of these battery cell blocks is affected by a thermal event.

[0027] In one embodiment of the assembly kit according to the present invention, the connecting plate of at least one (preferably each) of the Z-shaped busbars can be corrugated. The corrugated connecting plate of the Z-shaped busbar can include grooves or embayments. The grooves or embayments can extend in a straight line from the positive plate to the negative plate of the Z-shaped busbar.

[0028] In one embodiment of the assembly kit, a negative lead frame is provided for at least one of the Z-shaped busbars. The negative lead frame can be connected to a side of the negative plate of the Z-shaped busbar opposite to the side configured to be connected to the negative terminal of the battery cell of the battery cell block. The negative plate of the Z-shaped busbar includes a plurality of openings located at the positions of the negative terminals of the battery cells when the battery cell block is connected to the negative plate. When the battery cell block is connected to the negative plate, the negative lead frame can be permanently connected to the negative terminals of the battery cells through the openings in the negative plate.

[0029] When the battery cell block is connected to the negative plate by welding (preferably by laser welding), the (multiple) negative lead frames can be permanently connected to the negative terminals of the battery cells through openings in the negative plate.

[0030] Compared with the wall thickness of the Z-shaped bus bar, the (multiple) negative lead frames can have a lower wall thickness. This is advantageous in the aforementioned welding process. The wall thickness of the negative lead frame can correspond to the wall thickness of the battery cell can of the battery cell that is to be permanently connected to the negative lead frame. The wall thickness of the (multiple) negative lead frames can be in the range between 0.3 mm and 0.5 mm. Preferably, the wall thickness of the (multiple) negative lead frames is 0.4 mm.

[0031] In one embodiment of the assembly kit, a positive lead frame is provided for at least one of the Z-shaped bus bars; the positive lead frame can be connected to one side of the positive plate of the Z-shaped bus bar, which is opposite to the side configured to be connected to the positive terminals of the battery cells of the battery cell block; wherein the positive plate of the Z-shaped bus bar includes a plurality of openings, and when the battery cell block is connected to the positive plate, the plurality of openings are located at the positions of the positive terminals of the battery cells; and wherein when the battery cell block is connected to the positive plate, the positive lead frame can be permanently connected to the positive terminals of the battery cells through the openings in the positive plate.

[0032] When the battery cell block is connected to the positive plate by welding (preferably by laser welding), the (multiple) positive lead frames can be permanently connected to the positive terminals of the battery cells through openings in the positive plate.

[0033] Compared with the wall thickness of the Z-shaped bus bar, the (multiple) positive lead frames can have a lower wall thickness. This is advantageous in the aforementioned welding process. The wall thickness of the positive lead frame can correspond to the wall thickness of the battery cell can of the battery cell that is to be permanently connected to the positive lead frame. The wall thickness of the (multiple) positive lead frames can be in the range between 0.3 mm and 0.5 mm. Preferably, the wall thickness of the (multiple) positive lead frames is 0.4 mm.

[0034] In one embodiment of the assembly kit, at least one positive lead frame includes a plurality of openings, and for each positive lead frame including a plurality of openings, when the positive lead frame is connected to the corresponding positive plate of the Z-shaped bus bar in a proper manner, the positions of these openings correspond to the positions of the openings in the positive plate.

[0035] In one embodiment of the assembly kit, at least one negative lead frame includes a plurality of openings, wherein for each negative lead frame including a plurality of openings, when the negative lead frame is connected in a suitable manner to the corresponding negative plate of the Z-shaped busbar that can be connected to the negative lead frame, the positions of these openings correspond to the positions of the openings in the negative plate.

[0036] When the assembly kit is assembled with a set of battery cell blocks into a battery cell stack as described below, the openings in the positive lead frame or the negative lead frame can allow the emission of exhaust gas (in the case of a thermal event such as thermal runaway).

[0037] In one embodiment of the assembly kit, a plurality of first chamfered pins are provided, which protrude from the positive plate of at least one Z-shaped busbar to one side of the positive plate, and this side is configured to be connected to the positive terminals of the battery cells of the battery cell block, wherein the first chamfered pins are positioned such that when the battery cell block is connected to the positive plate, each first chamfered pin passes through the gaps between the battery cells of the battery cell block.

[0038] In one embodiment of the assembly kit, a plurality of second chamfered pins are provided, which protrude from the negative plate of at least one Z-shaped busbar to one side of the negative plate, and this side is configured to be connected to the negative terminals of the battery cells of another battery cell block, wherein the second chamfered pins are positioned such that when the another battery cell block is connected to the negative plate, each second chamfered pin passes through the gaps between the battery cells of the another battery cell block.

[0039] The above embodiments with chamfered pins are particularly useful for battery cell blocks including cylindrical battery cells. During the process of connecting the battery cell block to the corresponding positive plate or negative plate, the chamfered pins can be used as retainers to facilitate the positioning of the battery cells. In addition, the chamfered pins prevent exhaust gas from flowing into the gaps between the individual battery cells of the battery cell block.

[0040] In one embodiment of the assembly kit, a first pin frame is provided for at least one Z-shaped busbar, which can be connected to the positive plate of the Z-shaped busbar, or if applicable, can be connected to the positive lead frame that can be connected to the positive plate of the Z-shaped busbar, wherein the first chamfered pins protrude from the first pin frame, and wherein the positive plate of the Z-shaped busbar and if applicable the positive lead frame that can be connected to the Z-shaped busbar each include drilled holes, and when the first pin frame is connected to the positive plate of the Z-shaped busbar in a suitable manner or if applicable connected to the positive lead frame, the first chamfered pins of the first pin frame can be guided through the drilled holes.

[0041] In one embodiment of the assembly kit, a second pin frame is provided for at least one Z-shaped busbar, which can be connected to the negative plate of the Z-shaped busbar or, if applicable, to a negative lead frame that can be connected to the negative plate of the Z-shaped busbar, wherein a second chamfered pin projects from the second pin frame, and wherein the negative plate of the Z-shaped busbar and, if applicable, the negative lead frame that can be connected to the Z-shaped busbar each include a drilled hole through which the second chamfered pin of the second pin frame can be guided when the second pin frame is connected to the negative plate of the Z-shaped busbar or, if applicable, to the negative lead frame in a suitable manner.

[0042] In one embodiment of the assembly kit, the first fastening means of each Z-shaped busbar includes a strap, and each first fastening element of the first frame beam includes a groove configured to engage with the first fastening means of any one of the Z-shaped busbars.

[0043] In one embodiment of the assembly kit, the second fastening means of each Z-shaped busbar includes a strap, and each second fastening element of the second frame beam includes a groove configured to engage with the second fastening means of any one of the Z-shaped busbars.

[0044] In an embodiment of the assembly kit according to the present invention, straps are provided at the connection plates of at least one Z-shaped busbar. Additionally or alternatively, straps can be provided at the positive plates of at least one Z-shaped busbar. Additionally or alternatively, straps can be provided at the negative plates of at least one Z-shaped busbar.

[0045] In one embodiment, the assembly kit further includes a plurality of rivets. The first fastening means of each Z-shaped busbar includes at least one drilled hole, and each first fastening element of the first frame beam includes at least one drilled hole such that each first fastening element can be fixed to at least one first fastening means by inserting at least one rivet through the drilled hole of the first fastening element and simultaneously through the drilled hole of the first fastening means. Alternatively or additionally, the second fastening means of each Z-shaped busbar includes at least one drilled hole, and each second fastening element of the second frame beam includes at least one drilled hole such that each second fastening element can be fixed to at least one second fastening means by inserting at least one rivet through the drilled hole of the second fastening element and simultaneously through the drilled hole of the second fastening means.

[0046] In one embodiment, the assembly kit further includes: a positive terminal busbar configured to be connected to the positive terminals of the battery cells of at least one battery cell block; and / or a negative terminal busbar configured to be connected to the negative terminals of the battery cells of at least one battery cell block.

[0047] Instead of the term "positive extreme bus bar", the expression "first end bus bar" may be used. Correspondingly, instead of the term "negative extreme bus bar", the expression "second end bus bar" may be used. The shape of the positive extreme bus bar may correspond to the shape of the Z-shaped bus bar as described above, however, with the negative electrode plate omitted. Correspondingly, the shape of the negative extreme bus bar may correspond to the shape of the Z-shaped bus bar as described above, however, with the positive electrode plate omitted.

[0048] Another aspect of the present invention relates to an assembly kit for assembling a stack of battery cells, which includes an assembly kit for assembling a carrier frame for a stack of battery cell blocks according to the present invention, and further includes for each Z-shaped bus bar: a battery cell block, the positive terminal of the battery cells of which can be connected to the positive electrode plate of the Z-shaped bus bar; and another battery cell block, the negative terminal of the battery cells of which can be connected to the negative electrode plate of at least one Z-shaped bus bar; wherein the Z-shaped bus bar and the battery cell blocks can be assembled such that each Z-shaped bus bar is connected to the positive terminal of the battery cells of one of the battery cell blocks through the positive electrode plate of the Z-shaped bus bar, and is further connected to the negative terminal of the battery cells of another of the battery cell blocks through the negative electrode plate of the Z-shaped bus bar.

[0049] That is to say, if the number of Z-shaped bus bars in the assembly kit is N, then N + 1 battery cell blocks are required. Of course, the shapes of the N Z-shaped bus bars adopted may be the same as each other. In addition, the shapes of the N + 1 battery cell blocks may be the same as each other. However, note that the above-described assembly kit with battery cell blocks also covers embodiments in which the Z-shaped bus bars are not the same. Of course, when the assembly kit for assembling a stack of battery cells is in an assembled state, the Z-shaped bus bars must be isolated from each other. In the simplest case, isolation can be achieved by the gap between any two adjacent Z-shaped bus bars such that these Z-shaped bus bars do not contact each other. In addition, insulating materials can be used to establish isolation between any two adjacent Z-shaped bus bars.

[0050] Each connection between the battery terminals and the Z-shaped bus bar can be achieved by welding. Preferably, laser welding is used for this purpose.

[0051] In one embodiment of the assembly kit for assembling a stack of battery cells according to the present invention, it includes one or more battery cell brick-like bodies, wherein the number of battery cell brick-like bodies corresponds to the number of Z-shaped bus bars included in the assembly kit; and wherein each battery cell brick-like body contains a single Z-shaped bus bar with the positive terminals of the battery cells pre-connected to a single battery cell block through its positive electrode plate.

[0052] An alternative embodiment of the assembly kit for assembling a stack of battery cells according to the present invention includes one or more battery cell brick-like bodies, wherein the number of battery cell brick-like bodies corresponds to the number of Z-shaped busbars included in the assembly kit; and wherein each battery cell brick-like body includes a single Z-shaped busbar whose negative electrode plate is pre-connected to the negative terminal of the battery cell of a single battery cell block.

[0053] Another aspect of the present invention relates to a battery cell stack, which includes an assembly kit for assembling a stack of battery cells according to the present invention, wherein each Z-shaped busbar is connected to the positive terminal of the battery cell of one of the battery cell blocks through the positive electrode plate of the Z-shaped busbar, and is also connected to the negative terminal of the battery cell of another of the battery cell blocks through the negative electrode plate of the Z-shaped busbar; and wherein a first frame beam is connected to each Z-shaped busbar, and wherein a second frame beam is connected to each Z-shaped busbar.

[0054] Another aspect of the present invention relates to a vehicle including a battery cell stack according to the present invention.

[0055] Another aspect of the present invention relates to a method for assembling a battery cell stack, the method including the following steps: a) providing a plurality of battery cell brick-like bodies, each battery cell brick-like body including a Z-shaped busbar having a positive electrode plate, a negative electrode plate, and a connecting plate, each battery cell brick-like body further including a battery cell block, wherein the positive terminal of the battery cell of the battery cell block is connected to the positive electrode plate of one of the Z-shaped busbars, and wherein each Z-shaped busbar can be fixed to a first frame beam and a second frame beam; b) providing an additional battery cell block; c) providing a first frame beam and a second frame beam, each of the first frame beam and the second frame beam being configured to be fixed to each Z-shaped busbar; d) connecting the first battery cell brick-like body among the battery cell brick-like bodies by connecting the negative electrode plate of the Z-shaped busbar of the first battery cell brick-like body to the negative terminal of the battery cell of the other battery cell block provided in step b); e) connecting the additional one battery cell brick-like body by connecting the negative electrode plate of the Z-shaped busbar of the additional one battery cell brick-like body to the negative terminal of the battery cell of the battery cell block of the first battery cell brick-like body that has been connected in the previous step; f) repeating step e) until each battery cell brick-like body is connected; and g) fixing the first frame beam to each Z-shaped busbar and fixing the second frame beam to each Z-shaped busbar.

[0056] The above aspects or embodiments of the present invention at least provide the following advantages:

[0057] · Only simple sheet metal is used to implement the busbar, and the sheet metal combines the structural function and the electrical connection.

[0058] · A rigid Z-shaped busbar that can be used as a self-supporting unit carrier.

[0059] · An improved safety design where the vertical walls of the "Z" separate all parallel unit bricks from each other, thus providing diffusion prevention in the event of an exhaust event.

[0060] · Uniform battery cell orientation.

[0061] · Weldability, where individual unit bricks can be pre-joined / pre-assembled.

[0062] · Easy handling and better processing ability due to smaller pre-assembly units (tolerance stacking).

[0063] · Improved cooling performance if the present invention is used with a cooling system.

[0064] · Modular application: The length of the battery cell stack can be easily adjusted.

[0065] · A good cell-to-Package ratio with a high degree of functional and safety integration, achieved with a smaller number of components (i.e., lower cost), which also facilitates assembly.

[0066] Additional aspects of the present invention can be understood from the dependent claims or the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Features will become apparent to those of ordinary skill in the art by referring to the accompanying drawings in which the exemplary embodiments are described in detail, where:

[0068] Figure 1 is a schematic perspective view showing a "unit brick" that can be assembled with components of an assembly kit according to an exemplary embodiment of the present invention;

[0069] Figure 2 is Figure 1 an exploded view of the components of the unit brick shown;

[0070] Figure 3A and Figure 3B schematically shows the area of the positive electrode plate in the assembled assembly kit as previously referred to Figure 1 and Figure 2 described;

[0071] Figures 4A to 4C schematically shows the process of stacking assembled battery cell blocks according to an embodiment of the present invention;

[0072] Figure 5 schematically shows the current path in a battery cell stack according to an embodiment of the present invention;

[0073] Figures 6A to 6F Schematically shows the assembly of an embodiment of a battery cell stack according to the present invention;

[0074] Figure 7A Shows an embodiment of a battery cell stack according to the present invention;

[0075] Figure 7B Schematically shows a part (3D cut - off part) of a frame beam that can be used in an embodiment of a battery cell stack according to the present invention; and

[0076] Figures 8A to 8D Schematically shows an alternative embodiment of manufacturing a battery cell stack according to the present invention. Detailed Embodiments

[0077] Now, reference will be made in detail to embodiments, examples of which are shown in the drawings. The effects, features, and implementation methods of the exemplary embodiments will be described with reference to the drawings. In the drawings, the same reference numerals denote the same elements, and redundant descriptions are omitted. As used herein, the term "and / or" includes any and all combinations of one or more of the related listed items. In addition, the use of the term "may" in describing embodiments of the present invention means "one or more embodiments of the present invention".

[0078] It will be understood that although the terms "first" and "second" are used to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element without departing from the scope of the present invention.

[0079] In the following description of embodiments of the present invention, terms in the singular form may include the plural form unless the context clearly indicates otherwise.

[0080] It will also be understood that when a film, region, or element is referred to as being "above" or "on" another film, region, or element, it may be directly on the other film, region, or element, or there may be intervening films, regions, or elements.

[0081] Here, the terms "upper" and "lower" are defined according to the z - axis. For example, the upper cover is located in the upper part of the z - axis, and the lower cover is located in the lower part of the z - axis. In the drawings, for clarity, the dimensions of the elements may be exaggerated. For example, in the drawings, for illustrative purposes, the dimensions or thicknesses of each element may be arbitrarily shown, and thus the embodiments of the present invention should not be construed as being limited thereto.

[0082] In the drawings, for clarity, the relative dimensions of the elements, layers, and regions may be exaggerated.

[0083] It will be understood that when an element or layer is referred to as being "on", "connected to" or "coupled to" another element or layer, it can be directly on, directly connected to or directly coupled to the other element or layer, or there can be one or more intervening elements or layers. Further, it will be understood that when an element or layer is referred to as being "between" two elements or layers, it can be the only element or layer between the two elements or layers, or there can also be one or more intervening elements or layers.

[0084] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will also be understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and / or the present specification, and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0085] The general concept of the present invention is based on a busbar design shaped like a "Z". The busbar can be made of, for example, aluminum or copper. The reason for this Z-shape is mainly driven by the need to have a uniform top-down orientation of the battery cells (especially when using cylindrical cells) in order to improve the safety performance during thermal runaway events at least in embodiments of the present invention and in order to facilitate assembly (especially considering the electrical connection of the cells). Specifically, by the uniform orientation of the battery cells in the battery cell stack according to the present invention, the cooling system can be positioned at the opposite position of the exhaust port of the cells, which will preferably be located on the top side of the cell stack. Further, due to the Z-shape, the cooling behavior is improved in that the heat flow from the PLUS terminal of the cell (which is located on the bottom side in the preferred embodiment) to the cooling plate (which is located on the top side in the preferred embodiment) through the vertical walls of the Z-shaped busbar is greatly improved. Another advantage is that the vertical walls physically separate each serially connected "cell brick" (which basically represents a bundle of cells that are connected in parallel on one Z-shaped busbar; see below); thus, heat propagation between the individual cell brick bodies can also be prevented in the case of an exhaust event.

[0086] Finally, the shape itself is very rigid. As a result, additional support components are obsolete, which makes the Z-shaped busbar an integral part of the battery structure.

[0087] Figure 1 is a perspective view showing a "cell brick" 10 which can be assembled with the components of an assembly kit according to an exemplary embodiment of the present invention together with a block 5 of suitable battery cells (hereinafter simply referred to as "battery cell block"). Figure 2 isFigure 1 An exploded view of the unit brick-shaped body 10 shown, but without the battery unit block 5. For ease of description, Figure 1 and Figure 2 also show a Cartesian coordinate system with an x-axis, a y-axis, and a z-axis. The following will refer to Figures 6A - 8D a battery cell stack according to an embodiment of the present invention, i.e., an assembly kit for assembling a carrier frame for stacking battery unit blocks, which is fully assembled with a predetermined number of battery unit blocks in an intended manner.

[0088] Figure 1 Shown is a battery unit block 5 including 42 battery cells 50 of the same shape. Each battery cell 50 has a cylindrical shape and extends in the z-direction of the drawn coordinate system in the figure. In the battery unit block 5, the battery cells 50 are packed together as tightly as possible, i.e., each battery cell 50 is surrounded by six other battery cells 50 according to six-fold symmetry, except for the battery cells 50 at the edges of the battery unit block 5. In addition, all the battery cells 50 of the battery unit block 5 are oriented such that their positive terminals (PLUS terminals) are located at their respective bottom ends in the figure. Thus, the negative terminal (MINUS terminal) of each battery cell 50 of the battery unit block 5 is located at the upper end of the corresponding battery cell 50.

[0089] As Figure 1 and Figure 2 shown, the unit brick-shaped body 10 shown includes a bus bar 1 formed in a Z shape, or more precisely, a bus bar 1 having an approximately Z-shaped profile or cross-section. In Figure 1 and Figure 2 , this profile or cross-section extends along a plane parallel to the x-z plane of the drawn coordinate system. The bus bar 1 includes three parts, each part having a planar shape: a first part hereinafter referred to as the first plate or positive plate 11, which extends parallel to the x-y plane of the coordinate system in the figure and is sized such that it covers the cross-section (along the x-y plane of the coordinate system) of the battery unit block 5. More specifically, the positive plate 11 is formed such that it can be mechanically and electrically connected to each positive terminal of the battery cells 50 of the battery unit block 5. In other words, the bus bar 1 and the battery unit block 5 can be assembled such that each battery cell 50 abuts against the upper side of the positive plate 11, as Figure 1 shown.

[0090] The following second part of the bus bar 1, hereinafter referred to as the second plate or the negative plate 12, also extends parallel to the x-y plane of the coordinate system in the figure and is dimensioned similarly to the positive plate 11 such that it covers the cross-section (along the x-y plane of the coordinate system) of another battery cell block (not shown), the shape and orientation of which are the same as those of the battery cell block 5. More specifically, the negative plate 12 is formed such that it can be mechanically and electrically connected to each negative terminal of the battery cells of the said another battery cell block. In other words, the bus bar 1 and the said another battery cell block (not shown) can be assembled such that when the negative plate 12 is in the orientation as Figure 1 shown, each battery cell of the said another battery cell block abuts against the lower side of the negative plate 12.

[0091] Both the positive plate 11 and the negative plate 12 can exhibit an approximately rectangular shape (possibly except for the fastening means and / or a plurality of openings in the respective plates; see below). At least in the x-direction, when the bus bar 1 and the battery cell block 5 are arranged as Figure 1 drawn, the sizes of the positive plate 11 and the negative plate 12 should not exceed or should only slightly exceed the corresponding sizes of the battery cell block 5. The reason is to make the size of the complete battery cell stack assembled from a number of unit brick-like bodies 10 as shown in Figure 1 as small as possible. More specifically, when a plurality of unit brick-like bodies as shown in Figure 1 are pasted or inserted into each other in the x-direction as described in more detail below with reference to Figures 6A - 8D , any two adjacent battery cell blocks should be as close to each other as possible in space.

[0092] Finally, the following third part of the bus bar 1, hereinafter referred to as the connection plate 13, extends parallel to the y-z plane of the drawn coordinate system in the figure. It has an approximately rectangular shape (possibly except for the fastening means and / or a plurality of openings in the respective plates; see below) and is dimensioned such that its width (i.e., its extension in the y-direction) substantially corresponds to the respective widths of the positive plate 11 and the negative plate 12, and such that its height (i.e., its extension in the z-direction) substantially corresponds to the height of the battery cell block 5, i.e., the length of each battery cell 50.

[0093] As Figure 2 shown, the connection plate 13 may not be completely flat but may be corrugated, i.e., the connection plate 13 may include grooves or bays 135. Each of these grooves or bays 135 is configured to accommodate a part of the cylindrical surface of the battery cell 50 that abuts against the connection plate 13 when the battery cell block 5 is assembled with the bus bar 1 as Figure 1 shown. Therefore, the grooves or bays 135 can be small. The surface of the connection plate 13 that is not visible in Figure 2 (i.e., the surface of the connection plate 13 that is opposite to its surface in Figure 2 ​Figure 2 The surfaces opposite the visible surfaces may include corresponding grooves or bays. For example, when viewed in the x-y plane, the profile or cross-section of the connecting plate 13 may exhibit an approximately sinusoidal shape. The aforementioned geometry of the connecting plate 13 may promote the compactness (i.e., as small as possible in size) of the assembled stack (in the x direction) of battery cell blocks, the assembled stack of battery cell blocks including a plurality of unit bricks 10 as Figure 1 and Figure 2 shown.

[0094] Since the bus bar 1 is provided for conducting electric current, it must be made of a conductive material. However, in the assembled stack of battery cell blocks, the (multiple) bus bars 1 must not only provide electrical connection, but also provide appropriate structural rigidity for the stack of battery cell blocks. Therefore, the bus bar 1 may be made of metal. For example, the bus bar 1 may be made of copper or iron. Preferably, the bus bar 1 is made of a high-strength aluminum alloy (Al alloy). The thickness of the bus bar 1 (i.e., the wall thickness of each of the positive plate 11, the negative plate 12, and the connecting plate 13) may be in the range of 1 mm to 2 mm. In an embodiment, the thickness may be smaller or larger depending on the requirements for the structural stability required for a particular stack of battery cell blocks. Preferably, the thickness is 1.5 mm.

[0095] The three parts of the bus bar 1, namely the positive plate 11, the negative plate 12, and the connecting plate 13, may be originally separate parts that are welded together to form the bus bar 1. However, preferably, the bus bar 1 is integrally formed, i.e., it is made of one piece. For example, the bus bar 1 may be made of an elongated metal sheet, the ends of which are bent or angled in opposite directions relative to the middle part of the metal sheet. In an embodiment where the bus bar 1 is integrally formed from a bent metal sheet, a plurality of openings 1311, 1312 may have been inserted along lines into the metal sheet before, and the metal sheet is bent at the said lines during the manufacturing process of the bus bar 1.

[0096] Preferably, the bus bar 1 is shaped such that the plane in which the positive electrode plate 11 extends is parallel to the plane in which the negative electrode plate 12 extends. Preferably, the connecting plate 13 extends in a plane perpendicular to the planes in which the positive electrode plate 11 and the negative electrode plate 12 respectively extend. In other words, the positive electrode plate 11 is oriented perpendicular to the connecting plate 13, and the negative electrode plate 12 is likewise oriented perpendicular to the connecting plate 13. The connecting plate 13 extends between the positive electrode plate 11 and the negative electrode plate 12, and the positive electrode plate 11 and the negative electrode plate 12 protrude from the connecting plate 13 in opposite directions. The reason for the foregoing geometry of the bus bar 1 is to improve the compactness of the assembled stack of battery cell blocks, provided that each battery cell block has such a shape in which each cylindrical battery cell extends perpendicular to the plane in which the positive terminal of the battery cell is arranged and also perpendicular to the plane in which the negative terminal of the battery cell is arranged. Although in the foregoing geometry of the bus bar 1, the profile or cross-section taken parallel to the x-z plane of the drawn coordinate system does not exactly resemble the letter Z (because the middle line of the letter Z reaches the lower bar and the upper bar of the letter Z at an angle not equal to 90°), for the sake of simplicity, the term "Z-shaped" will still be used throughout this specification and the claims, such that it also encompasses the foregoing preferred geometry of the bus bar 1.

[0097] In an embodiment, an opening 116 is formed in the positive electrode plate 11 of the Z-shaped bus bar 1. Alternatively or additionally, an opening 126 may be formed in the negative electrode plate 12. These openings 116, 126 can facilitate the connection of the respective terminals of the battery cells of the battery cell block to the plates (i.e., electrical connection and / or mechanical connection).

[0098] Although the electrical connection between the positive terminal of the battery cell 50 of the battery cell block 5 and the positive electrode plate 11 can be established by mere contact, the mechanical connection between these components may be more difficult to achieve. This also applies to the electrical connection and mechanical connection between the negative terminal of the battery cell of the battery cell block and the negative electrode plate 12 of the bus bar 1. For example, in an embodiment in which the respective mechanical connection between the battery cell terminal and the respective plates 11, 12 of the bus bar 1 is established by welding (e.g., laser welding), the following may occur: Due to the different thicknesses of the plates 11, 12 and the battery cell can (battery cell housing), the battery cell terminal cannot be directly welded to the respective plates 11, 12 of the bus bar 1 because the energy required to weld the plates 11, 12 of the bus bar 1 must be so strong that it will damage the can of the battery cell 50.

[0099] Therefore, in an embodiment, a bus bar assembly 100 is employed instead of the mere bus bar 1, wherein the bus bar assembly 100 further includes a first lead frame or positive lead frame 21 and / or a second lead frame or negative lead frame 22.

[0100] In an embodiment of an assembly kit employing a bus bar assembly 100 having a negative lead frame 22 according to the present invention, the negative plate 12 of the Z-shaped bus bar 1 includes an opening 126 as already described above. Regarding Figure 1 and Figure 2 , the negative plate 12 is configured such that a battery cell block (not shown) can be connected to the negative plate 12 from below (the battery cell block is oriented such that the negative terminals of its battery cells are arranged on its upper side), and the negative plate 12 is further configured such that its upper surface is connected to the negative lead frame 22. Then, the negative lead frame 22 can be connected to the negative terminals of the battery cells of the battery cell block through the opening 126 of the negative plate 12, and the negative terminals will be connected to the negative plate 12.

[0101] Preferably, this connection between the negative plate 12 and the negative terminals of the battery cells of the battery cell block to be connected to the negative plate 12 is performed by welding, for example, by laser welding. Thus, the negative lead frame 22 must be made of a weldable material. Preferably, the negative lead frame 22 is made of metal. The negative lead frame 22 can be made of the same material as the Z-shaped bus bar 1 (see above). Specifically, the material of the negative lead frame 22 can be copper, iron, or aluminum, or can be an alloy including at least one of these materials. In an embodiment, the alloy material can also be selected according to the requirements of the laser welding process. It is desirable that the cans of the battery cells and the negative lead frame 22 have approximately the same wall thickness, as this is beneficial to the welding process. For example, the thickness of the negative lead frame 22 can be in the range between 0.3 and 0.5 mm. Preferably, the thickness of the negative lead frame is 0.4 mm.

[0102] In an embodiment, the negative lead frame 22 includes an opening 226. The number of openings 226 included in the negative lead frame 22 can be equal to the number of openings 126 included in the negative plate 12. Thus, when the negative lead frame 22 is connected to the upper side of the negative plate 12 as Figure 1 depicted, with reference to a plane parallel to the x-y plane of the coordinate system, the position of the opening 226 within the negative lead frame 22 can correspond to the position of the opening 126 of the negative plate 12. The opening 226 in the negative lead frame 22 can facilitate the welding process and / or can also provide the possibility of vent gas emission.

[0103] As an alternative or supplement to the negative lead frame 22, a positive lead frame 21 is employed in an embodiment of the assembly kit according to the present invention. In those embodiments, the positive plate 11 of the Z-shaped bus bar 1 includes an opening 116 as already described above. Regarding Figure 1 and Figure 2, the positive electrode plate 11 is configured such that the battery cell block 5 can be connected to the positive electrode plate 11 from above (the battery cell block 5 is oriented such that the positive electrode terminals of its battery cells 50 are arranged on its lower side), and the positive electrode plate 11 is further configured such that its lower surface is connected to the positive electrode lead frame 21. Thus, the positive electrode lead frame 21 can be connected to the positive electrode terminals of the battery cells 50 of the battery cell block 5 through the openings 116 of the positive electrode plate 11, and these positive electrode terminals will be connected to the positive electrode plate 11.

[0104] Preferably, the aforementioned connection between the positive electrode plate 11 and the positive electrode terminals of the battery cells 50 of the battery cell block 5 that will be connected to the positive electrode plate 11 is performed by welding, for example, by laser welding. Thus, the positive electrode lead frame 21 must be made of a weldable material. Preferably, the positive electrode lead frame 21 is made of metal. The positive electrode lead frame 21 can be made of the same material as the Z-shaped bus bar 1 (see above). Specifically, the material of the positive electrode lead frame 21 can be copper, iron, or aluminum, or can be an alloy including at least one of these materials. In an embodiment, the alloy material can also be selected according to the requirements of the laser welding process. It is desirable that the cans of the battery cells 50 and the positive electrode lead frame 21 have approximately the same wall thickness, as this is beneficial to the welding process. For example, the thickness of the positive electrode lead frame 21 can be in the range between 0.3 and 0.5 mm. Preferably, the thickness of the positive electrode lead frame is 0.4 mm.

[0105] In an embodiment, the positive electrode lead frame 21 includes openings 216. These openings 216 can be grouped such that a predetermined number of openings (for example, three openings) can together form a group of openings 2160 (opening group); this will be described in more detail below with reference to Figure 3A and Figure 3B . The number of groups of openings included in the positive electrode lead frame 21 can be equal to the number of openings 126 included in the positive electrode plate 11. Thus, when the positive electrode lead frame 21 is connected to the lower side of the positive electrode plate 11 as Figure 2 shown, with reference to a plane parallel to the x-y plane of the coordinate system, the positions of the groups of openings within the positive electrode lead frame 21 can correspond to the positions of the openings 116 of the positive electrode plate 11. The openings 216 in the positive electrode lead frame 21 can facilitate the welding process and / or can also provide the possibility of exhaust gas emission (see Figure 3A and Figure 3B below).

[0106] In a preferred embodiment, the bus bar assembly 100 includes both the negative electrode lead frame 22 and the positive electrode lead frame 21.

[0107] In addition to the one or two lead frames as described above, chamfered pins 238 can also be employed in the bus bar assembly 100. When the battery cell block 5 is connected to as Figure 1 and Figure 2When the positive electrode plate 11 shown is concerned, the chamfered pin 238 can improve the positioning of a single battery cell 50. However, the chamfered pin 238 can also play an important role in guiding the exhaust gas in the case of a thermal event (e.g., thermal runaway); this will be described in more detail below with reference to Figure 3A and Figure 3B be described in more detail.

[0108] In Figure 1 and Figure 2 In the bus bar assembly 100 shown, the chamfered pin 238 is provided at the positive electrode plate 11 of the Z-shaped bus bar 1. For ease of assembly, the chamfered pin 238 protrudes from one side of the pin frame 23. The pin frame 23 is configured to be attached to the positive electrode plate 11 directly or indirectly from below (referring to the drawings). In the example shown, the pin frame 23 is only indirectly attached to the positive electrode plate 11 because the positive lead frame 21 is clamped between the positive electrode plate 11 and the pin frame 23 during the shown assembly process. The positive electrode plate 11 includes a plurality of additional openings (also referred to as "drilled holes") 118 such that each chamfered pin 238 can be guided through one of the additional openings 118 during the process of attaching the pin frame 23 to the positive electrode plate 11 from below. As a result, the tip of the chamfered pin 238 protrudes from the upper side of the positive electrode plate 11 into the space for accommodating the battery cell block 5. Thus, when the battery cell block 5 is connected to the positive electrode plate 11 as shown in Figure 1 and Figure 2 shown, the battery cell block 5 can only be positioned on the upper side of the positive electrode plate 11 such that the tip of the chamfered pin 238 engages into the gap between the cylindrical battery cells 50 of the battery cell block 5. Due to the arrangement of the battery cells 50 within the battery cell block 5 (see above), each battery cell 50 on the inner side of the battery cell block 5 is surrounded by six gaps. Therefore, in the embodiment of the bus bar assembly 100 shown in Figure 1 and Figure 2 shown, the chamfered pins 238 are arranged in a six-fold rotational symmetry around each inner opening (i.e., the opening 116 that is not closest to the edge of the positive electrode plate 11) in the opening 116.

[0109] The material of the pin frame 23 can be copper, iron or aluminum, or can be an alloy including at least one of these materials. Preferably, the material of the pin frame 23 is the same as the material used for manufacturing the positive lead frame 21 that is clamped between the pin frame 23 and the positive electrode plate 11. However, the pin frame 23 can also be made of plastic. The pin frame 23 can be attached to the lower side of the positive lead frame 21 by welding (e.g., laser welding). Alternatively or additionally, the pin frame 23 can be connected to the bus bar assembly 100 via a plug connection between the chamfered pin 238 and the corresponding additional opening 118 provided in the positive electrode plate 11.

[0110] In addition, the opening 236 may be provided in the pin frame 23. When the pin frame 23 is attached to the positive electrode plate 11 from below (so that in the embodiment, as Figure 2 shown, the positive electrode lead frame 21 is clamped), with reference to a plane parallel to the x-y plane of the coordinate system, the position of the opening 236 of the pin frame 23 corresponds to the position of the opening 116 of the positive electrode plate 11.

[0111] Since Figure 2 all the components shown (i.e., the Z-shaped bus bar 1, the positive electrode lead frame 21, the negative electrode lead frame 22, and the pin frame 23) can be easily welded together (preferably by laser welding), the bus bar assembly 100 including the aforementioned components can be manufactured and delivered in a pre-assembled state. Similarly, as Figure 1 shown and including Figure 2 the components shown and the entire unit brick-shaped body 10 of a battery cell block 5 can be manufactured and delivered in a pre-assembled state.

[0112] However, depending on the skills of the supplier, it is also feasible to thin the unit interface area to ensure appropriate laser welding process capabilities. In this case, there is no particular need for lead frame components such as the positive electrode lead frame 21 and / or the negative electrode lead frame 22 as described above. Therefore, in an embodiment of the assembly kit according to the present invention, the lead frame can be omitted.

[0113] In an embodiment, the Z-shaped bus bar 1 further includes tabs or strips as will be described below with reference to Figures 6A to 8D which helps to fasten or fix the Z-shaped bus bar 1 or the complete bus bar assembly 100 to the frame beam. Specifically, the positive electrode plate 11 may include a first positive electrode plate strip 111 and a second positive electrode plate strip 112, the negative electrode plate 12 may include a first negative electrode plate strip 121 and a second negative electrode plate strip 122, and the connection plate 13 may include a first connection plate strip 131 and a second connection plate strip 132.

[0114] Figure 3A Schematically shows a region of the positive electrode plate 11 in the assembled bus bar assembly 100 as previously described with reference to Figure 1 and Figure 2 described. Through the opening 116 of the positive electrode plate 11, it can be seen that the positive electrode lead frame 21 has been attached to the positive electrode plate 11 from below. What is not visible in Figure 3A but pointed out in Figure 2 is the pin frame 23, which is in turn attached to the positive electrode lead frame 21 from below such that the latter is clamped between the pin frame 23 and the positive electrode plate 11. From Figure 2As can be seen from the corresponding description above, the openings 216 in the positive electrode lead frame 21 are located directly below each opening 116. In addition, the openings 236 of the pin frame 23 are located below each opening 116 of the positive electrode plate 11. Therefore, the arrangement of the openings allows gas to flow through the openings 116 of the positive electrode plate 11, the openings 216 of the positive electrode lead frame 21, and the openings 236 of the pin frame 23 through the positive electrode plate 11, the positive electrode lead frame 21, and the pin frame 23.

[0115] Below each opening 116 of the positive electrode plate 11 (and, even though not visible in Figure 3A , above each opening 236 of the pin frame 23), three openings 216a, 216b, 216c of the positive electrode lead frame 21 are grouped together. Any three of these grouped openings 216a, 216b, 216c together form an opening group 2160. Therefore, in the assembled bus bar assembly 100, the material block of the positive electrode lead frame 21 that separates the openings 216a, 216b, 216c from each other is provided below the opening 116 of the positive electrode plate 11, and thus this material block (which has a star shape including three bars; see Figure 3B ) can be welded to the positive terminal of the battery cell 50, which becomes a connecting member from above to the upper side of the positive electrode plate 11 when the bus bar assembly 100 is assembled.

[0116] In Figure 3A the six-fold rotational symmetry described above in the context of Figure 2 is clearly visible again, where the chamfered pins 238 are arranged around any one opening 116 (except for the openings 116 located at the edge of the positive electrode plate 11). The first functional aspect of the chamfered pins 238 is to assist in the alignment of the battery cell 50 when the battery cell block 5 is connected to the upper side of the positive electrode plate 11 as previously described with reference to Figure 1 and Figure 2 . A second functional aspect independent of the first functional aspect will be described below with reference to Figure 3B .

[0117] Figure 3B Schematically shows a region of the pin frame 23 in the assembled bus bar assembly 100, which bus bar assembly 100 has also been as previously described with reference to Figure 1 and Figure 2The positive terminal of the battery cell 50 connected to the battery cell block 5. If a thermal event such as thermal runaway occurs in one or more battery cells 50 of the battery cell block 5, hot exhaust gas 55 (represented by a flame symbol in the figure) can escape from the positive terminal of the affected battery cell 50 at high pressure. Then, the aforementioned geometry of the bus bar assembly 100 (in particular, the positioning of the openings provided in the positive electrode plate 11, the positive electrode lead frame 21, and the pin frame 23) allows for efficient discharge of exhaust gas from the affected battery cell 50 and the battery cell block 5.

[0118] However, the individual battery cells 50 are not rotationally aligned. Therefore, the exhaust openings of the battery cells 50 can be covered by the bars in the positive electrode lead frame 21 that separate the openings 216a, 216b, 216c of the opening group 2160 in the positive electrode lead frame 21 from each other (see the description above regarding Figure 3A . Since the battery cells 50 are not sealed against the Z-shaped bus bar 1, the exhaust gas flow can now turn upward between the battery cells 50 (i.e., in the positive z-direction with respect to the Figure 1 and Figure 2 coordinate system). However, the chamfered pins 238 of the pin frame 23 prevent the exhaust gas from flowing into the gaps between the battery cells 50. This is the second functional aspect of the chamfered pins 238 provided in the embodiment of the bus bar assembly 100, which can be used in the embodiment of the assembly kit according to the present invention.

[0119] Figures 4A to 4C Schematically shows the process of assembling a stack 6 of battery cell blocks using a plurality of bus bar assemblies 100 as shown in Figure 2 and a plurality of battery cell blocks 5 as drawn in Figure 1 . Figure 4C The drawn coordinate system is applied to each of Figure 4A and Figure 4B . It indicates the orientation of the bus bar assembly 100 and the battery cell block 5 in the same manner as in Figure 1 and Figure 2 . In one embodiment of the manufacturing process, the first step S1 of the manufacturing process includes assembling a "battery cell brick" 10 (hereinafter simply referred to as "cell brick" 10). Assume that the bus bar assembly 100 has been (pre)-assembled. Then, the first step S1 (shown in Figure 4A ) includes connecting the battery cell block 5 to the positive electrode plate 11 of the bus bar assembly 100 (see Figure 2)。Specifically, the battery cell block 5 includes a bundle of battery cells (in the illustration, a bundle of 42 battery cells), where each battery cell is oriented such that its positive terminal is disposed at its bottom end and its negative terminal is disposed at its top end. Then, in the first sub-step S11 of the first step S1, the battery cell block 5 is positioned on the upper side of the positive electrode plate 11 of the Z-shaped bus bar 1 of the bus bar assembly 100 (see Figure 2 ). This is indicated by the arrow pointing downwards in Figure 4A . Next, in the second sub-step S12 of the first step S1, each of the positive terminals of the battery cells of the battery cell block 5 is welded to the positive electrode plate 11 of the Z-shaped bus bar 1. The welding process is represented by a flame in Figure 4A . Preferably, laser welding is used for the welding process. The laser is represented by the laser beam L1 in Figure 4A . The laser beam L1 is guided from below to the assembly (with respect to the drawing), and then passes through the opening 116 provided in the positive electrode plate 11 (see Figure 2 ) to cause a welded connection between the material of the positive electrode lead frame 21 (see Figure 2 ) and the positive terminals of the battery cells of the battery cell block 5. The result of the manufacturing step S1 is the assembled unit brick-like body 10 as drawn in Figure 1 .

[0120] For Figures 4A to 4C the next (drawn in Figure 4B ) second step S2 of the manufacturing process shown, a predetermined number of unit brick-like bodies 10 must be provided. Note that Figure 4B only five unit brick-like bodies 101, 102, 103, 104, 105 are shown, while the predetermined number of unit brick-like bodies can be different and is usually greater than five (for example, Figure 4C the number of unit brick-like bodies in the assembled stack 6 of battery cell blocks shown according to Figure 1 and Figure 4A adds up to 15). First, the starting battery cell block 50 at the beginning must be provided. The starting battery cell block 50 is not included in the unit brick-like bodies according to Figure 1 . Preferably, the starting battery cell block 50 is equipped with a first end bus bar or positive terminal bus bar E1, which can be used as Figure 4C the positive terminal of the entire stack 6 of battery cell blocks shown. Thus, the positive terminal bus bar E1 is (at least electrically) connected to Figure 4C the positive terminals of the battery cells of the first battery cell block (viewed in the x direction) included in the stack 6 of battery cell blocks drawn. The starting battery cell block 50 together with the positive terminal bus bar E1 can be provided together as the initial unit brick-like body 100 in a pre-assembled state. Then, the negative terminals of the battery cells included in the starting battery cell block 50 are connected to the Z-shaped bus bar (see Figure 1and Figure 2 ) is (detachably) connected to the bottom side of the negative electrode plate. Subsequently, the negative electrode terminals of the battery cells included in the first unit brick 101 are connected to the Z-shaped bus bar (see Figure 1 and Figure 2 ) is (detachably) connected to the bottom side of the negative electrode plate. This process is indicated by the arrow P2 in Figure 4B . Then this process is repeated for the remaining unit bricks (as drawn and indicated by the arrows P3, P4 and P5 for the additional unit bricks 103, 104 and 105 in Figure 4B ) until each unit brick is positioned as shown in Figure 4C .

[0121] After performing step S2, each unit brick is indeed arranged in the correct position to form an assembled stack of the battery cell block (see Figure 4C ) and has been loosely connected to the adjacent unit bricks, but the individual unit bricks (and the starting battery cell block 50) have not been connected to each other in a permanent manner. To achieve a permanent connection between the unit bricks (including the initial unit brick 100) in the stack 6 of the battery cell block, the third step S3 of the manufacturing process is performed, which is drawn in Figure 4C .

[0122] If a certain number N of unit bricks are to be assembled into the stack 6 of the battery cell block (where the initial unit brick 100 is not counted), then N permanent connections must be established, and each of these connections will be established between one of the battery cell blocks and the negative electrode plate of the Z-shaped bus bar. For this purpose, N sub-steps are performed. In each of these sub-steps, the negative electrode terminals of the battery cells included in the battery cell block of a single unit brick become permanently connected to the negative electrode plate of the Z-shaped bus bar included in the adjacent unit brick. These permanent connections can be established by welding (preferably by laser welding). One of these sub-steps is represented as sub-step S3n in Figure 4C . In sub-step S3n, a laser beam L3 is guided from above to the negative electrode lead frame (see Figure 1 and Figure 2 ) included in the bus bar assembly as drawn in Figure 1 and Figure 2 , and this bus bar assembly is in turn included in one of the unit bricks included in the stack 6 of the battery cell block. Thus, the material of the negative electrode lead frame 22 is then welded through the opening 126 of the negative electrode plate to the negative electrode terminal of the battery cell of the battery cell block located below this negative electrode lead frame 22. The welding process of sub-step S3n is represented by a flame symbol in Figure 4C , and the laser is represented by the laser beam L3.

[0123] In Figure 4CAlso visible in the stack 6 of the battery cell blocks shown is a second end busbar or negative end busbar E2, which can be used as the negative terminal of the entire stack 6 of battery cell blocks. Accordingly, the negative end busbar E2 is (at least electrically) connected to the negative terminals of the battery cells of the last battery cell block (viewed in the x direction) included in the stack 6 of battery cell blocks.

[0124] Figure 5 Schematically shown are the current paths and current flow directions ("technical current flow directions") in a battery cell stack according to an embodiment of the present invention (i.e., a battery cell stack including an assembly kit according to an embodiment of the present invention, the assembly kit being used to assemble a carrier frame for a stack of battery cell blocks). Four battery cell blocks 5 n 、5 n+1 、5 n+2 、5 n+3 are shown, arranged with respect to the x-axis of the two-dimensional coordinate system drawn in the figure. The x- and z-axes of this coordinate system are consistent with the x- and z-axes of the coordinate system Figure 4C shown. Figure 5 The battery cell blocks 5 n 、5 n+1 、5 n+2 、5 n+3 can be any four adjacent battery cell blocks included in the stack of battery cell blocks drawn. Each of the battery cell blocks 5 Figure 4C includes four battery cells. However, the first battery cell block 5 n 、5 n+1 、5 n+2 、5 n+3 and the last battery cell block 5 n and the last battery cell block 5 n+3 (viewed in the reverse x direction) are only shown incompletely. Each battery cell in each battery cell block is oriented such that its positive terminal is at the lower end of the battery cell and its negative terminal is at the upper end of the battery cell. Each battery cell block amplifies the voltage between the end terminals of the stack of battery cell blocks, and these end terminals can be realized by a first end busbar E1 and a second end busbar E2 as shown in Figures 4A to 4C and Figure 7A . Although the electrochemical process in the battery cells is much more complex than a simple current flow, the battery cells can be regarded as black boxes, and current flows through these black boxes as shown by the arrows (oriented from top to bottom) drawn in each of the shown battery cells.

[0125] The four battery cell blocks 5 n 、5 n+1 、5 n+2 、5 n+3 are connected via three as previously shown in Figure 1 and Figure 2The Z-shaped busbars or busbar assemblies (not shown) described in the context of are connected in series. The profiles or cross-sections of these Z-shaped busbars or busbar assemblies respectively correspond to those schematically added to Figure 5 the Z-shaped arrow A n , A n+1 and A n+2 in shape. The meaning of arrow A n , A n+1 and A n+2 will be described below. For example, the positive plate of the Z-shaped busbar connecting the nth battery cell block 5 n to the (n + 1)th battery cell block 5 n+1 corresponds to the lower horizontal part a n of arrow A n , and the positive plate of the Z-shaped busbar connecting the (n + 1)th battery cell block 5 n+1 to the (n + 2)th battery cell block 5 n+2 corresponds to the lower horizontal part a n+1 of arrow A n+1 . Correspondingly, the negative plate of the Z-shaped busbar connecting the nth battery cell block 5 n to the (n + 1)th battery cell block 5 n+1 corresponds to the upper horizontal part c n of arrow A n , and the negative plate of the Z-shaped busbar connecting the (n + 1)th battery cell block 5 n+1 to the (n + 2)th battery cell block 5 n+2 corresponds to the upper horizontal part c n+1 of arrow A n+1 .

[0126] Then, the positive terminal of the battery cell 50 n in the nth battery cell block 5 n serves as a current source, which supplies current to the positive plate of the Z-shaped busbar corresponding to arrow A n , and this positive plate is located at the position of the lower horizontal part a n of the Z-shaped arrow A n . In addition, the negative terminal of the battery cell 50 n in the battery cell block 5 n+1 adjacent (observed in the reverse x direction) to the battery cell block 5 n+1 is connected to the negative plate of this Z-shaped busbar. Therefore, due to the potential established between the positive terminal of the battery cell 50 n and the negative terminal of the battery cell 50 n+1 , a current will be established in the Z-shaped busbar connecting the positive terminal of the battery cell 50 n and the negative terminal of the battery cell 50 n+1 . The direction of this current is inFigure 5 is indicated by arrow A n in the figure, i.e., the current is collected at the lower horizontal portion a n of the Z-shaped arrow A n and then guided via the vertical portion b n of the arrow A n to the upper horizontal portion c n of the arrow A n The position of the upper horizontal portion c n corresponds to the position of the negative plate of the Z-shaped bus bar that connects the positive terminal of the battery cell 50 n and the negative terminal of the battery cell 50 n+1 .

[0127] The (n + 1)-th battery cell block 5 n+1 is arranged such that its battery cell 50 n+1 is connected to the negative plate of the Z-shaped bus bar located at the position of arrow A n through its negative terminal and further connected to the positive plate of the Z-shaped bus bar located at the position of arrow A n+1 through its positive terminal. The latter Z-shaped bus bar is connected to the battery cell 50 n+1 of the (n + 2)-th battery cell block 5 n+1 through its negative plate (located at the position of the upper horizontal portion c n+2 of the arrow A n+2 . Thus, similar to the situation described previously for the Z-shaped bus bar located at the position of arrow A n , a potential is established between the positive terminal of the battery cell 50 n+1 in the battery cell block 5 n+1 and the negative terminal of the battery cell 50 n+2 in the adjacent battery cell block 5 n+2 . Due to the latter potential, the current is collected at the positive plate of the Z-shaped bus bar located at the position of the lower horizontal portion a n+1 of the Z-shaped arrow A n+1 and then guided via the vertical portion b n+1 of the arrow A n+1 to the upper horizontal portion c n+1 of the arrow A n+1 The position of the upper horizontal portion c n+1 corresponds to the position of the negative plate of the Z-shaped bus bar that connects the positive terminal of the battery cell 50 n+1 and the negative terminal of the battery cell 50 n+2 .

[0128] Between the positive terminal of the battery cell block 5 n+2 and the battery cell block 5 n+3A similar process is performed between the negative extreme terminals, such that current flows along the Z-shaped bus bar located at the position of arrow A n+2 Of course, a similar process is also performed between the additional battery cell blocks (not shown) located to the right of the four battery cell blocks 5 n Shown, 5 n+1 Shown, 5 n+2 Shown, 5 n+3 Shown and located to the left of the four battery cell blocks 5 n Shown, 5 n+1 Shown, 5 n+2 Shown, 5 n+3 Shown.

[0129] Figures 6A to 6F Schematically shows the assembly of an embodiment of a battery cell stack according to the present invention. Figures 6A to 6F Is Figures 4A to 4C A continuation of; specifically, Figures 6A - 6C The drawn steps S1 to S3 are the same as the corresponding steps shown in Figures 4A to 4C Shown. Therefore, for simplicity, most of the reference numerals are omitted in Figures 6A - 6C And with regard to the description of steps S1 to S3, reference is made to the above description regarding Figures 4A to 4C Shown.

[0130] According to an embodiment of a method (manufacturing process) for assembling a stack of battery cells according to the present invention, as Figure 4C And Figure 6C Shown, the stack 6 of battery cell blocks (also simply referred to as "stack" 6 below) is further stabilized by two frame beams 71, 72. The length of each of the two frame beams 71, 72 is configured to cover one of the sides of the stack 6. The installation of the frame beams 71, 72 onto the stack 6 is drawn in Figures 6D - 6F Shown. Therefore, after the steps S1, S2 and S3 described with reference to Figures 4A to 4C Shown, the further step S4 shown in Figure 6D Shown is performed. Step S4 includes: a first sub-step S41 of attaching the first frame beam 71 to the left side of the stack 6 (in the orientation shown); and a second sub-step S42 of attaching the second frame beam 72 to the opposite right side of the stack 6. The attachment processes performed in sub-steps S41 and S42 are indicated by the corresponding arrows in Figure 6D Shown.

[0131] Step S4 is also shown by the detailed view of Figure 6E Shown, Figure 6E Shown shows Figure 6D An enlarged intercepted portion of. Again, the arrow indicates how the left side of the stack 6 is connected to the first frame beam 71. The bus bar of the unit brick-shaped body for forming the stack 6 (see the above description regarding Figures 4A to 4C Shown) includes a tab or strip 120. In connection with asFigure 1 and Figure 2 the unit brick-shaped body corresponding to the unit brick-shaped body shown (i.e., each unit brick-shaped body except for the initial unit brick-shaped body 100; see the description in Figures 4A to 4C ), in this case, these tabs or strips are provided by strips 111 and 112 of the positive electrode plate 11, strips 121 and 122 of the negative electrode plate 12, and strips 131 and 132 of the connection plate 13.

[0132] Corresponding to each tab or strip 120 used as a male fastening device, the first frame beam 71 includes a plurality of slots 700, and each slot serves as a female fastening element configured to engage with one of the tabs or strips 120. Of course, the slots 700 are arranged at positions on the first frame beam 71 corresponding to the positions of the tabs or strips 120, such that when the stack 6 and the first frame beam 71 are attached to each other in the expected manner, each tab or strip 120 passes through one of the slots 700. The slots 700 can be implemented as flat openings in the first frame beam 71. Then, as shown in Figure 6F and Figure 7A drawn, after assembling the frame beams 71, 72 and the stack 6 to form the battery cell stack 60, these slots 700 remain visible. The positions of the slots 700 in the first frame beam 71 are also indicated in Figure 6F .

[0133] Figure 6E and Figure 6F explains the interaction between the tabs or strips 120 of the unit brick-shaped body and the slots 700 of the frame beam with respect to the first frame beam 71. It is understood that a similar structure of tabs or strips configured to engage with suitable slots is also provided for mounting the second frame beam 72 to the stack 6.

[0134] Referring to Figures 6D - 6F the result of step S4 explained is an embodiment of the battery cell stack 60 according to the present invention as shown in Figure 7A . Specifically, Figure 7A the battery cell stack 60 shown includes a stack 6 of battery cell blocks as described above with reference to Figure 4C and Figure 6C , and a first frame beam 71 and a second frame beam 72 attached to the sides of the stack 6 of battery cell blocks. The end of the battery cell stack 60 oriented in the x direction of the drawn coordinate system is formed by the negative terminal bus bar E2 described above in the context of Figure 4C . Specifically, the negative terminal bus bar E2 can be used as the negative terminal of the battery cell stack 60.

[0135] In the embodiment shown in Figures 6A to 6F , each Z-shaped bus bar - and thus each unit brick-shaped body - is equipped with three strips 120 in the lateral region, and these three strips 120 are inserted into appropriate slots 700 on the frame beam (see Figure 7B) Then, the main structure connection can thus be established using an adhesive material 702 (see Figure 6F ).

[0136] Figure 7B Schematically shows a part of the frame beam 7 (3D cut-out), and the frame beam 7 can be the first frame beam 71 or the second frame beam 72 as introduced in the context of Figures 6A to 6F and Figure 7A . The sides of the frame beam 7 can be strengthened by a strut structure 720 (rib structure), which includes a plurality of vertical struts (oriented in the z-direction of the coordinate system) and a plurality of horizontal struts (oriented in the x-direction). One functional aspect of the strut structure 720 is to provide improved mechanical stability of the frame beam 7. Another functional aspect of the strut structure 720 is to form a plurality of slots 700 as described in more detail with reference to Figures 6A to 6F .

[0137] The material of the frame beam 7 is a non-conductive material. Preferably, the frame beam 7 (and thus the first frame beam 71 and the second frame beam 72 introduced with reference to Figures 6A to 6F and Figure 7A ) is made of a high-strength plastic.

[0138] Specifically, the high-strength plastic profile of the frame beam 7 can be manufactured using established combination processes. Figure 7B The hatched lines in are the crossbeam structure 750 (H-profile), which further improves the mechanical stability of the frame beam 7. The crossbeam structure 750 can be strengthened with continuous glass fiber filaments (pultrusion technology). Any remaining structures such as the rib structure 720, the fixing points, and the connection areas (slots 700) for the Z-shaped busbar interface (tabs or strips 120; see Figures 6A to 6F ) can be integrally formed by conventional injection molding techniques, i.e., formed as one piece.

[0139] The following will describe the manufacture of an alternative embodiment of the battery cell stack according to the present invention with the aid of Figures 8A to 8D . Figure 8A Shows an example of a stack 6a of battery cell blocks that is substantially corresponding to the stack 6 of battery cell blocks as described with reference to Figures 4A to 4C and Figures 6A to 6F . However, Figure 8A the drawn stack 6a of battery cell blocks includes unit brick-like bodies using a Z-shaped busbar with tabs or strips T, as opposed to the tabs or strips 120 shown in Figures 6A to 6F (or Figure 1The tabs or strips 111, 112, 121, 122, 131, 133) of the Z-shaped bus bar 1 shown are different. The tab or strip T is bent downward along the z-direction or against the z-direction at its outer tip, thereby forming a bent notch. Each of these tabs or strips T includes a pair of drilled holes O arranged thereon, and each drilled hole O is configured to receive a rivet 730.

[0140] A first frame beam 71a and a second frame beam 72a are also provided. The frame beams 71a, 72a may be made of the same material as the frame beams 71, 72 described above for the embodiments Figures 6A to 6F and Figure 7A , Figure 7B introduced. The first frame beam 71a and the second frame beam 72a may each have a U-shaped profile. Specifically, the first frame beam 71a and the second frame beam 72a each include a plurality of drilled holes 711a, 721a that are also configured to receive the rivets 730. Then, the first frame beam 71a and the second frame beam 72a may be attached to the sides of the stack 6a of battery modules such that the positions of the drilled holes O provided in each bent tab or strip T, as observed in a plane parallel to the x-z plane of the coordinate system, correspond to the positions of the drilled holes 711a, 721a provided in the first frame beam 71a and the second frame beam 72a. This is indicated by the dashed line R in Figure 8C .

[0141] Then, in Figure 8B the step S4a shown (which corresponds to Figure 6D the step S4 in the manufacturing process shown, referring to Figure 7A the embodiment of the battery cell stack 60 shown), the first frame beam 71a is attached to the left side of the stack 6a in the first sub-step S41a of step S4a, and the second frame beam 72a is attached to the right side of the stack 6a in the second sub-step S42a of step S4a. The first sub-step S41a and the second sub-step S42a are indicated by arrows in the figure.

[0142] Figure 8C shows Figure 8B a cut-away portion, in which the structural details of the stack 6a and the first frame beam 71a are shown in an enlarged view. In particular, it is indicated that when the first frame beam 71a becomes attached to the left side of the stack 6a, the drilled holes 711a of the first frame beam 71a will overlap with the drilled holes O of the bent tab or strip T.

[0143] Finally, Figure 8D shows the assembled Figure 8CThe same area is depicted, except that the first frame beam 71a and the stack 6a of battery modules are in a state where they are attached to each other. In particular, a rivet 730 has been inserted through the drilled hole 711a of the first frame beam 71a and the drilled hole O of the tab or strip T, such that the first frame beam 71a is permanently fastened to the tab or strip of the Z-shaped busbar employed in the stack 6a of battery modules in Figure 8A the stack 6a of battery modules in

[0144] Figures 8A to 8D The characteristics of the embodiment of

[0145] Reference numerals

[0146] 1 Z-shaped busbar

[0147] 5 Battery unit block

[0148] 5 n 、5 n+1 、5 n+2 、…… Battery unit block

[0149] 6, 6a Stack of battery unit blocks

[0150] 7 Frame beam

[0151] 10 Battery unit brick-like body

[0152] 100, 101, 102, …… Battery unit brick-like bodies

[0153] 11 Positive plate

[0154] 12 Negative plate

[0155] 13 Connection plate

[0156] 21 Positive lead frame

[0157] 22 Negative lead frame

[0158] 23 Pin frame

[0159] 50 Battery cell

[0160] 50 n 、50 n+1 、50 n+2 、…… Battery cells

[0161] 55 Exhaust gas

[0162] 60 Stack of battery cells

[0163] 71, 71a Frame beams

[0164] 72, 72a Frame beams

[0165] 100 Busbar assembly

[0166] 111, 112 Tabs or strips

[0167] 120 Tabs or strips

[0168] 121, 122 Tabs or strips

[0169] 131, 132 Tabs or strips

[0170] 116 Opening in the positive electrode plate

[0171] 126 Opening in the negative electrode plate

[0172] 216 Opening in the positive lead frame

[0173] 216a, 216b, 216c Openings in the positive lead frame

[0174] 226 Opening in the negative lead frame

[0175] 236 Opening in the pin frame

[0176] 238 Chamfered pin

[0177] 700 Groove

[0178] 711a Drilled hole

[0179] 720 Strut structure / rib structure

[0180] 721a Drilled hole

[0181] 730 Rivet

[0182] 750 Crossbeam structure

[0183] 1312 Opening in the Z-shaped busbar

[0184] 2160 Group of openings

[0185] A n 、A n+1 、A n+2 、…… Z-shaped arrow

[0186] a n 、a n+1 Part of the Z-shaped arrow

[0187] b n 、b n+1 Part of the Z-shaped arrow

[0188] c n 、c n+1 Part of the Z-shaped arrow

[0189] Positive extreme busbar of E1

[0190] Negative extreme busbar of E2

[0191] L1, L3 Laser beams

[0192] O Drilling hole

[0193] P2, P3, P4, P5 Arrows

[0194] R Dashed line

[0195] S1, S2, S3, S4, S4a Manufacturing steps

[0196] S11, S12 Sub-steps of step S1

[0197] S3n Sub-steps of step S3

[0198] S41, S42 Sub-steps of step S4

[0199] S41a, S42a Sub-steps of step S4a

[0200] T Drilling hole

[0201] x, y, z Axes of the Cartesian coordinate system

Claims

1. An assembly kit for assembling a carrier frame for stacking a plurality of battery cell blocks, the assembly kit comprising: One or more Z-shaped busbars (1) serving as self-supporting unit carriers and having a Z-shape before being connected to battery cells; A first frame beam (71) and a second frame beam (72), each of the first frame beam (71) and the second frame beam (72) extending along one of the opposite sides of the stack to overlap the plurality of battery cell blocks, and the length of each of the first frame beam (71) and the second frame beam (72) being configured to cover one of the opposite sides of the stack; Wherein each of the Z-shaped busbars (1) comprises: A positive plate (11) configured to be connected to the positive terminal of a battery cell (50) of a battery cell block (5); A negative plate (12) configured to be connected to the negative terminal of a battery cell of another battery cell block; and A connection plate (13) connecting the positive plate and the negative plate, the connection plate (13) facing directly the battery cells in the battery cell block adjacent thereto among the plurality of battery cell blocks and separating the adjacent battery cell blocks among the plurality of battery cell blocks from each other; Wherein each of the Z-shaped busbars (1) further comprises: A first fastening means configured to be fastened to the first frame beam (71); and A second fastening means configured to be fastened to the second frame beam (72); and wherein the first frame beam (71) comprises one or more first fastening elements such that all of the one or more Z-shaped busbars (1) are connected to the first frame beam (71) through the respective first fastening means of the Z-shaped busbars; Wherein the second frame beam (72) comprises one or more second fastening elements such that all of the one or more Z-shaped busbars (1) are connected to the second frame beam (72) through the respective second fastening means of the Z-shaped busbars.

2. The assembly kit according to claim 1, wherein at least one of the Z-shaped busbars (1) is integrally formed.

3. The assembly kit according to claim 1, wherein the connection plate (13) of each of the Z-shaped busbars (1) is configured to separate a pair of battery cell blocks when one battery cell block (5) of the pair of battery cell blocks is connected to the positive plate (11) of the Z-shaped busbar (1) and the other battery cell block of the pair of battery cell blocks is connected to the negative plate (12) of the Z-shaped busbar (1).

4. The assembly kit according to claim 1, Wherein a negative lead frame (22) is provided for at least one of the Z-shaped busbars (1); Wherein the negative lead frame (22) is connectable to a side of the negative plate (12) of the Z-shaped busbar (1) opposite to the side configured to be connected to the negative terminal of the battery cell of the other battery cell block; The negative plate (12) of the Z-shaped bus bar (1) includes a plurality of openings (126), and when the additional battery cell block is connected to the negative plate (12), the plurality of openings (126) are located at positions of the negative terminals of the battery cells of the additional battery cell block; and When the additional battery cell block is connected to the negative plate (12), the negative lead frame (22) can be permanently connected to the negative terminals of the battery cells of the additional battery cell block through the openings (126) in the negative plate.

5. The assembly kit according to claim 4, wherein a positive lead frame (21) is provided for at least one of the Z-shaped bus bars (1); wherein the positive lead frame (21) can be connected to one side of the positive plate (11) of the Z-shaped bus bar (1), and this side is opposite to the side configured to be connected to the positive terminals of the battery cells (50) of the battery cell block (5); The positive plate (11) of the Z-shaped bus bar (1) includes a plurality of openings (116), and when the battery cell block (5) is connected to the positive plate (11), the plurality of openings (116) are located at positions of the positive terminals of the battery cells (50) of the battery cell block (5); and When the battery cell block (5) is connected to the positive plate (11), the positive lead frame (21) can be permanently connected to the positive terminals of the battery cells (50) of the battery cell block (5) through the openings (116) in the positive plate (11).

6. The assembly kit according to claim 5, wherein at least one of the positive lead frames (21) includes a plurality of openings (216), and for each positive lead frame (21) including the plurality of openings (216), when the positive lead frame (21) is connected to the corresponding positive plate (11) of the Z-shaped bus bar (1) that can be connected to the positive lead frame (21), the positions of the openings (216) correspond to the positions of the openings (116) in the positive plate (11); and / or wherein at least one of the negative lead frames (22) includes a plurality of openings (226), and for each negative lead frame (22) including the plurality of openings (226), when the negative lead frame (22) is connected to the corresponding negative plate (12) of the Z-shaped bus bar (1) that can be connected to the negative lead frame (22), the positions of the openings (226) correspond to the positions of the openings (126) in the negative plate (12).

7. The assembly kit according to claim 5, A plurality of first chamfered pins (238) are provided, the plurality of first chamfered pins (238) protruding from the positive electrode plate (11) of at least one of the Z-shaped busbars (1) to one side of the positive electrode terminal of the battery cell (50) of the battery cell block (5) configured to be connected to the positive electrode plate (11), wherein the first chamfered pins (238) are positioned such that when the battery cell block (5) is connected to the positive electrode plate (11), each of the first chamfered pins (238) passes through the gap between the battery cells (50) of the battery cell block (5); and / or A plurality of second chamfered pins are provided, the plurality of second chamfered pins protruding from the negative electrode plate of at least one of the Z-shaped busbars to one side of the negative electrode terminal of the battery cell of the other battery cell block configured to be connected to the negative electrode plate, wherein the second chamfered pins are positioned such that when the other battery cell block is connected to the negative electrode plate, each of the second chamfered pins passes through the gap between the battery cells of the other battery cell block.

8. The assembly kit according to claim 7, A first pin frame (23) is provided for at least one of the Z-shaped busbars (1), the first pin frame (23) being connectable to the positive electrode plate (11) of the Z-shaped busbar (1) or connectable to the positive electrode lead frame (21), the positive electrode lead frame (21) being connectable to the positive electrode plate (11) of the Z-shaped busbar (1), wherein the first chamfered pins (238) protrude from the first pin frame (23), and wherein each of the positive electrode plate (11) of the Z-shaped busbar (1) and the positive electrode lead frame (21) connectable to the positive electrode plate (11) of the Z-shaped busbar (1) includes a drilled hole, and when the first pin frame (23) is connected to the positive electrode plate (11) of the Z-shaped busbar (1) or connected to the positive electrode lead frame (21), the first chamfered pins (238) of the first pin frame (23) are guided through the drilled hole; and / or A second pin frame is provided for at least one of the Z-shaped busbars, the second pin frame being connectable to the negative electrode plate of the Z-shaped busbar or connectable to the negative electrode lead frame, the negative electrode lead frame being connectable to the negative electrode plate of the Z-shaped busbar, wherein the second chamfered pins protrude from the second pin frame, and wherein each of the negative electrode plate of the Z-shaped busbar and the negative electrode lead frame connectable to the negative electrode plate of the Z-shaped busbar includes a drilled hole, and when the second pin frame is connected to the negative electrode plate of the Z-shaped busbar or the negative electrode lead frame, the second chamfered pins of the second pin frame are guided through the drilled hole.

9. The assembly kit according to claim 1, wherein the first fastening means of each said Z-shaped bus bar (1) comprises straps (111, 121, 131), and each said first fastening element of the first frame beam comprises a groove (700) configured to engage with the first fastening means of any one of the Z-shaped bus bars; and / or wherein the second fastening means of each said Z-shaped bus bar (1) comprises straps (112, 122, 132), and each said second fastening element of the second frame beam comprises a groove (700) configured to engage with the second fastening means of any one of the Z-shaped bus bars.

10. The assembly kit according to claim 1, further comprising at least one rivet (730), wherein the first fastening means of each said Z-shaped bus bar comprises at least one drilled hole (O), and each said first fastening element of the first frame beam comprises at least one drilled hole (711a) such that each said first fastening element can be fixed to at least one of the first fastening means by inserting the at least one rivet (730) through the at least one drilled hole (711a) of the first fastening element and through the at least one drilled hole (O) of the first fastening means; and / or wherein the second fastening means of each said Z-shaped bus bar comprises at least one drilled hole, and each said second fastening element of the second frame beam comprises at least one drilled hole such that each said second fastening element can be fixed to at least one of the second fastening means by inserting the at least one rivet through the at least one drilled hole of the second fastening element and through the at least one drilled hole of the second fastening means.

11. The assembly kit according to claim 1, further comprising: a positive terminal bus bar (E1) configured to be connected to the positive terminals of the battery cells of at least one battery cell block; and / or a negative terminal bus bar (E2) configured to be connected to the negative terminals of the battery cells of at least one battery cell block.

12. The assembly kit according to claim 1, the assembly kit being for assembling a stack of battery cells, and for each said Z-shaped bus bar further comprising: a battery cell block, the positive terminals of the battery cells of which can be connected to the positive plate of the Z-shaped bus bar; one additional battery cell block, the negative terminals of the battery cells of which can be connected to the negative plate of the Z-shaped bus bar; wherein the Z-shaped bus bar, the battery cell block and the additional battery cell block are assembled such that each said Z-shaped bus bar is connected to the positive terminals of the battery cells of the battery cell block through the positive plate of the Z-shaped bus bar, and is also connected to the negative terminals of the battery cells of the additional battery cell block through the negative plate of the Z-shaped bus bar.

13. A battery cell stack comprising the assembly kit for assembling a stack of battery cells according to claim 12.

14. A vehicle comprising the battery cell stack according to claim 13.

15. A method for assembling a battery cell stack, the method comprising the following steps: a) providing a plurality of battery cell bricks (10, 101, 102, 103, 104, 105), each battery cell brick (10) including a Z-shaped bus bar (1), the Z-shaped bus bar (1) having a positive plate (11), a negative plate (12) and a connecting plate (13), each battery cell brick (10) further including a battery cell block (5), wherein the positive terminal of the battery cell (50) of the battery cell block (5) is connected to the positive plate (11) of one of the Z-shaped bus bars (1), the Z-shaped bus bar (1) serving as a self-supporting unit carrier and having a Z shape before being connected to the battery cell; b) providing an additional battery cell block (50); c) providing a first frame beam (71) and a second frame beam (72), each of the first frame beam and the second frame beam being configured to be fixed to each of the Z-shaped bus bars; d) connecting the first battery cell brick (101) among the battery cell bricks by connecting the negative plate of the Z-shaped bus bar of the first battery cell brick (101) to the negative terminal of the battery cell of the additional battery cell block (50) provided in step b); e) connecting another one of the battery cell bricks (102, 103, 104, 105) among the battery cell bricks by connecting the negative plate of the Z-shaped bus bar of the another one of the battery cell bricks (102, 103, 104, 105) to the negative terminal of the battery cell of the battery cell block of the first battery cell brick (101) that has been connected in the previous steps among the battery cell bricks (101, 102, 103, 104, 105); f) repeating step e) until each of the battery cell bricks (101, 102, 103, 104, 105) is connected to form a stack of a plurality of battery cell blocks; g) fixing the first frame beam (71) to all of the Z-shaped bus bars of the plurality of battery cell bricks (10, 101, 102, 103, 104, 105), and fixing the second frame beam (72) to all of the Z-shaped bus bars of the plurality of battery cell bricks (10, 101, 102, 103, 104, 105), wherein each of the first frame beam (71) and the second frame beam (72) extends along one of the opposite sides of the stack to overlap the plurality of battery cell blocks, and wherein the connecting plate (13) directly faces the battery cells in the battery cell block adjacent to it among the plurality of battery cell blocks and separates the battery cell blocks adjacent to each other among the plurality of battery cell blocks from each other.

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