Battery pack, system and method

Abstract

The invention relates to a battery pack (1) for a battery device (50), the battery pack (1) having a battery cell pack (2), a connecting device (3) and at least one electrical busbar unit (4) which electrically connects the battery cell pack (2) to the connecting device (3), according to the invention, the busbar unit (4) has an electrically conductive core (5) and an electrically insulating stabilizing body (6), which has an electrically insulating material or is made of an electrically insulating material, the core (5) having a first insertion section (7) facing the connecting device (3) and a second insertion section (8) facing away from the first insertion section (7).

Description

Technical Field

[0001] This invention relates to a battery pack for battery devices, particularly processing devices, charging devices, adapter devices, or battery transport devices. The invention also relates to a system having such a battery device and such a battery pack. Furthermore, the invention relates to a method for manufacturing a bus unit for such a battery pack. Summary of the Invention

[0002] The objective of this invention is to create a battery pack for battery devices, particularly processing devices, charging devices, adapter devices, or battery transport devices, as well as a system having such battery devices and such battery packs, and a method for manufacturing bus units for such battery packs, which have better performance.

[0003] The task is addressed by the subject matter of the independent claim. Preferred embodiments are the subject matter of the dependent claims.

[0004] The battery pack according to the invention is configured for use with battery devices, particularly processing devices, charging devices, adapter devices, or battery transport devices. Especially when the battery device is a processing device, it can operate electrically using energy from the battery pack. The battery device can be correspondingly referred to as a battery-operated or battery-powered device. The battery pack here has individual battery cells for storing electrical energy. The battery pack also has connection means for connecting the battery pack to the battery device. Furthermore, the battery pack has at least one, for example, exactly one or more, electrical bus unit that electrically connects the individual battery cells to the connection means. Here, the bus unit has a conductive core and an electrically insulating stabilizer, wherein the electrically insulating stabilizer is made of or constructed of an electrically insulating material. The core has a first embedded section facing the connection means and a second embedded section facing away from the first embedded section. Furthermore, the core also has a fuse protection section, particularly integrally formed, with a reduced cross-section relative to the two embedded sections. The two embedded sections are electrically and mechanically connected, i.e., particularly physically, via a fuse-protected section. Each of the two embedded sections is embedded in the electrically insulating material of the stabilizer. In this context, "embedded" may mean that the embedded section is completely surrounded by the electrically insulating material along the circumference of the bus unit. The stabilizer also has at least one bridging section that extends between the two embedded sections, spaced apart from the fuse-protected section. The two embedded sections are mechanically, i.e., particularly physically, supported by the bridging section, in addition to their connection via the fuse-protected section. The bus unit, despite being narrowed due to the fuse-protected section, has advantageously proven to be particularly mechanically stable, which simplifies the installation of the battery pack according to the invention.

[0005] The electrical bus unit can be electrically connected to the individual battery cells via a power switch that can be turned on in the battery pack. The power switch can be part of the power electronics of the battery pack. The embedded section can be in direct contact with the material of the stabilizer without intermediaries. The stabilizer can correspondingly be attached to the embedded section without intermediaries or directly. The stabilizer and the embedded section are particularly bonded and / or form-fitted to each other. The fuse protection section can constitute the rated breaking point of the core for automatically interrupting the electrical circuit constructed by the core in the event of overload. The fuse protection section is particularly constructed for automatically interrupting the circuit at current intensities of 100A (Amperes) to 2000A, particularly about 150A. The core can have a larger circuit cross-section next to its fuse protection section, particularly in the embedded section, than the circuit cross-section in the fuse protection section. The cross-sectional area of ​​the circuit can be reduced within the fuse protection zone, particularly narrowed to 0.05 to 0.5 times, particularly 0.1 times, the narrowest cross-sectional area of ​​the core outside or adjacent to the fuse protection zone. The narrowest cross-sectional area of ​​the core outside the fuse protection zone can be 2.4 mm. 2 (cubic millimeters) to 30 mm 2 Especially 10mm 2 .

[0006] The battery pack may be configured to be rechargeable or non-rechargeable. If the battery pack is configured to be rechargeable, then the battery pack may be a storage battery pack. In this case, the battery cell pack is a storage battery cell pack.

[0007] Battery-powered processing equipment can be ground-guided and / or hand-operated, particularly handheld, and / or backpack-type and / or garden, forestry, land, and / or construction processing equipment. Processing equipment can be, in particular, saws, chainsaws, or high-branch trimmers, or hedge trimmers, or bush trimmers, or pruning shears, cutters, or blowers, or leaf blowers, or suction devices, or blade suction devices, or cleaning devices, or pressure cleaners, or sweeping devices, or sweeping rollers, or sweeping brushes, or lawnmowers, or lawn shears, or brush cutters, or rippers. Processing equipment may additionally or alternatively include processing tools and / or, in particular, electrically driven motors for driving the processing tools.

[0008] The drive motor can be powered by a battery pack.

[0009] Electrical devices configured as charging equipment can be power connectors for electrical connection to a power source, such as a power supply network. Charging equipment can be used to charge battery packs.

[0010] A battery device configured as an adapter can be constructed to house a battery pack. Here, the adapter device itself can be connected to a higher-level battery device, allowing the battery pack to be electrically connected to the higher-level battery device via the adapter device. In this respect, the adapter device can function as a battery adapter for interchangeably connecting the battery pack to the higher-level battery device mechanically and / or electrically.

[0011] A battery transport device configured as a battery transport apparatus can be constructed for transporting battery packs. The battery transport apparatus can be configured to detachably and electrically connect an electrical consumer to the battery pack housed within it. In this case, the battery transport apparatus may have at least one electrical output connector for connecting an electrical consumer, wherein the output connector is electrically connected to or to the housed battery pack to supply electrical energy from the battery pack to the connected consumer. Alternatively, the battery transport apparatus may be configured to electrically insulate the housed battery pack.

[0012] In particular, battery devices configured as processing devices, charging devices, adapter devices, or battery transport devices can be configured as backpack-style devices. When a battery device is configured as a backpack device, at least one housing device for accommodating a battery pack can be provided for carrying by a user on the back. For this purpose, the battery device may include a device configured for carrying the housing device by a user. The device may have at least one shoulder strap and / or waist belt and / or chest strap.

[0013] The battery pack can be configured for mechanical connection to battery devices, particularly in a tool-free and / or non-destructive manner, and / or configured to be user-replaceable or user-removable, particularly from battery devices. The battery pack can be particularly configured for carrying via battery devices. A battery cell pack can have multiple battery cells. The battery cells can be arranged, in particular, within the packaging housing of the battery pack. The battery cells can be, or alternatively, additionally, electrochemically based electrical energy storage elements. The battery cells can be, or alternatively, further additionally, ... A single battery cell can be configured to supply electric drive power to a battery device and / or to provide electrical charging power via the battery device.

[0014] The term “configuration” can be used synonymously with the term “construction”.

[0015] The terms “including” or “have” can be used synonymously with the term “have”.

[0016] "Arrangement" can refer to a spatial and / or fixed arrangement, particularly a locational arrangement, especially a fixed one. The term "positioning" may be used additionally or alternatively synonymously with the term "arrangement".

[0017] In the design of this invention, the conductive material of the core is exposed in its fusible protection zone. The core is particularly constructed as a plate, especially wherein the material of the core is a copper plate or has a copper plate. The core can therefore include or be composed of a copper plate. "Exposed" in this context can mean existing without contact with other entities, particularly without contact with stable bodies. The copper plate can include or be composed of a copper alloy. The copper alloy can have at least 50% by weight of copper. The copper plate can be zinc-plated.

[0018] The cross-section of the core outside the fuse protection zone appropriately corresponds to a rectangle having a first side length of 0.3 mm to 1.0 mm and a second side length of 8 mm to 30 mm. The aspect ratio of the rectangle is 3 to 4.

[0019] In a further embodiment of the invention, the core extends longitudinally along the longitudinal direction of the bus unit from its first embedded section to its second embedded section. Here, the core extends laterally along the width direction of the bus unit, perpendicular to the longitudinal direction. The core has a particularly uniform core thickness perpendicular to both the longitudinal and width directions. This core thickness is particularly between 0.3 mm and 1.0 mm, especially 0.5 mm. In this way, a sufficiently large line cross-section can be provided while achieving a sufficiently flat construction of the bus unit.

[0020] In a further embodiment of the invention, the busbar unit is at least partially configured as planar and / or flat and at least partially attached to the battery cell pack. This advantageously results in a particularly compactly constructed battery pack.

[0021] The battery pack appropriately has a generally cylindrical, particularly prismatic, or especially cuboid shape. Here, the longitudinal direction can extend from the circular or polygonal base of the battery pack to the upper side opposite that base. The base and / or upper side can be constructed, for example, as a triangle, rectangle, or octagon. The maximum width of the busbar unit is particularly smaller than the width of the side of the battery cell on which the busbar unit is arranged.

[0022] In a further embodiment of the invention, the stabilizer has a thickness perpendicular to both the longitudinal and width directions. This thickness is typically 1 to 5 times, particularly 3 times, the core thickness. The layer thickness of the stabilizer material can be approximately the same as the core thickness in the core embedding section. The thickness corresponds to the material thickness in the bridging section and is composed of the core thickness and a double layer thickness in the embedding section.

[0023] In a further embodiment of the invention, the stabilizer has two bridging sections arranged opposite each other along the width direction of the busbar unit, positioned on either side of a fuse protection section at a certain distance. Here, the fuse protection section connects the two embedded sections transversely, and particularly perpendicularly, to each other in the width direction. The fuse protection section can have a length of 5 to 30 mm, for example, 23 mm. The transition between each embedded section and the fuse protection section can be rounded. At the transition, the core material can be exposed. The core can thus have a region where the core material is exposed and this region includes the transition and the fuse protection section. This region can have a length of 6 to 35 mm, for example, 25 mm. The region can have a width of 3 to 10 mm, for example, 5 mm.

[0024] Busbar units appropriately have at least partially a substantially straight and / or wavy shape.

[0025] The circuit breaker protection section preferably extends in a generally straight line. However, alternative circuit breaker protection sections can also have a curved, wavy, and / or S-shaped shape. Multiple circuit breaker protection sections can exist, arranged at intervals between each other, and they can be electrically and mechanically interconnected with each other.

[0026] In a further embodiment of the invention, at least one of the embedded sections, particularly each embedded section, has at least one protrusion, particularly nose-shaped or tongue-shaped. This protrusion extends into the gap between the embedded sections of the core and extends along the fuse-protected section. In particular, at least one of the embedded sections, particularly each embedded section, has two such protrusions, which are arranged opposite each other along the width direction of the busbar unit. The embedded sections can function as heat sinks. The protrusions can facilitate the aforementioned heat dissipation function. Furthermore, the protrusions can be embedded as part of the corresponding embedded section in the material of the stabilizer, so that the distance between the embedded sections that needs to be widened by bridging sections can be reduced by means of the protrusions. In this respect, the protrusions can strengthen the support between the embedded sections facilitated by the bridging sections.

[0027] In a further embodiment of the invention, the bus unit has a pair of positioning protrusions in the region of at least one of the two embedding sections, the pair of positioning protrusions being arranged opposite each other along the width direction of the bus unit. The positioning protrusions are specifically provided for the orientation and / or fastening of the bus unit relative to the battery cell pack and / or relative to the connecting device. This orientation and / or fastening can be accomplished by means of the positioning protrusions when the bus unit is engaged to the battery cell pack and / or the connecting device for manufacturing a battery pack. The positioning protrusions can additionally or alternatively be used to orient the bus unit relative to a device by which pre-installation can be performed.

[0028] In a further embodiment of the invention, the first contact section of the core, connected to the first embedded section, is material-fitted and connected to a connecting device, particularly by welding or brazing. The second contact section of the core, connected to the second embedded section, is additionally or alternatively material-fitted and connected to the battery cell pack or to power electronics electrically connected to the battery pack and the battery cells, particularly by welding or brazing. The contact sections can be bent relatively longitudinally to surround the battery cell pack, particularly on the upper and lower sides. This method achieves a particularly reliable connection, especially to meet specification requirements. Furthermore, this method also ensures particularly reliable conductivity. Moreover, the material-fitted connection makes hasty and / or non-compliant repairs of the battery pack difficult in the event of melting or burning before the fuse-protected section.

[0029] In a further embodiment of the invention, the electrically insulating material of the stabilizer is a particularly flame-retardant plastic or includes such a plastic. The two embedding sections are additionally or alternatively coated with plastic surrounding them for their embedding. The stabilizer additionally or alternatively constitutes an injection-molded encapsulation structure of the bus unit, wherein the injection-molded encapsulation structure surrounds the embedded sections of the core.

[0030] The embedded section can be coated with plastic around the circumference of the bus unit. The circumferential direction can extend in a plane perpendicular to the longitudinal direction. The thickness direction of the bus unit can extend perpendicular to both the longitudinal and width directions.

[0031] At least one major component of the plastic may be selected from the group consisting of polybutylene terephthalate (PBT), polyamide (PA), and polypropylene (PP). The plastic may be glass fiber reinforced. For example, the plastic may contain 20 to 40 weight percent glass fiber. PBT GF 30, i.e., polybutylene terephthalate with a 30 weight percent glass fiber share, has proven to be a particularly suitable plastic because it is well-processed and, moreover, meets the standard requirements for flame retardancy particularly well.

[0032] In a further embodiment of the invention, the bridging section protrudes directionally away from the fuse protection section along the width direction of the bus unit, particularly highlighting the value of the free distance between the fuse protection section and the bridging section along the width direction. The free distance can be 1 to 10 mm, for example, 1.5 mm.

[0033] In a further embodiment of the invention, the battery pack has two busbar units, particularly those with identical structures, arranged specifically on opposite sides of the battery pack. The two busbar units are positioned on either side of the individual battery cells. The individual battery cells can be electrically connected, terminal by terminal, to a connecting device via the two busbar units. The battery pack additionally or alternatively has additional electrical safety devices with redundancy relative to the fuse protection section, particularly wherein the additional electrical safety devices have electronic power switches.

[0034] The system according to the invention includes a battery device, particularly a processing device, a charging device, an adapter device, or a battery transport device. Furthermore, the system also includes at least one battery pack according to the invention as described above. In this regard, the advantages of the battery pack listed above can also be applied to the system according to the invention. The battery pack can be electrically connected, in particular, to the battery device to supply power to and / or obtain power from the battery device.

[0035] Busbar units for the battery pack according to the invention can be manufactured as previously described using the method according to the invention. In this respect, the method according to the invention allows full utilization of the advantages of the battery pack according to the invention listed above. Here, according to the method, the stabilizer surrounds the core, particularly using or molded from plastic.

[0036] Busbar units can be manufactured by casting a core using a casting resin for the stabilizer. Alternatively, the core can be inserted into a rubber impregnation tank to form the stabilizer for manufacturing the busbar unit. Another option is to separately manufacture, particularly cast, insulating elements for the stabilizer and then bond the insulating elements together to embed the core.

[0037] In a further embodiment of the invention, the method comprises the steps described below. According to step a), a closable die-casting mold with a cavity having a complementary profile that is complementary to the shape of the stabilizer. According to a further step b), the core is positioned in and / or within the open die-casting mold. According to a further step c), the die-casting mold is closed such that the core is arranged, particularly clamped, within the cavity of the die-casting mold, such that the melt-protected zone is covered. According to a further step d), the stabilizer is cast, wherein the core is injection-molded into the material of the stabilizer next to its melt-protected zone, so that the two embedded sections are embedded in the material of the stabilizer.

[0038] The core can be separated, particularly stamped and / or modified, in time before performing step a). The bus unit can be modified and / or separated in time after performing step d).

[0039] The battery pack according to the invention can be manufactured in such a way that the battery cells of the battery pack or the power electronics of the battery pack that are electrically connected to the battery cells are connected to the battery pack by means of a bus unit manufactured according to the method. Attached Figure Description

[0040] Further advantages and features of the invention will become apparent from the claims and from the following description of preferred embodiments of the invention illustrated with reference to the accompanying drawings. Here, the same reference numerals refer to the same or similar or functionally identical components.

[0041] It goes without saying that the features mentioned above and those to be explained below can be used not only in the combinations described, but also in other combinations or individually, without departing from the scope of the invention.

[0042] Figure 1 An embodiment of the system according to the invention, having one embodiment of the battery pack according to the invention, is shown in a schematic side view;

[0043] Figure 2 The schematic perspective view shows a bus unit manufactured according to the present invention. Figure 1 The battery pack;

[0044] Figure 3 The button is shown separately in the schematic 3D diagram. Figure 2 The bus unit of the battery pack;

[0045] Figure 4 The schematic 3D diagram shows the sectioned arrangement of the... Figure 3 Busbar unit;

[0046] Figure 5 The schematic cross-sectional view shows the arrangement of... Figure 3 and 4 Busbar unit;

[0047] Figure 6 The schematic 3D diagram shows the pressing... Figures 3 to 5 The core of the bus unit; and

[0048] Figure 7 The schematic 3D diagram shows the pressing... Figures 3 to 5 The stabilizer of the bus unit. Detailed Implementation

[0049] The system 100 according to the invention includes a battery device 50. The battery device 50 can be configured as a processing device, a charging device, an adapter device, or a battery transport device. Figure 1 The battery device 50 is configured, for example, as a processing device, existing as a chainsaw. The system 100 also has at least one battery pack 1. The battery pack 1 is, for example, interchangeably connected to the battery device 50 to supply power to the battery device 50. The battery pack 1 is additionally or alternatively connected to the battery device 50 to obtain power from the battery device 50.

[0050] The battery pack 1 has individual battery cells 2 for storing electrical energy. Furthermore, the battery pack 1 includes a connection device 3 for electrically connecting the battery pack 1 to a battery device 50. Additionally, the battery pack 1 has at least one electrical bus unit 4 that electrically connects the individual battery cells 2 to the connection device 3. Currently, there are two electrical bus units 4, which are constructed identically, for example. The two bus units 4 are arranged on opposite sides 22 and 23 of the battery pack 1, positioned on either side of the individual battery cells 2.

[0051] Bus unit 4 has a conductive core 5 and an electrically insulating stabilizer 6, the stabilizer being made of or constructed of an electrically insulating material. The core 5 has a first embedded section 7 facing the connection device 3 and a second embedded section 8 facing away from the first embedded section 7. The core 5 also has a fuse-protected section 9 with a reduced cross-section relative to the two embedded sections 7 and 8, the two embedded sections 7 and 8 being electrically and mechanically connected to each other through the fuse-protected section. The two embedded sections 7 and 8 are respectively embedded in the electrically insulating material of the stabilizer 6. The stabilizer 6 has at least one bridging section 10, which extends between the two embedded sections 7 and 8 at a distance A from the fuse-protected section 9, so that the two embedded sections 7 and 8 mechanically support each other in addition to their connection through the fuse-protected section 9.

[0052] The battery pack 1 may have an additional electrical safety device 24 that is redundant with the fuse protection section 9. Here, the additional electrical safety device 24 may include an electronically operable power switch 25. The electrical bus unit 4 may be electrically connected to the individual battery cells 2 via the power switch 25 of the battery pack 1. The power switch 25 may be a component of the power electronics of the battery pack 1.

[0053] Currently, the stabilizer 6 has two bridging sections 10, which are arranged opposite each other along the width direction B of the busbar unit 4, positioned on both sides of the fuse protection section 9 at a distance A. Here, the fuse protection section 9 connects the two embedded sections 7 and 8 to each other transversely, and particularly perpendicularly, to the width direction B of the busbar unit 4. The fuse protection section 9 is currently arranged between the two bridging sections 10 along the width direction B.

[0054] The embedded segments 7 and 8 come into contact with the material of the stabilizer 6 without any intermediaries and / or directly, that is, the stabilizer 6 is attached to the embedded segments 7 and 8 without any intermediaries or directly. The stabilizer 6 and the embedded segments 7 and 8 are connected to each other in a particularly adhesive and / or shape-fitting manner.

[0055] The fuse protection section 9, which forms the integral structure, includes a rated breakage point for the core 5 to automatically interrupt the electrical circuit constructed from the core 5 in the event of an overload. The fuse protection section 9 is specifically designed to automatically interrupt the circuit under current intensities of 100A to 2000A, particularly about 150A.

[0056] Currently, core 5 has a larger line cross-section beside its fuse protection zone 9, particularly in embedded sections 7 and 8, than the line cross-section in fuse protection zone 9. This line cross-section in fuse protection zone 9 can be reduced, particularly narrowed, to 0.05 to 0.5 times, particularly 0.1 times, the narrowest line cross-section of core 5 outside or beside fuse protection zone 9. The narrowest line cross-section of core 5 outside fuse protection zone 9 can be 2.4 mm. 2 Up to 30mm 2 For example, 10mm 2 .

[0057] The core 5, for example, has a conductive material, which is exposed in the fusible protection zone 9. Here, the core 5 is constructed, for example, as a plate 11, and in particular, the material of the core 5 is a copper plate or has a copper plate. The copper plate comprises a copper alloy having at least 50% by weight of copper or is, for example, composed of said copper alloy. The copper plate may be zinc-plated.

[0058] The core 5 extends longitudinally along the longitudinal direction L of the bus unit 4, for example, from its first embedded section 7 to its second embedded section 8. Here, the core 5 extends laterally to the width direction B of the bus unit 4, transverse to the longitudinal direction L. The core 5 has, at least locally, a particularly uniform core thickness K, perpendicular to both the longitudinal direction L and the width direction B. The core thickness K is, for example, from 0.3 mm to 1.0 mm, particularly 0.5 mm.

[0059] Currently, the busbar unit 4 is constructed at least partially in a planar or flat manner. Here, the busbar unit 4, which is constructed at least partially in a planar manner, is at least partially attached to the battery cell pack 2.

[0060] The battery pack 1 has, for example, a generally cylindrical shape, particularly a prismatic shape, currently a cuboid shape. Currently, the longitudinal direction L extends from the bottom side of the generally rectangular shape of the battery pack 1 to the top side of the generally rectangular shape opposite the bottom side. "Generally rectangular" here refers to the fact that the corners of the bottom or top side may, for example, be rounded. The maximum width of the bus unit 4 is, for example, less than the width of the sides 22, 23 of the battery pack 1.

[0061] The stabilizer 6 has at least a local thickness I in the direction perpendicular to the longitudinal direction L and perpendicular to the width direction B. The thickness I is, for example, 1 to 5 times, particularly 3 times, the core thickness K of the core 5. Here, the layer thickness S of the material of the stabilizer 6 is, for example, approximately the same as the core thickness K in the embedding sections 7 and 8 of the core 5. The thickness I corresponds to the material thickness in the bridging section 10 and is composed of the core thickness K and the double layer thickness S in the embedding sections 7 and 8.

[0062] The fuse protection section 9 has a length of, for example, 5 mm to 30 mm, currently 23 mm. The transition between one of the embedding sections 7 and 8 and the fuse protection section 9 can be rounded. At the transition, the material of the core 5 can be exposed. The core 5 can thus have a region where the material of the core 5 is exposed, and this region includes the transition and the fuse protection section 9. This region can have a length of 6 mm to 35 mm, currently 25 mm. The region can have a width of 3 mm to 10 mm, currently 5 mm.

[0063] At least one of the embedding sections 7 and 8, currently each embedding section, has at least one, particularly nose-shaped or tongue-shaped, protrusion 12. The protrusion 12 extends into the gap 13 of the core 5 that exists between the embedding sections 7 and 8 and extends along the fuse protection section 9. Here, at least one of the embedding sections 7 and 8, currently each embedding section, has two protrusions 12, which are arranged opposite each other along the width direction B of the busbar unit 4.

[0064] The embedded sections 7 and 8 can function as heat sinks. The protrusion 12 enhances the heat dissipation function of the embedded sections 7 and 8. Furthermore, the protrusion 12 can be embedded as part of the corresponding embedded sections 7 and 8 into the material of the stabilizer 6, thereby reducing the distance between the embedded sections 7 and 8 that needs to be widened by the bridging section 10. In this respect, the protrusion 12 improves the support between the embedded sections 7 and 8 facilitated by the bridging section 10.

[0065] Bus unit 4 may have a pair of positioning protrusions 14 in the region of at least one of the two embedded sections 7 and 8. The pair of positioning protrusions 14 may be arranged opposite each other along the width direction B of bus unit 4. Currently, the two embedded sections 7 and 8 have such a pair of positioning protrusions 14. Here, the positioning protrusions 14 are provided, for example, for the orientation and / or fastening of bus unit 4 relative to battery cell pack 2 and, additionally or alternatively, relative to connecting device 3.

[0066] The first contact section 16 of the core 5, connected to the first embedding section 7, is material-fitted to the connecting device 3. The second contact section 17 of the core 5, connected to the second embedding section 8, is additionally or alternatively material-fitted to the battery cell pack 2 or to the power electronics of the battery pack 1 electrically connected to the battery cell pack 2. The material-fitted connection between the first contact section 16 and the connecting device 3 can be achieved by welding or brazing. The material-fitted connection between the second contact section 17 and the battery cell pack 2 or to the power electronics of the battery pack 1 can be achieved by welding or brazing. The contact sections 16 and 17 can be bent relative to the longitudinal direction L as currently described, in order to surround the battery cell pack 2, particularly on the upper and lower sides.

[0067] The electrically insulating material of the stabilizer 6 includes, for example, a particularly flame-retardant plastic or is composed of such a plastic. The two embedded sections 7 and 8 are additionally or alternatively coated with plastic for their embedding. The stabilizer 6 additionally or alternatively constitutes the injection-molded encapsulation structure of the bus unit 4, wherein the injection-molded encapsulation structure surrounds the embedded sections 7 and 8 of the core 5.

[0068] Embedded sections 7 and 8 are coated with plastic around the circumferential direction U of the bus unit 4. The circumferential direction U extends in a plane perpendicular to the longitudinal direction L. The thickness direction D of the bus unit 4 extends perpendicular to the longitudinal direction L and perpendicular to the width direction B.

[0069] Plastics, particularly their main components, can be selected from the group consisting of polybutylene terephthalate (PBT), polyamide (PA), and polypropylene (PP). Plastics can be, for example, glass fiber reinforced. Plastics can, for example, contain 20 to 40 weight percent glass fiber. Currently, the plastic is PBT GF 30, i.e., polybutylene terephthalate with a 30 weight percent glass fiber share.

[0070] Currently, the bridging section 10 protrudes directionally away from the fuse protection section 9 along the width direction B of the bus unit 4. The bridging section 10 protrudes, for example, along the width direction B by the value of the free spacing A between the fuse protection section 9 and the bridging section 10 along the width direction B. The spacing A can be from 1 mm to 10 mm, for example, 1.5 mm.

[0071] The bus unit 4 of the battery pack 1 is currently manufactured using a method in which a stabilizer 6 is formed around a core 5. The stabilizer 6 is, for example, formed of or around the core 5 using plastic. The core 5 can be manufactured by casting synthetic resin. Alternatively, the stabilizer 6 can be manufactured by inserting the core 5 into a rubber impregnation tank made of rubber material. It is also conceivable, in principle, that multiple insulating elements of the stabilizer 6 are pre-formed, for example, die-cast, and bonded together in an embedded arrangement at the core 5.

[0072] However, the stabilizer 6 is, for example, cast. Here, the method may have a first step a), in which a closable die-casting mold with a cavity is provided, wherein the cavity has a complementary profile that complements the shape of the stabilizer 6. The method may also have a step b), in which the core 5 is positioned in / within the open die-casting mold. Another step c) of the method may be followed, in which the die-casting mold is closed so that the core 5 is arranged, particularly clamped, within the cavity of the die-casting mold, such that the melt-protected protection section 9 is covered. Furthermore, the method may have a step d), in which the stabilizer 6 is cast, wherein the core 5 is injection-molded into the material of the stabilizer 6 beside its melt-protected protection section 9, so that the two embedded sections 7, 8 are embedded in the material of the stabilizer 6.

[0073] For example, a separation process in the form of stamping and a modification of core 5 can be performed before step a).

[0074] The battery pack 1 according to the present invention can be manufactured in such a way that the battery cell pack 2 of the battery pack or the power electronic device of the battery pack 1 that is electrically connected to the battery cell pack 2 is electrically connected to the connection device 3 of the battery pack 1 by means of a bus unit 4 manufactured according to the aforementioned method.

Claims

1. A battery pack (1) for a battery device (50), in particular a handling device or a charging device or an adapter device or a battery transport device, wherein: The battery pack (1) comprises: - a battery cell pack (2) for storing electrical energy, - a connecting device (3) for electrically connecting the battery pack (1) to the battery device (50), and at least one electrical busbar unit (4), which electrically connects the battery cell pack (2) to the connecting device (3), wherein the busbar unit (4) comprises an electrically conductive core (5) and an electrically insulating stabilizing body (6), the electrically insulating stabilizing body comprising an electrically insulating material or consisting of an electrically insulating material, - wherein the core (5) has a first embedded section (7) facing toward the connecting device (3) and a second embedded section (8) facing away from the first embedded section (7), wherein the core (5) has a fuse protection section (9) of reduced cross-section relative to the two embedded sections (7, 8), the two embedded sections (7, 8) being electrically and mechanically connected to one another via the fuse protection section, - wherein the two embedding sections (7, 8) are each embedded in the electrically insulating material of the stabilizing body (6), and - wherein the stabilizing body (6) has at least one bridging section (10) which extends between the two embedded sections (7, 8) at a distance (A) from the fuse protection section (9) so that the two embedded embedded sections (7, 8) also mechanically support each other in addition to their connection via the fuse protection section (9).

2. The battery pack (1) according to the preceding claim, -in, The electrically conductive material of the core (5) is present nakedly at its fuse protection zone (9). In particular, the core (5) is designed as a sheet metal part (11), in particular, its material is copper sheet or comprises copper sheet.

3. The battery pack (1) according to any one of the preceding claims, - wherein the core (5) extends longitudinally along the longitudinal direction (L) of the busbar unit (4) from its first embedded section (7) to its second embedded section (8), -in, The core (5) extends transversely to the longitudinal direction (L) along the width direction (B) of the busbar unit (4), wherein the core (5) has, perpendicularly to the longitudinal direction (L) and perpendicularly to the width direction (B), an in particular uniform core thickness (K), in particular wherein the core thickness (K) is 0.3 mm to 1.0 mm, in particular 0.5 mm.

4. The battery pack (1) according to any one of the preceding claims, wherein the busbar unit (4) is at least partially of planar design and rests at least partially against the battery cell pack (2).

5. The battery pack (1) according to any of the preceding claims, in particular according to claim 3, in, The stabilizing body (6) has a thickness (I) perpendicular to the longitudinal direction (L) and perpendicular to the width direction (B), which is 1 to 5 times greater, in particular 3 times greater, than the core thickness (K).

6. The battery pack (1) according to any one of the preceding claims, -in, The stabilizing body (6) has two bridging sections (10), which are arranged opposite to each other along the width direction (B) of the busbar unit (4) so ​​as to be placed on both sides of the fuse protection section (9) at a spacing (A) therebetween. wherein the fuse protection section (9) connects the two embedded sections (7, 8) to one another transversely, in particular perpendicularly, to the width direction (B).

7. The battery pack (1) according to any one of the preceding claims, -in, At least one of the embedded sections (7, 8), in particular each embedded section, has at least one, in particular nose-shaped or tongue-shaped, projection (12), which projects into a gap (13) of the core (5) which exists between the embedded sections (7, 8) and extends along the fuse protection section (9), In particular, at least one of the insertion sections (7, 8), in particular each insertion section, has two projections (12), which are arranged opposite one another along the width direction (B) of the busbar unit (4).

8. The battery pack (1) according to any one of the preceding claims, -in, The busbar unit (4) has a pair of positioning protrusions (14) in the region of at least one of the two embedding sections (7, 8), the pair of positioning protrusions being arranged opposite to each other along a width direction (B) of the busbar unit (4), In particular, the positioning projection (14) is provided for the purpose of orienting and / or fastening the busbar unit (4) relative to the battery cell pack (2) and / or relative to the connecting device (3).

9. The battery pack (1) according to any one of the preceding claims, -in, A first contact section (16) of the core (5) connected to the first embedded section (7) is connected to the connecting device (3) in a materially bonded manner, in particular welded or soldered, and / or - wherein a second contact section (17) of the core (5) connected to the second embedded section (8) is connected to the battery cell pack (2) or to a power electronic device of the battery pack (1) electrically connected to the battery cell pack (2) by a material fit, in particular welded or soldered.

10. The battery pack (1) according to any one of the preceding claims, -in, The electrically insulating material of the stabilizing body (6) is a particularly flame-retardant plastic or comprises such a plastic, and / or wherein the two embedding sections (7, 8) are coated circumferentially with the plastic for their embedding, and / or wherein the stabilizing body (6) forms an injection-molded encapsulation of the busbar unit (4), which surrounds the embedded insertion sections (7, 8) of the core (5).

11. The battery pack (1) according to any one of the preceding claims, in, The bridging section (10) protrudes in a direction away from the fuse protection section (9) along the width direction (B) of the busbar unit (4), in particular protruding the value of a free spacing (A) between the fuse protection section (9) and the bridging section (10) along the width direction (B).

12. The battery pack (1) according to any one of the preceding claims, -in, The battery pack (1) has two busbar units (4) of particularly identical structure, the busbar units being particularly arranged on mutually opposite side surfaces (22, 23) of the battery pack (1) so as to be placed on both sides of the battery cell pack (2); and / or - wherein the battery pack (1) has an additional electrical fuse (24) which is redundant with respect to the fuse protection section (9), in particular wherein the additional electrical fuse (24) has an electronic power switch (25).

13. A system (100), comprising: - a battery device (50), in particular a handling device or a charging device or an adapter device or a battery transport device, and - at least one battery pack (1) according to any one of the preceding claims, - Especially among them, The battery pack (1) is replaceably electrically connected to the battery device (50) so as to supply electrical energy to the battery device (50) and / or obtain electrical energy from the battery device (50).

14. Method for producing a busbar unit (4) for a battery pack (1) according to any one of the preceding claims, in, The stabilizing body (6) is formed around the core (5) and in particular comprises plastic or consists of plastic.

15. The method according to the preceding claim, in, The method comprises the following steps: a) providing a closable injection molding die having a die cavity, wherein the die cavity has a complementary contour which is complementary to the shape of the stabilizing body (6); b) positioning the core (5) at / in the opened die casting mold, c) closing the die casting mold in order to arrange, in particular clamp, the core (5) in the mold cavity of the die casting mold in such a way that the fuse protection zone (9) is concealed; d) Casting the stabilizing body (6), wherein the core (5) is injection-molded around its fuse protection section (9) with material from the stabilizing body (6) in order to embed the two embedding sections (7, 8) in the material of the stabilizing body (6).

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