Battery system for an electric vehicle and vehicle comprising same

Abstract

The present disclosure relates to a battery system for an electric vehicle and a vehicle comprising the same, the battery system comprising at least one high voltage assembly and a touch protection element for protecting a user from accidental contact with the high voltage assembly, wherein the touch protection element comprises a pivotably mounted isolation flap (12) which is pivotable between a blocking position in which the isolation flap (12) blocks access to the at least one high voltage assembly and an access position in which the isolation flap (12) allows access to the at least one high voltage assembly, wherein the isolation flap (12) is adapted such that if a sufficient force is applied to the isolation flap (12) in the blocking position, the isolation flap (12) is pivoted towards the high voltage assembly into the access position.

Description

Technical Field

[0001] This invention relates to a battery system for an electric vehicle, the battery system comprising a high-voltage assembly and a touch protection element for protecting a user from accidental contact with the high-voltage assembly. The invention also relates to an electric vehicle including such a battery system. Background Technology

[0002] In recent years, vehicles using electricity as a power source for transporting goods and people have been developed. These electric vehicles are automobiles powered by electric motors using energy stored in rechargeable batteries. Electric vehicles can be powered solely by batteries or can take the form of hybrid vehicles powered by, for example, gasoline generators. Furthermore, vehicles can include a combination of electric motors and conventional internal combustion engines. Typically, electric vehicle batteries (EVBs) or traction batteries are batteries used to power the drive of battery electric vehicles (BEVs). Because electric vehicle batteries are designed to provide power for a continuous period of time, they differ from starter batteries, lighting batteries, and ignition batteries. Rechargeable batteries, or secondary batteries, differ from primary batteries in that they can be repeatedly charged and discharged, while primary batteries only provide the irreversible conversion of chemical energy into electrical energy. Low-capacity rechargeable batteries are used as power sources for small electronic devices such as cell phones, laptops, and cameras, while high-capacity rechargeable batteries are used as power sources for hybrid vehicles, etc.

[0003] Typically, a rechargeable battery includes an electrode assembly, a housing containing the electrode assembly, and electrode terminals electrically connected to the electrode assembly, which includes a positive electrode, a negative electrode, and a separator positioned between the positive and negative electrodes. An electrolyte solution is injected into the housing so that the battery can be charged and discharged via electrochemical reactions between the positive and negative electrodes and the electrolyte solution. The shape of the housing (e.g., cylindrical or rectangular) depends on the intended purpose of the battery. Lithium-ion (and similar lithium polymer) batteries are widely known for their use in laptops and consumer electronics and dominate the development of the latest electric vehicle groups.

[0004] Rechargeable batteries can be used as battery modules formed by multiple individual battery cells connected in series and / or parallel to provide high energy density, particularly for electric motor drives in hybrid vehicles. In other words, battery modules are formed by interconnecting the electrode terminals of multiple individual battery cells according to the required electrical power to achieve high-power rechargeable batteries.

[0005] Battery modules can be constructed in a block design or a modular design. In a block design, each battery cell is integrated into a common current collector structure and a common battery management system, and the battery cells are arranged in a housing. In a modular design, multiple battery cells are connected to form submodules, and several submodules are connected to form a battery module. In automotive applications, battery systems typically consist of multiple battery modules connected in series to provide a desired voltage. A battery module may include submodules with multiple stacked battery cells, each stack comprising multiple battery cells connected in parallel (XpYs) or multiple battery cells connected in series (XsYp).

[0006] A battery pack is a group of any number (preferably identical) battery modules. They can be configured in series, parallel, or a combination of both to deliver a desired voltage, capacity, or power density. The components of a battery pack include individual battery modules and interconnects that provide conductivity between the battery modules.

[0007] To meet the dynamic power demands of various devices connected to the battery system, static control of battery power output and charging is insufficient. Therefore, stable information exchange between the battery system and the controllers of the devices is required. This information includes the battery system's actual state of charge (SoC), potential electrical performance, charging capacity, and internal resistance, as well as the actual or predicted power demand or remaining capacity of the devices. Consequently, a battery system typically includes a Battery Management System (BMS) for acquiring and processing this system-level information, and multiple Battery Module Managers (BMMs), which are part of the system's battery modules, for acquiring and processing module-level information. Specifically, the BMS typically measures system voltage, system current, localized temperatures at different locations within the system housing, and insulation resistance between charged components and the system housing. Additionally, the BMMs typically measure the individual cell voltage and temperature of the battery cells within the battery modules.

[0008] Therefore, BMS / BMM is provided for managing battery packs, such as by protecting the batteries from operation outside their safe operating areas, monitoring their status, calculating auxiliary data, reporting that data, controlling their environment, certifying them, and / or balancing them.

[0009] In abnormal operating conditions, the battery pack should typically be disconnected from the loads connected to its terminals. Therefore, the battery system also includes a battery disconnect unit (BDU) electrically connected between the battery modules and the battery system terminals. Thus, the BDU is the primary interface between the battery pack and the vehicle's electrical system. The BDU includes electromechanical switches that open or close high-current paths between the battery pack and the electrical system. The BDU provides feedback to the battery control unit (BCU) accompanying the battery modules, such as voltage and current measurements. The BCU controls the switches in the BDU using low-current paths based on the feedback received from the BDU. Therefore, the primary functions of the BDU can include controlling the current flow between the battery pack and the electrical system, as well as current sensing. The BDU can also manage additional functions such as external charging and pre-charging.

[0010] In electric vehicles, the battery system typically includes a high-voltage battery formed by the battery pack, which serves as the traction battery for driving the electric vehicle. This high voltage typically exceeds 60V. The high-voltage battery and other electrical components connected to it (particularly components of the vehicle's high-voltage grid) carry voltages high enough to endanger humans. For example, contact with live components under high voltage can cause injury to the vehicle's operator or maintenance personnel.

[0011] Therefore, battery systems for electric vehicles include touch protection elements to protect users from accidental contact with high-voltage components. However, many such high-voltage components must be accessible to users, particularly for maintenance or repair purposes, which necessitates the removal of the corresponding touch protection elements. Therefore, for such high-voltage components, the touch protection elements need to be removable and preferably reusable, allowing them to be reattached to the high-voltage components after maintenance procedures are completed.

[0012] To date, such touch protection elements have primarily been applied manually to high-voltage load-bearing components. High-voltage components can be, for example, busbar threaded connections, and the touch protection element can be a separate / loose isolation cap that can be placed on the threaded connection. To provide access to the busbar threaded connection (e.g., tightening or loosening the connection), the isolation cap needs to be removed manually. Furthermore, even if the tightening process itself is automated, subsequent application of the isolation cap must be done manually by the operator. Specifically, for this reason, known touch protection elements for threaded connections are only validated according to the IPXXB standard. Additionally, this is a safety-related process, and documentation of the manual process is crucial. Furthermore, there is a risk of losing the touch protection element, especially during maintenance.

[0013] DE102019128434B3 describes a high-voltage battery comprising multiple battery modules having interfaces covered by flaps, wherein, when a connector moves toward an interface, the flaps are pushed by the connector into an open position away from the interface, thereby providing an opening between the flaps so that the connector can access the interface. This configuration is complex and error-prone, especially due to the specific movement of the flaps away from the interface.

[0014] Therefore, the purpose of this disclosure is to overcome or reduce at least some of the disadvantages of the prior art and to provide a battery system for electric vehicles that includes adequate protection for high-voltage components while still allowing easy access to these components. Summary of the Invention

[0015] The embodiments disclosed herein seek to address at least one problem present in the prior art, to some extent.

[0016] Specifically, the battery system according to the invention includes at least one high-voltage component and a touch protection element for protecting a user from accidental contact with the high-voltage component, wherein the touch protection element includes a pivotally mounted isolation flap that is pivotable between a blocking position and an access position. In the blocking position, the isolation flap blocks access to at least one high-voltage component, and in the access position, the isolation flap allows access to at least one high-voltage component. The isolation flap is adapted such that if sufficient force is applied to the isolation flap in the blocking position, the isolation flap pivots toward the high-voltage component to the access position.

[0017] Battery systems may include high-voltage batteries, particularly high-voltage traction batteries for driving electric vehicles. The high-voltage battery itself and / or any components electrically in contact with the battery can be understood as high-voltage components. Such high-voltage components need to be isolated to avoid endangering the user, while, as explained above, at least some of these high-voltage components need to be accessible, for example, for maintenance. A touch protection element according to the invention is provided that, on the one hand, allows such access, and on the other hand, prevents accidental contact of the high-voltage components by the user (e.g., with their fingers).

[0018] This is achieved via an isolating flap, which, in a blocking position, prevents accidental contact by preventing access to the high-voltage component (e.g., by covering the high-voltage component). In the blocking position, access to the high-voltage component is blocked at least to the extent that accidental contact will not occur. In other words, the isolating flap can be adapted to withstand a force acting in the blocking position to pivot the isolating flap toward the access position, said force typically occurring when the isolating flap is accidentally touched by a person's finger or hand. However, if a sufficiently large force is applied to the isolating flap in the blocking position, the isolating flap pivots to the access position, thereby allowing access to the high-voltage component. Therefore, according to the invention, the isolating flap pivots toward the high-voltage component, rather than pivoting away from the high-voltage component. In other words, by this movement, the distance between the isolating flap and the high-voltage component is reduced, such that at least a portion of the isolating flap is closer to the high-voltage component in the access position than in the blocking position. In particular, the isolating flap can be pivoted toward the high-voltage component, for example, via a tool, to move the isolating flap from the blocking position to the access position. The isolating flap can be used as an electrically insulating member and can be made, in particular, of an electrically non-conductive material.

[0019] This invention's isolation flap offers several advantages over existing technologies. First, it allows easy access to high-voltage components while still providing adequate protection against accidental contact. Unlike detachable or loose touch protection elements, the isolation flap according to the invention, which serves as a touch protection element covering the busbar threaded connection mentioned in the introduction, does not require removal from the high-voltage components to allow access. Instead, the installed isolation flap remains connected to its mounting portion (e.g., an isolation member located at or near the high-voltage components), simply pivoting open to allow access. This allows for easier access to the high-voltage components and also prevents accidental loss of the touch protection element. In particular, manual removal of the touch protection element is eliminated, reducing maintenance and documentation work. Furthermore, the isolation flap can be constructed to meet not only IPXXB but also higher standards, particularly the enhanced safety level of IPXXD. Moreover, because the isolation flap pivots towards the high-voltage components rather than away from them when moving from the blocking position to the access position, the battery system according to the invention is less complex and less prone to errors compared to existing touch protection elements.

[0020] According to an embodiment, the isolation flap is preloaded into a blocking position. Due to the preload, the isolation flap always returns to the blocking position after pivoting away from it. Therefore, when the force applied to the isolation flap (e.g., because the tool has been removed) is no longer large enough to pivot the isolation flap to the access position, the isolation flap springs back to the blocking position. Specifically, the isolation flap is preloaded into the blocking position with a force greater than 1 N. In other words, the isolation flap can be adapted such that the isolation flap pivots from the blocking position toward the high-voltage component only when a force greater than 1 N is applied to it at a right angle. Therefore, according to this embodiment, a force greater than 1 N needs to be applied to the isolation flap at a right angle to pivot the isolation flap from the blocking position to the access position. As mentioned above, this force can be applied by a force-applying tool (e.g., a screwdriver). Therefore, by pivoting the isolation flap toward the high-voltage component to the access position, the force-applying tool can reach the high-voltage component. The isolation flap has resistance to this force, which is sufficient to prevent accidental contact between the user and the high-voltage component. In particular, this resistance is sufficient to meet IPXXD requirements.

[0021] According to an embodiment, the isolation flap is integrally mounted to the isolation member. Integral mounting of the isolation flap to the isolation member can be understood as the isolation flap being mounted to the isolation member at least with respect to non-destructive forces, or non-removably. This connection with the isolation member is particularly robust and sufficient to prevent accidental detachment. According to a corresponding embodiment, the isolation flap is mounted to the isolation member via an integral hinge, which refers to a flexible bearing, particularly a movable hinge, a movable hinge made of the same material as the two components it connects to. Therefore, the isolation member and the isolation flap can be non-removable parts of the same element, particularly made of the same material. In this respect, the term "mounted" can be understood as "connected to". This connection between the isolation flap and the isolation member is particularly robust because it further reduces the risk of losing the touch protection element, especially during maintenance or repair. The isolation member isolates the high-voltage components. The isolation member can form a load-bearing component for supporting (i.e., holding) the isolation flap.

[0022] According to an embodiment, the isolation member isolating the high-voltage component includes an access opening that is covered by an isolation flap in a blocking position and uncovered in an access position. The isolation member isolates the high-voltage component relative to its surroundings, thereby providing electrical insulation. However, the high-voltage component is accessible via the access opening, for example, for maintenance. This access opening is covered by an isolation flap according to the invention to protect the user from accidental contact with the high-voltage component through the access opening. As explained above, the isolation flap can be pivotally mounted to the isolation member, which serves as a load-bearing portion. Such an access opening can be covered particularly simply and securely with the isolation flap according to the invention. According to a corresponding embodiment, the access opening is an opening for inserting a force-applying instrument (especially a screwdriver). Therefore, the opening can have an opening width that allows insertion of the corresponding instrument and access to the high-voltage component.

[0023] The present invention also relates to an electric vehicle comprising a battery system as explained above.

[0024] Other aspects of this disclosure may be understood from the following description. Attached Figure Description

[0025] Features will become apparent to those skilled in the art from the detailed description of exemplary embodiments with reference to the accompanying drawings, in which:

[0026] Figure 1 The invention illustrates an isolation flap and an isolation member supporting the isolation flap, with the isolation flap in a blocking position.

[0027] Figure 2 The isolation flap in the access location is shown. Detailed Implementation

[0028] Referring now to embodiments, examples of which are illustrated in the accompanying drawings. The effects and features of exemplary embodiments and their implementation methods will be described with reference to the drawings. In the drawings, the same reference numerals denote the same elements, and redundant descriptions are omitted. However, this disclosure may be embodied in various different forms and should not be construed as being limited to the embodiments shown herein. Rather, these embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey aspects and features of this disclosure to those skilled in the art.

[0029] Therefore, processes, elements, and techniques that are not considered essential for a full understanding of the aspects and features of this disclosure by those skilled in the art are not described. In the accompanying drawings, the relative dimensions of elements, layers, and regions may be exaggerated for clarity.

[0030] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Furthermore, the word "may" is used in describing embodiments of the invention to mean "one or more embodiments of this disclosure." In the following description of embodiments of this disclosure, singular terms may include plural forms unless the context clearly indicates otherwise. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Expressions such as "at least one of..." modify the entire column of elements when preceding a column of elements, without modifying any individual elements in that column.

[0031] As used herein, the terms “substantially,” “about,” and similar terms are used as approximate terms rather than terms of degree, and are intended to take into account the inherent biases of measured or calculated values ​​that will be recognized by one of ordinary skill in the art. Furthermore, if the term “substantially” is used in conjunction with a feature that can be expressed numerically, the term “substantially” means a value within a range of + / - 5% centered on that value.

[0032] It will also be understood that the terms “comprising,” “including,” or variations thereof, specify properties, areas, fixed quantities, steps, processes, elements, components, and combinations thereof, but do not exclude other properties, areas, fixed quantities, steps, processes, elements, components, and combinations thereof.

[0033] In the following description of embodiments of this disclosure, terms in the singular form may include those in the plural form unless the context clearly indicates otherwise.

[0034] Furthermore, those skilled in the art should recognize that, without departing from the scope of exemplary embodiments of this disclosure, the functions of various computing devices may be combined or integrated into a single computing device, or the functions of a particular computing device may be distributed across one or more other computing devices.

[0035] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will also be understood that terms (such as those defined in a general dictionary) shall be interpreted as having the same meaning as they have in the relevant field and / or the context of this specification, and shall not be interpreted in an idealized or overly formal sense, unless expressly defined herein.

[0036] Figure 1 and Figure 2A portion of a battery system is shown, comprising an isolation flap 12 and an isolation member 10 that carries the isolation flap 12 in its vertical cross-section, thus forming a support portion for the isolation flap. The isolation flap 12 is pivotally mounted to the isolation member 10 via an integral hinge 14. The isolation member 10 also has a horizontal portion including a container 16 for a busbar threaded connection (not shown), the container 16 having an opening 18 for accessing the busbar threaded connection. The busbar threaded connection is a high-voltage assembly that carries a high voltage under operating conditions because it is electrically connected to the HV grid and therefore to the HV traction battery of the electric vehicle.

[0037] The isolation flap 12 can pivot relative to the isolation member 10 between a blocking position and an access position via an integral hinge 14. In the blocking position, the isolation flap 12 blocks access to the busbar threaded connection, and in the access position, the isolation flap 12 allows access to the busbar threaded connection.

[0038] exist Figure 1 As can be seen, the isolation flap 12 is in its blocking position. In this position, the isolation flap 12 blocks access to the opening 18 of the container 16, and thus blocks access to the manifold threaded connection. The isolation flap 12 is preloaded into the blocking position with a force greater than 1 N (Newtons). In the blocking position, the isolation flap 12 covers the opening 18, thus protecting personnel from accidental contact with the manifold threaded connection. To overcome the preload, a force greater than 1 N must be applied to the isolation flap 12 at a right angle relative to its extending plane. This is not typically the case when, for example, a finger of the hand accidentally touches the isolation flap 12.

[0039] exist Figure 2 In the diagram, the isolation flap 12 can be seen in its access position. In this position, the isolation flap 12 allows access to the opening 18 of the container 16, and thus access to the busbar threaded connector. The isolation flap 12 has been pivoted to the access position by a screwdriver 20. A force greater than 1 N is applied to the isolation flap 12 at a right angle via the screwdriver 20, causing the isolation flap 12 to be pushed open, thereby pivoting towards the container 16, and thus towards the busbar threaded connector. Therefore, the busbar threaded connector can be reached and maintained using the screwdriver 20. When the screwdriver is removed from the busbar threaded connector and thus from the container 16, the isolation flap 12 will automatically re-enter the blocking position due to its preload.

[0040] Therefore, the isolation flap allows easy access to the busbar threaded connection while still providing sufficient protection against accidental contact. Unlike detachable or loose contact protection elements (e.g., isolation covers over the busbar threaded connection), the isolation flap according to the invention does not require removal from the busbar threaded connection to allow access. Instead, the installed isolation flap remains connected to the isolation member at all times, only pivoting open to allow access to the busbar screw connection. This allows for easier access to the busbar threaded connection and also prevents accidental loss of the contact protection element. In particular, there are no manually removable contact protection elements (e.g., isolation covers). Furthermore, the isolation flap not only meets IPXXB standards but also IPXXD standards because it withstands more than 1N.

[0041] Figure Labels

[0042] 10. Isolation components

[0043] 12 Isolation Flip-up Panels

[0044] 14 One-piece hinge

[0045] 16 Containers

[0046] 18 Openings

[0047] 20 screwdrivers

Claims

1. A battery system for an electric vehicle, the battery system comprising at least one high-voltage component and a touch protection element for protecting a user from accidental contact with the high-voltage component, wherein, The touch protection element includes an isolation member (10) and an isolation flap (12) pivotally mounted to the isolation member (10), the isolation member (10) including a container (16) for the high-voltage component, the container (16) having an access opening (18) for accessing the high-voltage component, the isolation flap (12) being pivotable between a blocking position and an access position, in the blocking position the isolation flap (12) blocks access to the at least one high-voltage component, and in the access position the isolation flap (12) allows access to the at least one high-voltage component, wherein the isolation flap (12) is adapted such that if sufficient force is applied to the isolation flap (12) in the blocking position, the isolation flap (12) pivots toward the high-voltage component to the access position.

2. The battery system according to claim 1, wherein, The isolation flap (12) is preloaded into the blocking position.

3. The battery system according to claim 2, wherein, The isolation flap (12) is preloaded into the blocking position with a force of at least 1N.

4. The battery system according to claim 3, wherein, The isolation flap (12) is integrally installed onto the isolation component (10).

5. The battery system according to claim 4, wherein, The isolation flap (12) is mounted to the isolation member (10) via an integral hinge (14).

6. The battery system according to claim 5, wherein, The access opening (18) is covered by the isolation flap (12) at the blocking position and is not covered by the isolation flap (12) at the access position.

7. The battery system according to claim 6, wherein, The access opening (18) is an opening for inserting a force-applying device.

8. The battery system according to claim 7, wherein, The force-applying device includes a screwdriver (20).

9. The battery system according to any one of the preceding claims, wherein, The battery system includes a high-voltage traction battery for the electric vehicle.

10. An electric vehicle comprising a battery system according to any one of the preceding claims.

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