Module layer and the battery system built from it

Abstract

This invention relates to a modular layer and a battery system constructed from such a modular layer, the battery system serving as a means for supplying and storing electrical energy between two interlocking terminals, comprising a number of battery modules electrically connected in series with each other. Here, each module consists of a number of basic battery cells, which are typically lithium-ion batteries. To provide the above-mentioned type of device while improving the accessibility of individual battery stacks and their cooling, the modular layer (1) is constructed as a structural unit, in which the battery cells (9) are arranged side by side on the base plate element (3) of the tray (2) and surrounded by an outer frame (4) configured as a heat sink, which serves as the edge of the tray (2), the outer frame (4) having a sealing portion (5) and a section (6) of the modular layer (1) having a central channel (7), into which a busbar (12) electrically connected to the battery cells (9) of the corresponding modular layer (1) extends.

Description

Technical Field

[0001] This invention relates to a modular layer and a battery system constructed from such a modular layer, the battery system serving as a means for supplying and storing electrical energy between two interlocking terminals, comprising a number of battery modules electrically connected in series with each other. Each module consists of a number of basic battery cells, typically lithium-ion batteries. Background Technology

[0002] As is known from the prior art, the above-described type of battery system is constructed using battery modules that are stacked on top of each other in a module-level manner and locked and mechanically fixed between two terminal components, including external connectors, electronic control devices, and safety devices. This results in a battery system composed of stacked, interconnected module levels, as shown in, for example, EP 2343752A2 or DE 102013100545A1.

[0003] In known battery systems, battery cells are arranged in a so-called battery pack level between two plate-shaped terminals, mechanically clamped together as a unit by traction bolts. In such battery systems, the battery cells are also arranged to form a series circuit, for example, by directly connecting the battery cells in series, wherein the positive terminal of one battery cell contacts the cup of the outer casing, and another battery cell in the subsequent layer contacts the negative terminal. This arrangement can be chosen such that the series circuit extends from the start to the end of the battery system on one side and returns from the end to the start on the opposite side. This achieves a low-impedance design with two external connections without requiring a dedicated return conductor, for example, see EP3082174A1.

[0004] US 2013 / 0122341A1 also discloses a structure consisting of a hierarchical or layered battery cell pack, where the electrical connections between the battery cells are different.

[0005] To construct a stacked battery system, it is necessary to connect the individual battery modules of each stage in series and distribute the combined current, or total current, to the individual parallel-connected battery cells. Furthermore, the two potentials of the complete series circuit of the stacked or piled battery system must be concentrated in a high-voltage junction box. Feedback at a battery terminal should not occur outside the casing, because circuit-breaking elements must always be provided before outward guidance, and these circuit-breaking elements are preferably located only within the high-voltage junction box, which is typically a component of one of the terminals.

[0006] While the aforementioned battery systems achieve high energy densities, they rely on the flow of insulating coolant between the battery cells for cooling. Furthermore, a common characteristic of all stacked battery systems is that they are mechanically shortened during assembly directly by inserting and tightening levers. This involves, for example, compressing seals or pressing electrical spring contacts together. In this case, according to the prior art cited above, the layered or stacked structure is always implemented layer by layer; that is, it must be built one layer at a time. Therefore, lower-positioned modules are already wired and thus no longer accessible for, for example, mechanical alignment. Summary of the Invention

[0007] The object of the present invention is to provide a device of the above type, while improving the accessibility of individual battery stacks and their cooling.

[0008] According to the present invention, this task is solved by the following method: the module layer is constructed as a structural unit, wherein the battery unit is arranged in the module layer on the base plate element of the tray and surrounded by an outer frame of the tray, which is constructed as a heat sink. The outer frame of the tray has a sealing part and the tray has a section of central channel in the central region of the base plate element, and a busbar electrically connected to the battery unit of the corresponding module layer extends into the section.

[0009] Compared to known structures, treating each module layer as a unit significantly improves accessibility to such a single battery stack. This allows individual module layers or battery stacks to now be directly replaced as units, something previously impossible in known battery systems. Therefore, the module layer according to the invention also features a heat-conducting section for dissipating heat from the module layer, entering the cooling system through the floor, arranged at the edge of the base plate. In embodiments of the invention, the base plate responsible for dissipating heat from the battery cells is preferably made of aluminum, which conducts the heat loss from the battery cells to the edge of the base plate and there to the wall of the outer frame of the tray, which is constructed as a heat sink. There, the heat is conducted, for example, to the coolant. Furthermore, in each base plate, a section of the central channel is arranged in the central region, where battery cells can be omitted. Therefore, battery cells typically located in the center of the base plate naturally have relatively poor heat dissipation because these cells are, on average, furthest from the edge, and many other battery cells that need heat dissipation also release heat along this path. In other ways, utilizing the hottest area, larger-area cooling at the outer frame improves the cooling or heat dissipation of all battery cells in the module layer. To improve heat dissipation, according to the invention, battery cells are not disposed in the central region of the proposed module layer. More specifically, electrical connections are disposed in sections of the central channel. Preferably, at the center of each module layer, the central channel formed when multiple module layers are stacked is constructed through its sections for heat dissipation in the central region. In this way, such a channel is also advantageously used for additional heat dissipation and for bundling other wires, or signal and / or control lines.

[0010] According to an extended embodiment of the invention, a section of the central channel is disposed in the base plate element surrounding a recess. Here, the section is fixedly arranged as a die-cast part made of plastic or aluminum. The section is constructed, for example, as a rectangular hollow body or a cylindrical hollow body, which is snap-fitted into or around the recess in the base plate element, or is constructed integrally with the tray as an element in the base plate element.

[0011] The following battery system is also an advantageous solution to the aforementioned task: This battery system, serving as a device for supplying and storing electrical energy between two interlocking terminals, has a certain number of module layers of the aforementioned type. The battery system is constructed as a stack of similar module layers in a direction parallel to the longitudinal axis of the battery cells, wherein the sealing portions at the edges of the module layers are electrically and sealingly arranged on the base plate elements of adjacent module layers. Each module layer has a section of a central channel into which a busbar, electrically connected to the battery cells of the corresponding module layer, extends to form a busbar that leads through all module layers to the two external contact electrodes of the battery system.

[0012] Advantageous extensions are the subject of the various dependent claims. Thus, the modules are constructed as prefabricated units in which battery cells mounted in a tray are fixed to a base plate element by means of casting material. This results in a compact unit with considerable mechanical load-bearing capacity, which, during mechanical fixing, is sealed and electrically insulated on its open upper side by means of the base plate element of the subsequent module layer or by means of terminations.

[0013] In a particularly advantageous extension of the invention, a portion of the central channel of each module layer is constructed as a segment or section. This segment is itself divided into spaces that are separated from each other almost over the entire height of the segment, so as to allow, for example, the insertion of a busbar. Thus, each module layer is constructed such that a central channel of a stack of module layers is divided into multiple sub-channels. In this way, sub-busbars and return fluids, as the respective contents of these sub-channels, are separated from each other by the segments and are also electrically and mechanically protected to some extent, as illustrated in the accompanying drawings of the embodiment.

[0014] The central channel advantageously has two separate sections. These sections are spatially separated to accommodate at least two external contact electrode arrangements leading through all module layers to the battery system. The busbars then extend into the section electrically connected to the battery cells of the corresponding module layer in the central region with the worst heat dissipation in each module layer. The subsequently stacked sections of multiple module layers then form the central channel, through which the busbars of all module layers pass to form conductive connections to the two external contact electrodes of the battery system. Besides the possibility of additional heat dissipation directly at the center of each module layer, the central channel also provides ample space to compensate for length variations in the seals, frame, and / or conductors due to mechanical or thermal factors, in the case of electrical and mechanical separation of sub-busbars and busbars.

[0015] In a particularly advantageous extension of the invention, a section of the central channel has a receiving portion that serves to secure or lock the busbar. The busbar is connected to a network via contact points, which interconnects the basic battery cells of the relevant module layer. Temperature differences and vibrations can transmit forces from the battery cells to the busbar. The locking or securing of the section of the central channel counteracts this in a stress-relieving manner. Thus, no additional mechanical stress is introduced into the entire central channel.

[0016] The connector is advantageously constructed in such a way that busbar length compensation is possible only in the direction parallel to the longitudinal axis of the battery cell. Therefore, compensation along the longitudinal axis is possible, while avoiding any loose sections within the described structure.

[0017] Preferably, battery cells in a module layer are electrically connected to each other via contact circuit boards in series and / or parallel sub-circuits. For each polarity, the contact circuit boards are electrically connected to busbars via connecting strips. In an extended embodiment of the invention, the connecting strips are arranged along the opposing outer edges of the contact circuit boards, wherein the connecting strips themselves are configured in a comb shape to provide multiple connectors for rails in or out of the contact circuit boards.

[0018] In an important extension of the invention, at least one sub-bus is provided as an electrical connection between adjacent module layers in the battery system. This sub-bus has a generally S-shaped orientation. At its free end, each sub-bus is configured to contact the end of the section of the busbar extending into the central channel.

[0019] Therefore, form-locking, force-locking, and / or material-locking connections may be optionally provided. Electrical connections are particularly preferred here by means of extrusion or bolting.

[0020] In one embodiment of the invention, the busbar is made of aluminum or copper as a stamped and bent component. In an extended embodiment of the invention, these metal components are coated with an electrically insulating layer, except for the end regions constructed for form-locking, force-locking, and / or material-locking connections. This insulation is preferably implemented as a coating or a flexible hose.

[0021] Thus, the foregoing description describes a battery system composed of modular layers as individual units. This battery system does not rely on the circulation around each individual battery cell for heat dissipation and includes the following electrical connection possibilities: to withstand or compensate for changes in path and spacing between modules due to the tensioning of seals during stacking or stacking; and to receive branch current from each battery cell parallel circuit of a modular layer and to inexpensively, with low loss, and simply distribute such branch current to the first battery cell parallel circuit layer of the next modular layer. Here, these modular layers are preferably always constructed identically. According to the invention, to eliminate the fundamental disadvantage of heat dissipation of battery cells located in the middle of the respective battery stack, battery cells are not placed there at all. Instead, the central region is selected as the location for arranging the electrically connected circuit elements of the modular layers for the corresponding sections of the central channel. The bottom plate of the modular tray has a recess in this region. A generally cylindrical or cylindrical section with a rectangular cross-section is inserted into the recess in the bottom plate element, said section preferably being made of plastic or die-cast aluminum with electrically insulating parts.

[0022] The positive and negative busbars of each module are guided to the corresponding sections of the central channel. At least one guiding busbar is constructed such that, when a module is assembled onto a module below it, it can be directly or indirectly electrically connected to the module below it via additional busbar elements, forming an electrical series circuit. In this case, the at least one busbar is constructed to withstand path or length variations, for example, within approximately 2 mm, occurring between modules during the pressing of the modules into a stacked battery system. For this purpose, necessary space is provided in the top region of the battery cells in the module layer, and the positions of the individual buses are fixed along other spatial axes by means of plastic components.

[0023] To achieve current distribution to the battery cells in a space-saving and weight-reducing manner, distribution rails are placed at the battery cell side ends of the busbar extending towards the central channel. These distribution rails are preferably made of aluminum extrusion profiles cut to length. Advantageously, by selecting extrusion profiles specific to the module, the internal contour of the module wall can be ideally modeled, and the distribution rails can conform to this internal contour. This enables a particularly space-saving and less expensive option compared to copper rails for current distribution to the battery cells. Simultaneously, good heat dissipation is ensured by the distribution rails being fitted to the inner wall of the module housing, which serves as the component housing, behind the module tray frame, where water flows. The resistivity of aluminum, especially various extruded alloys, is slightly higher than that of copper, and therefore not significantly higher in terms of losses. Because the inner wall of the multi-housing frame can be made of plastic, there is no issue of constructing insulation spacing in this embodiment, which is typically the case in the case of metal module housings. For corrosion protection, the busbar extending to the central channel is also preferably made of aluminum.

[0024] The plastic or aluminum sections of the central channel section form multiple conduits. One of these conduits, when the module layers are stacked, forms a hollow cavity extending through all the module layers to accommodate a fully continuous busbar made of aluminum or copper. These busbars form the return path from the rearmost module to the high-voltage junction box.

[0025] Mechanical fixation of these continuous busbars is achieved using individual spacing retaining elements, preferably through the S-shaped meandering structure of the busbars themselves, so that the busbars are pressed against the walls in the continuous hollow cavities and thereby fix themselves in the hollow cavities.

[0026] Advantageously, the central channel, as the sum of interconnected sections, is designed for heat dissipation in the central region of each module layer. To better dissipate heat in the central region of the module layer and in conductors carrying high current loads, the central channel preferably utilizes active ventilation and active air circulation between the high-voltage junction box module with coolant distributor and the terminal pressure plate in the opposite position, thereby improving heat dissipation in the central region. This reduces the temperature difference between individual battery cells and also allows for the dissipation of lost heat from the inside out. Attached Figure Description

[0027] Other features and advantages of embodiments according to the present invention will be described in more detail below with reference to the accompanying drawings. In the schematic drawings:

[0028] Figure 1 A perspective view of a tray is shown, the tray having a base plate element and an outer frame that is adjacent to the edge and terminates at the end side, wherein the base plate element has a section surrounding a central channel of a recess;

[0029] Figure 2 Showing according to Figure 1 A view of a tray filled with basic battery cells that are oriented parallel to each other and arranged vertically.

[0030] Figure 3 A perspective view of the assembly structure of the contact circuit board, connecting strip, and busbar is shown.

[0031] Figure 4 A perspective view showing the fully assembled module layers;

[0032] Figure 5a Showing according to Figure 1 , Figure 2 and Figure 4 A top view of the central passage section;

[0033] Figure 5b Show Figure 5a A cross-sectional view in plane AA;

[0034] Figures 6a to 6c Show Figure 4 A three-dimensional view and a top view of part B;

[0035] Figure 6d Show Figure 4 A 3D view of a local B, with inserted sub-buses;

[0036] Figure 6e Show Figure 6d A three-dimensional view of a portion of C;

[0037] Figure 6f A perspective view of the sub-bus connector is shown;

[0038] Figure 7a and Figure 7b Show Figure 6d A three-dimensional diagram in a plane DD, with inserted and connected sub-buses;

[0039] Figure 8 A perspective view showing the cross-section EE through three module layers, and

[0040] Figure 9 This diagram shows a three-dimensional view of the sub-buses and return buses that pass through 10 module layers. Detailed Implementation

[0041] Throughout the various figures of the accompanying drawings, the same reference numerals are used for the same elements or method steps. Without limiting the invention, the flat, rectangular module layer is shown and described below solely for the purpose of illustrating embodiments of the invention in a battery module with cylindrical battery cells designed for electric vehicles. However, it will be apparent to those skilled in the art that other spatial shapes can be adapted in the same manner, such as using curved module layers instead of flat ones to better utilize existing space. Furthermore, the individual battery cells are not required to be arranged vertically, nor are they necessarily all adjacent to each other.

[0042] The solutions according to the present invention include different combinations of features, particularly defined by the following sequentially numbered embodiments:

[0043] 1. A module layer (1) having a certain number of basic battery cells (9) electrically connected in series and parallel circuits, characterized in that the module layer (1) is constructed as a structural unit, wherein the battery cells (9) of the module layer (1) are arranged in a tray (2) on a base plate element (3) of the tray (2) and surrounded by an outer frame (4) which serves as the edge of the tray (2) and is constructed as a heat sink, the outer frame (4) having a sealing part (5) and the tray (2) having a section (6) of a central channel (7) in the central region of the base plate element (3), wherein a busbar (12) electrically connected to the battery cells (9) of the corresponding module layer (1) extends into the section.

[0044] 2. The module layer (1) according to the aforementioned embodiment is characterized in that each module layer (1) is constructed as a prefabricated unit, in which each battery unit (9) installed in the tray (2) is fixed to the base plate element (3) by means of casting material.

[0045] 3. The module layer (1) according to one of the aforementioned embodiments is characterized in that the bottom plate element (3) of the tray (2) is made of aluminum.

[0046] 4. The module layer (1) according to the foregoing embodiment is characterized in that the segment (6) is disposed in the base plate element (3) around a recess (8), and the segment (6) is fixedly arranged there as a die casting made of plastic or aluminum.

[0047] 5. The module layer (1) according to one of the aforementioned embodiments is characterized in that the segment (6) is constructed as a segment of the central channel (7) and has mutually separated spaces (13, 14, 15) over almost the entire height (H) of the segment (6).

[0048] 6. The module layer (1) according to the foregoing embodiment is characterized in that the central channel (7) has segments separated by mutually separated spaces (13, 15), the spaces being at least for busbars (19, 22) arranged through all module layers (1) to the two external contact electrodes of the battery system.

[0049] 7. The module layer (1) according to one of the aforementioned embodiments is characterized in that the section (6) of the central channel (7) has a receiving part (17) for fixing or locking the busbar (12).

[0050] 8. The module layer (1) according to the foregoing embodiment is characterized in that the receiving part (17) is configured to compensate for the length of the sub-busbar (19) or busbar (12) only in the direction parallel to the longitudinal axis (z) of the battery cell (9).

[0051] 9. The module layer (1) according to one of the foregoing embodiments is characterized in that the battery cells (9) are electrically connected to each other via contact circuit boards (10) in the manner of series and / or parallel sub-circuits, and for each polarity, the contact circuit boards (10) are electrically connected to the busbar (12) via connecting strips (11).

[0052] 10. The module layer (1) according to the foregoing embodiment is characterized in that the connecting strip (11) is arranged along the opposing outer edges of the contact circuit board (10) and is configured in a comb shape.

[0053] 11. A battery system, which serves as a means for supplying and storing electrical energy between two interlocking terminals, comprising a number of module layers (1) according to one of the foregoing embodiments, characterized in that the battery system is constructed as a stack of similar module layers (1) in a direction parallel to the longitudinal axis (z) of the battery cell (9), wherein a sealing portion (5) at the frame (4) of the module layer (1) is arranged electrically and sealingly on the base plate element (3) of the adjacent module layer (1), each module layer (1) having a section (6) of a central channel (7) into which a busbar (12) electrically connected to the battery cell (9) of the corresponding module layer (1) extends to form a busbar (19, 22) leading through all module layers (1) to two external contact electrodes of the battery system.

[0054] 12. The battery system according to the foregoing embodiment is characterized in that, as an electrical connection between adjacent module layers (1), at least one sub-bus (19) or bus (22) is provided, the bus utilizing an S-shaped orientation for connection by form-locking, force-locking and / or material-locking, preferably by extrusion, to contact the free end (16) of the bus bar (12).

[0055] 13. The battery system according to one of the two aforementioned embodiments, characterized in that the busbars (12, 19, 22) are made of aluminum as stamped and bent parts.

[0056] 14. The battery system according to one of the three embodiments described above, characterized in that the busbars (12, 19, 22) are provided with an electrical insulating portion (21) outside the area where a connection for form-locking, force-locking and / or material-locking is constructed.

[0057] 15. The battery system according to one of the four embodiments described above, characterized in that the central channel (7) is constructed as the sum of interconnected segments (6) for heat dissipation in the central region of each module layer (1).

[0058] To illustrate the advantages of the battery system according to the present invention, the progressive construction of module layer 1 is described below. Therefore, Figure 1 A perspective view of tray 2 is shown, which has a base element 3 and an outer frame 4 adjacent to the edge of the base element 3. The outer frame 4 has a double-shell or double-walled structure and terminates at a sealing portion 5 on the end side. The base element 3 also has a section 6 of a central channel 7 in the central region, which is centrally disposed in the base element 3 of tray 2 around a recess 8. In this embodiment, all components of tray 2 are constructed as a single injection-molded part.

[0059] Figure 2 Showing according to Figure 1A view of tray 2, which is filled with basic battery cells 9 oriented parallel to each other. Lithium-ion technology is typically applied to the structure of these cylindrical battery cells 9. The individual battery cells 9, loosely inserted into tray 2, are secured to each other and to base plate element 3 by means of casting material in a method not shown in more detail graphically. This method of securing provides, on the one hand, the construction of the modular layer 1 as both a mechanical and structural unit, and on the other hand, good thermal coupling between the individual battery cells 9 and, in particular, good thermal coupling with the plate-like base plate element 3 for heat dissipation. The base plate element 3 is crucial for heat dissipation of the battery cells 9 and is therefore made, for example, of aluminum. The heat dissipated by the battery cells 9 is conducted through the base plate element 3 to its edges and then to the outer frame 4. The outer frame 4, as the enclosed outer wall of tray 2, is a heat sink, through which the heat dissipated is released to the coolant in a manner not further shown when using the fully assembled battery system. If necessary, the outer wall can also be constructed as a double wall.

[0060] Figure 3 A perspective view is shown, in which the contact circuit board 10 is assembled with the connecting strip 11 and the busbar 12 for the two polarities by bolts. This step completes the interconnection of the individual battery cells 9, through which the battery cells 9 are electrically connected to each other in series and parallel sub-circuits via the contact circuit board 10.

[0061] For each polarity, the contact circuit board 10 is electrically connected to the busbar 12 via connecting strips 11 to achieve the necessary current level and predetermined voltage for a battery system composed of multiple module layers 1, sufficient for use in a car or truck. The total current of the battery system, not shown in detail here, must therefore be distributed to the individual battery cells 9 of the module layer 1 via a network of different conductor segments, and, arguably, must converge again for transmission to the corresponding vehicle in the high-voltage junction box. In this case, the connecting strips 11 are arranged along the opposing outer edges of the contact circuit board 10 and are configured in a comb shape for connection to rails (not shown in detail) on the contact circuit board 10.

[0062] Figure 4 The three-dimensional view of the figures described above shows the assembled module layer 1. Therefore, in conjunction with... Figure 3 The described arrangement for interconnecting the battery cells 9, up to the busbar 12, is placed and secured to the battery cells 9 fixed in the tray 2. Due to heating caused by electrical losses in the battery cells 9, the central region of the tray 2 is always at its highest temperature. Therefore, it is highly advantageous not to place the battery cells 9 directly in this central region, but rather to have well-protected devices for electrical interconnections passing through the various module layers 1 within a compact, integrated structure. For this purpose, a section 6 of the central channel 7 is provided.

[0063] Figure 5a Showing according to Figure 1 , 2 The top view of section 6, which traverses the central channel 7 formed by multiple module layers 1, and section 4. This section 6, made of electrically insulating plastic as an injection molded part, is inserted into the recess 8 at the center of the base plate element 3 and is locked there in a snap-fit ​​manner. (Refer to the section with...) Figure 5a Sectional view in plane AA Figure 5b The section 6, which is constructed here as having a generally square basic plane, is segmented and thus has spaces 13, 14, 15 that are separated from each other over almost the entire height H of the section 6, each of which has a function to be described later.

[0064] Figures 6a to 6c yes Figure 4 The perspective and top views of section B now illustrate the different functions of spaces 13, 14, and 15 within section 6. The central channel 7 has separate sections within section 6, which contains spaces 13, 14, and 15, in which busbars are subsequently installed, extending through all module layers 1 to the two external contact poles of the battery system. For this purpose, spaces 14 and 15 are constructed in a square shape, while space 13 has a generally L-shaped cross-section into which the free ends 16 of the busbars 12 extend. These free ends 16, serving as inflow and outflow points respectively, are arranged staggered from each other, and during the assembly of the battery system from multiple module layers 1, one free end is electrically connected to a subsequent module layer 1 and the other free end is electrically connected to a previous module layer 1.

[0065] Section 6 of the central channel 7 has a receiving portion 17 in the region of space 13 for locking and securing the busbar 12. Here, the receiving portion 17 is constructed such that length compensation of the busbar 12 is possible only in the z-axis direction of a Cartesian coordinate system parallel to the longitudinal axis of the battery cell 9. Correspondingly, the free end 16 of the busbar 12 can also only move in the z-direction within the space 13 of section 6. The receiving portion 17 has spring-loaded locking protrusions that engage with recesses 18 on the free end 16 of the busbar 12.

[0066] Figure 6d yes Figure 4A perspective view of part B, showing inserted sub-buses 19. These sub-buses 19 have curved end regions 20 for contacting the free ends 16 of the busbars 12 fixed in section 6 of the module layer 1 involved, thus having an S-shaped orientation in multiple planes. Referring to the given Cartesian coordinate system, a sub-bus 19 has a generally S-shaped orientation in the xy plane, xz plane, and yz plane. Due to this orientation, the available space inside the L-shaped space 13 is well utilized while optimizing the length compensation of the sub-buses 19. Between the two connection regions connected to the end regions 20, the sub-buses 19 are surrounded by electrical insulators 21, as are the busbars 12 between their respective connection regions.

[0067] Figure 6e Show Figure 6c A perspective view of part C. Enlarged details show how the free end 16 of the busbar 12 is locked in the xy-plane in the receiving portion 17 at the space 13 of segment 6 via a recess 18 near the free end 16, and arranged to be movable in the z-direction within a defined area. This allows the busbar 12 to compensate for tolerances and thermal expansion or contraction in the z-direction.

[0068] Figure 6f yes Figure 6e A perspective view of the connector of the sub-bus 19. The sub-bus 19 extends from the section enclosed by the electrical insulator 21 through the notch-shaped recess 18 to the free end 16.

[0069] Figure 7a and Figure 7b It shows Figure 6d A perspective view of a plane DD with a sub-busbar 19 that is inserted only and electrically connected, the sub-busbar 19 now being connected between the two free ends 16 of the busbars 12 of two module layers 1 stacked sequentially along the z-direction. Figure 7b The initial situation is shown in the dashed area, while Figure 7a The final position of the components fixed to each other is shown. Here, a continuous and sufficiently conductive connection is established by pressing down the corresponding free ends 16 and end regions 20.

[0070] Figure 8 The diagram shows a perspective view of the sub-bus 19 and a section of the return bus 22 in the cross-section EE passing through the three module layers 1. In this case, the sections of the sub-bus 19 and the return bus 22 are guided through the three sections 6 of the module layer 1 in spaces 13 and 15 of the central channel 7, respectively. The wave shape described above is additionally used to secure the sub-bus 19 and the return bus 22 in the respective spaces 13 and 15.

[0071] Reference Figure 7bSpaces 13 and 15 are occupied by busbars after assembly and plating interconnection, while space 14 remains free to accommodate electrical control lines and / or signal lines for subsystems (not further shown) used to regulate the various module layers 1. Furthermore, the entire central channel 7 serves as additional heat dissipation in the area of ​​the described arrangement, which typically experiences the highest temperatures during operation.

[0072] at last, Figure 9 This is a perspective view of the sub-buses 19 (not shown further) and the one-piece return bus 22 of the 10 module layers 1. The entire wave-like shape of the connecting chain, or sub-buses 19 and return bus 22, is used to compensate for manufacturing tolerances and temperature expansion. In the z-direction, compensation is provided by elastic deformation and tolerances, which are generated by contact and connection with the sub-buses 19 for connection to adjacent planes via compression. Finally, in the assembly of the battery system with 10 module layers 1, the return bus 22 passes through the central channel 7 through the insertion space 15 of all module layers 1, and then is electrically connected at the connector 16' to the bus bar 12 of the bottommost module layer 1'. Next, two connectors extend from the topmost module layer 1'', through which there is a total current of 10 module layers 1 connected in series with each other, along with a potential difference of 10 times that of a single module layer 1. A high-voltage junction box (not shown further) is connected here, which is typically part of one of the two terminals of the battery system described. Other end-side enclosures and possible housings of the battery system, as well as the fixing of module layer 1, are not shown either, as they are self-evident when adapted to specific use cases and therefore it is up to those skilled in the art to take known measures.

[0073] Figure 9 The image also illustrates how it is relatively easy to select the necessary current level and predetermined voltage for each module layer 1 with sufficient capacity for automotive, truck, or other applications, and to quickly adjust them. Finally, the length of the return bus 22 is selected solely based on the application and the number of module layers 1. Conversely, all other components remain unchanged as standardized prefabricated modules for this adaptation. This allows for rapid, problem-free, and reliable replacement of any module layer within the battery system, in addition to the freedom to adjust electrical parameters over a wide range.

[0074] List of reference numerals

[0075] 1. Module layer

[0076] 1' The bottommost module layer in a stack or pile

[0077] 1'' The topmost module layer in a stack or pile

[0078] 2 trays

[0079] 3. Base plate components of tray (2)

[0080] 4. The outer frame of the pallet (2) may be double-walled.

[0081] 5. Sealing on the end side of the outer frame (4) of the tray (2)

[0082] 6. Section of the central channel (7) in the base plate component (3)

[0083] 7. Central passageway

[0084] 8 Recess in base plate element (3)

[0085] 9 Basic Battery Cells

[0086] 10 Contact circuit board

[0087] 11 Connecting strip

[0088] 12 busbars

[0089] 13. Separated spaces in section (6) of the central passage (7)

[0090] 14. Separated spaces in section (6) of the central passage (7)

[0091] 15. Separated spaces in section (6) of the central passage (7)

[0092] 16. Free end of busbar (12)

[0093] 17. The receiving part at space (13) that serves as a locking and fixing mechanism

[0094] 18. Recess at the free end (16) of the busbar (12)

[0095] 19. Sub-busbars with an S-shaped orientation

[0096] The curved end region of the 20 sub-busbars (19)

[0097] 21 Electrical insulators

[0098] 22 Return bus (one-piece, wave-shaped)

[0099] Height of the outer frame (4) of tray (2)

[0100] x, y, z are coordinates in a Cartesian coordinate system, with z representing the vertical axis of battery cell 9.

Claims

1. A module layer (1) having multiple battery cells (9) electrically connected in series and parallel circuits, Its features are, The module layer (1) is constructed as a structural unit, wherein the battery cell (9) of the module layer (1) is arranged in the tray (2) on the base plate element (3) of the tray (2) and is surrounded by an outer frame (4) which is configured as a heat sink and serves as the edge of the tray (2). The outer frame (4) has a sealing part (5) and the tray (2) has a section (6) with a central channel (7) in the central region of the base plate element (3). A busbar (12) electrically connected to the battery cell (9) of the corresponding module layer (1) extends into the section.

2. The module layer (1) according to claim 1, characterized in that, Each module layer (1) is constructed as a prefabricated unit, in which each battery unit (9) installed in the tray (2) is fixed to the base plate element (3) by means of casting material.

3. The module layer (1) according to claim 1, characterized in that, The base plate element (3) of the tray (2) is made of aluminum.

4. The module layer (1) according to claim 2, characterized in that, The base plate element (3) of the tray (2) is made of aluminum.

5. The module layer (1) according to claim 1, characterized in that, The section (6) is disposed in the base plate element (3) around a recess (8), and the section (6) is fixedly arranged there as a die casting made of plastic or aluminum.

6. The module layer (1) according to claim 4, characterized in that, The section (6) is disposed in the base plate element (3) around a recess (8), and the section (6) is fixedly arranged there as a die casting made of plastic or aluminum.

7. The module layer (1) according to claim 1, characterized in that, The section (6) is constructed as a segment of the central passage (7) and has mutually separated spaces (13, 14, 15) over the entire height (H) of the section (6).

8. The module layer (1) according to claim 6, characterized in that, The section (6) is constructed as a segment of the central passage (7) and has mutually separated spaces (13, 14, 15) over the entire height (H) of the section (6).

9. The module layer (1) according to claim 1, characterized in that, The central channel (7) has sections separated by mutually separate spaces, which are at least used for sub-busbars (19) and return busbars (22) arranged to the two external contact poles of the battery system through all module layers (1).

10. The module layer (1) according to claim 8, characterized in that, The central channel (7) has sections separated by mutually separate spaces, which are at least used for sub-busbars (19) and return busbars (22) arranged to the two external contact poles of the battery system through all module layers (1).

11. The module layer (1) according to claim 1, characterized in that, The section (6) of the central channel (7) has a receiving part (17) for fixing or locking the busbar (12).

12. The module layer (1) according to claim 10, characterized in that, The section (6) of the central channel (7) has a receiving part (17) for fixing or locking the busbar (12).

13. The module layer (1) according to claim 11, characterized in that, The receiving part (17) is configured to compensate for the length of the sub-busbar (19) or busbar (12) only in the direction parallel to the longitudinal axis (z) of the battery cell (9).

14. The module layer (1) according to claim 12, characterized in that, The receiving part (17) is configured to compensate for the length of the sub-busbar (19) or busbar (12) only in the direction parallel to the longitudinal axis (z) of the battery cell (9).

15. The module layer (1) according to any one of claims 1 to 14, characterized in that, The battery cells (9) are electrically connected to each other via a contact circuit board (10) in series and / or parallel sub-circuits, and for each polarity, the contact circuit board (10) is electrically connected to the bus bar (12) via a connecting strip (11).

16. The module layer (1) according to claim 15, characterized in that, The connecting strip (11) is arranged along the opposing outer edges of the contact circuit board (10) and is configured in a comb shape.

17. A battery system, serving as a means for supplying and storing electrical energy between two interlocking terminals, comprising a plurality of module layers (1) according to any one of claims 1 to 16, characterized in that, The battery system is constructed as a stack of similar modular layers (1) in the direction parallel to the longitudinal axis (z) of the battery cells (9). In this case, the sealing part (5) at the outer frame (4) of the module layer (1) is electrically and sealingly arranged on the base plate element (3) of the adjacent module layer (1). Each module layer (1) has a section (6) of a central channel (7) into which a busbar (12) electrically connected to the battery cell (9) of the corresponding module layer (1) extends to form a sub-busbar (19) and a return busbar (22) that pass through all module layers (1) to the two external contact poles of the battery system.

18. The battery system according to claim 17, characterized in that, As an electrical connection between adjacent module layers (1), at least one sub-bus (19) or return bus (22) is provided, the sub-bus utilizing an S-shaped orientation for contacting the free end (16) of the busbar (12) via form-locking, force-locking and / or material-locking connections.

19. The battery system according to claim 17, characterized in that, The busbar (12) is made of aluminum as a stamped and bent part.

20. The battery system according to claim 18, characterized in that, The busbar (12) is made of aluminum as a stamped and bent part.

21. The battery system according to any one of claims 17 to 20, characterized in that, The busbar (12) has an electrical insulation portion (21) outside the area where a connection for form-locking, force-locking and / or material-locking is constructed.

22. The battery system according to claim 17, characterized in that, The central channel (7) is the sum of the interconnected segments (6) and is used to provide heat dissipation for the central region of each module layer (1).

23. The battery system according to claim 21, characterized in that, The central channel (7) is the sum of the interconnected segments (6) and is used to provide heat dissipation for the central region of each module layer (1).

24. The battery system according to claim 18, characterized in that, The connection of the form-locking, force-locking and / or material-locking is extrusion.

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