Contact adapter, bus bar, contact system, contact method and assembly method

Abstract

The invention relates to a contact system, a contact adapter and a bus bar. The contact adapter includes a center contact adapter extending in an axial direction and having a bottom surface for attachment to a center terminal of the battery, an opposite end for passing through a center contact opening of the bus bar, where the end rises from the bottom surface to a center contact height, and a side surface extending between the end and the bottom surface, there is a center contact portion for contacting a center terminal of a center contact opening of a bus bar in a radial direction. Furthermore, the contact adapter comprises a peripheral contact adapter for arrangement around the central contact adapter, the peripheral contact adapter having a base plate for attachment to an annular terminal of the battery and a hollow contact barrel rising in an axial direction from the base plate to a peripheral contact height, and a peripheral contact portion having a peripheral terminal for contacting the peripheral contact opening of the bus bar in a radial direction. The central contact is higher than the peripheral contacts.

Description

Technical Field

[0001] The present invention relates to a contact adapter and a corresponding busbar. The invention also relates to a contact system having such a contact adapter and such a busbar, and a method for contacting a plurality of batteries. The invention also relates to an assembly method for producing a plug-in battery pack. Background Art

[0002] Multiple battery cells are currently connected by welding or gluing to the cell contacting system to achieve seamless connections. This is how parallel and series connections are achieved. For battery packs with more than 1,000 individual cells, this method has disadvantages in terms of process time, post-processing, quality, and reversibility. Summary of the Invention

[0003] The problem underlying the present invention is to provide a monomer contacting system which meets at least one of the above requirements in a better, cheaper or simpler way.

[0004] The above problems are solved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims.

[0005] In a general solution, a plug-in battery pack having multiple batteries is manufactured through an assembly method. The method first involves providing a carrier structure having cell contacts for contacting the multiple batteries, each battery having two concentric terminals arranged together on an end face of the battery extending in the axial direction. The method then involves inserting the multiple batteries into the carrier structure to electrically connect at least two cells via the cell contacts. Prior to the insertion of the multiple batteries, the carrier structure is provided with the cell contacts to contact the batteries in the battery pack. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] For a better understanding of the present invention, the present invention will be explained in more detail with the aid of the exemplary embodiments shown in the following figures. Identical components are thus provided with the same reference numerals and the same component names. Furthermore, individual features or combinations of features of the various examples shown and described may also represent independent, inventive, or inventive solutions in their own right.

[0007] The present invention will now be described with reference to the accompanying drawings.

[0008] This is illustrated by:

[0009] Figure 1 end faces of the contact adapter and the battery before the contact adapter is attached;

[0010] Figure 2 an end face of the contact adapter and the battery after the contact adapter is attached;

[0011] Figure 3 busbars;

[0012] Figure 4 A bus bar having a contact ring;

[0013] Figure 5 according to Figure 4 A cross-sectional view of a contact system having a portion of a bus bar;

[0014] Figure 6 according to Figure 4 A cross-sectional view of a contact system for a module having multiple busbars;

[0015] Figure 7 Figure 6 Top view of the contact system;

[0016] Figure 8 multiple bus bars and insulators;

[0017] Figure 9 A contact system having a battery cell;

[0018] Figure 10 Flowchart for the assembly method,

[0019] Figure 11 a battery pack having a plurality of battery cells, and

[0020] Figure 12 Multiple battery cells. DETAILED DESCRIPTION

[0021] Batteries are becoming increasingly important, particularly in the field of electromobility, placing extensive demands on them.

[0022] For example, it may be desirable to use a battery cell with both terminals on a common surface. That is, the positive (+) and negative (-) terminals are adjacent to each other on a surface or side of the battery. Batteries are typically bipolar, meaning the positive and negative terminals are on opposite sides of the battery. Batteries in which both poles are located on the same surface are sometimes referred to as "monopolar batteries." One advantage of these "monopolar" battery cells is that they can be more compact and easier to handle.

[0023] Furthermore, there are various designs of battery cells, which are used depending on the application and requirements of the battery. For example, there are cylindrical cells, which have the shape of a cylinder. In addition, there are prismatic cells or pouch cells, for example.

[0024] In a "monopole" cell having a cylindrical shape, the terminals are usually arranged concentrically, e.g. Figure 12 shown. Figure 12 A cell system 1000 is shown, consisting of a plurality of six battery cells. Each battery cell has a central terminal 1110, which is typically circular and, in this case, represents the positive (+) terminal. Central terminal 1110 is typically surrounded by a ring terminal 1120, which in this case represents the negative (-) terminal. An insulating region 1130 is located between them. In other words, the two terminals 1110, 1120 and insulating region 1130 are arranged concentrically.

[0025] Concentric refers to an arrangement of shapes or structures having the same center point, in this case the center point of the center terminal 1110. The ring terminal 1120 spaced apart from the concentric terminal in the radial direction R has the same center point as the center terminal 1110 and is thus concentrically arranged.

[0026] In the following description of cylindrical monomers, reference is made to a cylindrical coordinate system. In this case, the monomer extends in an axial direction A, wherein the distance from the axis is represented by the radial axis R. Finally, the circumferential direction U refers to the azimuthal angle.

[0027] In addition to the geometry of the battery cells and the arrangement of the terminals, electrical parameters are often also defined. These include, in particular, the total voltage, capacity, or power. This can be achieved by appropriately connecting the battery cells in series and / or in parallel. This requires the use of a cell contacting system.

[0028] As described above, the above problems are solved by an assembly method. In particular, these problems are solved by a contact system consisting of a contact adapter, a bus bar and an insulator.

[0029] The contact adapter allows the contact to be changed from an axial direction to a radial direction. By arranging peripheral contact adapters around the central contact adapter, ie peripheral contact adapters extending in the circumferential direction U, a partial form fit can be achieved, so that multiple batteries can be inserted via the contact system.

[0030] The busbars are connected in series by means of a bent current busbar portion which makes the height difference between the peripheral contact portion and the peripheral contact heights of two adjacent cells equal in the axial direction.

[0031] In other words, this problem is solved by placing contact adapters at the terminals to establish a plug-in connection. This arrangement is performed at the cell level, for example by welding, and assembly into the battery pack is then performed solely via plug-in connections, simplifying the process. Different adapter heights at the (+) and (-) terminals allow segmented battery cells to be connected at different height levels. This enables a simple modular design.

[0032] Busbars allow for serial plug connections with highly conductive materials such as copper. The plug connection can be optimized by adding stiff spring elements (e.g., steel spring rings) to generate high contact forces. This achieves a friction fit in addition to a positive fit. This ensures the required current-carrying capacity, low component costs, and reliability with respect to vibrations and long-term stability.

[0033] Furthermore, the same busbar can be used multiple times. Adaptation of the busbar only needs to be performed for the first and last segments. This allows the busbar to be manufactured cost-effectively as a stamped part. Furthermore, the modular design enables improved tolerance compensation by connecting smaller sections of cell groups. Furthermore, different circuit configurations, such as varying numbers of battery cells connected in series or parallel, can be easily implemented.

[0034] Furthermore, the required insertion force is reduced by the fact that not all cells of a module are connected simultaneously, but only subgroups.The circuit concept can be adapted to different types of connections between the terminals and the cell contact system.

[0035] The adapter can be implemented directly into the one-piece design to avoid the soldering process.

[0036] The first example relates to a contact adapter for contacting two concentric terminals to a busbar for connecting a plurality of such batteries, the two concentric terminals being arranged together on an end face of the battery extending in the axial direction (A). For a description of such a single unit, please refer to the above Figure 10 Description.

[0037] The contact adapter of the first example includes a central contact adapter extending in an axial direction (A) and peripheral contact adapters to be arranged around the central contact adapter.

[0038] The two parts are supplied separately. They are made of conductive material and can be connected to the battery cell by gluing or welding. Specifically, the connection is non-detachable, meaning it cannot be disconnected without causing damage. Since the connection to the contact adapter is made at the cell level, it can be completed in a compact and easily controlled environment, enabling a high level of precision at the cell level. Alternatively, the two parts of the contact adapter can be connected integrally to the battery cell.

[0039] The peripheral contact adapter extends circumferentially around the central contact adapter. Thus, the peripheral contact adapter extends around the center formed by it and the central contact adapter. The peripheral contact adapter can completely enclose the central contact adapter, i.e., circumferentially enclosing it 360°. Minor deviations from this are conceivable, for example, due to interruptions in the manufacture of the peripheral contact adapter as a stamped and bent component. This arrangement results in the contacts crossing when two adjacent contacts are connected in series, as the peripheral contact adapter must pass radially to make contact with the central contact adapter.

[0040] The center contact adapter includes a bottom surface for attaching the center contact adapter to a center terminal of a battery, a tip opposite the bottom surface for passing through a center contact opening of a busbar, wherein the tip rises from the bottom surface to a center contact height, and a side surface extending between the tip and the bottom surface. The side surface has a center contact portion for contacting the center terminal of the center contact opening of the busbar in a radial direction R.

[0041] This arrangement allows the contact direction at the center terminal of the battery to be reversed, ie from a contact direction perpendicular to the axial direction to a contact direction in the radial direction.

[0042] The tip of the center contact adapter preferably has a smaller diameter than the bottom surface. This allows the bottom surface to achieve maximum contact with the center terminal of the battery, with the center contact adapter also serving as a guide for aligning the busbar relative to the battery cell. This allows for greater tolerances during insertion.

[0043] Advantageously, the central contact portion has a larger diameter than the end portions and a smaller diameter than the bottom surface. Thus, the height of the busbar against the central contact portion can be defined.

[0044] The peripheral contact adapter has a base plate for attachment to a ring terminal of a battery, and a hollow contact barrel that rises from the base plate to a peripheral contact level in an axial direction A. The hollow contact barrel, also known as a contact lamella, has a peripheral contact portion for contacting a peripheral terminal of a peripheral contact opening of a busbar in a radial direction R.

[0045] With this arrangement, the contact direction at the battery's ring terminal (ie, the contact direction perpendicular to the axial direction) can be deflected to a contact direction in the radial direction. This arrangement can also be used for terminals other than the battery's ring terminal.

[0046] The hollow contact barrel is a flat, thin, ribbon-like element. The base plate serves as a carrier structure for the hollow contact barrel. The hollow contact barrel extends parallel to the center contact adapter. Therefore, the center contact adapter and hollow contact barrel can be connected to the busbar in a single mating operation.

[0047] According to a first example, the center contact height is greater than the peripheral contact height.

[0048] The space required for contact in the radial direction is generated by the assembly height in the axial direction A. Different assembly heights enable contact at two different heights. This overcomes the problem of crossed contacts. The busbars described below enable a system in which identical busbars, which can be constructed compactly, can be used for connection. These compact busbars can then be connected with reduced insertion force, increasing installation tolerances and ensuring long-term stability of the contact system, as the flat busbars, for example, can reduce the effects of vibrations.

[0049] The second example relates to the contact adapter according to the first example, wherein the center contact adapter further comprises a shoulder element, wherein the shoulder element protrudes from the side surface in a radial direction. The shoulder element allows the movement of the bus bar to be limited in an axial direction.

[0050] A third example relates to a contact adapter according to one of the above examples, wherein the center contact adapter is designed rotationally symmetrically with respect to the axial direction. This makes it particularly easy to align the battery with the busbar. It is particularly preferred that the center contact adapter is formed as a pin.

[0051] A fourth example is a contact adapter according to one of the above examples, wherein the hollow contact barrel is integrally connected to the base plate. This makes it particularly easy to manufacture the peripheral contact adapter, for example as a stamped and bent part.

[0052] A fifth example relates to a contact adapter according to one of the above examples, wherein the hollow contact cylinder and the base plate have an L-shaped profile. The base plate allows the movement direction of the busbar to be limited to the axial direction.

[0053] A sixth example relates to a contact adapter according to one of the above examples, wherein the base plate is configured to be rotationally symmetrical with respect to the axial direction. In particular, the base plate is annular. Additionally or alternatively, the hollow contact sleeve is configured to be rotationally symmetrical with respect to the axial direction. In particular, the hollow contact sleeve has a separate contact web. This makes it particularly easy to align the battery with the busbar.

[0054] A seventh example relates to a busbar for contacting a plurality of batteries in series via a contact adapter according to one of the above examples, each battery having two concentric terminals arranged together at one end face of the battery and extending in an axial direction A.

[0055] For a description of the contact adapter and battery, refer to the description above.

[0056] The bus bar includes a central bus bar portion, a peripheral bus bar portion, and a bent bus bar portion.

[0057] These three parts are inseparably connected. For example, the busbar can be manufactured from a single sheet of metal as a stamped and bent part. The busbar is made of a conductive material, preferably copper. This allows the busbars to be connected in series, with the arrangement providing sufficient space for the insulators.

[0058] The center busbar portion has a center contact opening for passing a center contact adapter through the center contact opening. The center contact adapter has a side surface extending in the axial direction, and the center terminal is configured to contact the side surface of the center contact adapter in the radial direction. This arrangement allows the busbar to be plugged into the center contact adapter in the axial direction. Furthermore, this arrangement enables a partial form-fit connection between the busbar and the center contact adapter.

[0059] The center terminal can, for example, be arranged on the inner surface of the center contact opening or form the center contact opening. This allows for a particularly compact design. Furthermore, the center terminal can facilitate frictional connection. This can also simultaneously improve electrical conductivity, for example by removing oxide layers during connection.

[0060] The peripheral busbar portion has a peripheral contact opening for passing through a hollow contact barrel of the peripheral contact adapter, which extends in the axial direction A to the height of the peripheral contact, and a peripheral terminal for contacting the peripheral contact portion of the hollow contact barrel in the radial direction (R) at the height of the peripheral contact portion. This arrangement allows the busbar to be plugged into the peripheral contact adapter in the axial direction. Furthermore, this arrangement enables a partial form-fit connection between the busbar and the peripheral contact adapter.

[0061] The peripheral terminals can advantageously form the inner surface of the peripheral contact opening. This enables a particularly compact design. Furthermore, the peripheral terminals can facilitate frictional connection. Thus, the peripheral terminals can also increase electrical conductivity, for example by removing oxide layers during connection.

[0062] Furthermore, the busbar has a bent busbar portion disposed between the central busbar portion and the peripheral busbar portion. The bent busbar portion serves to compensate for a height difference in the axial direction A between a height of the peripheral contact portion and a height of the peripheral contact.

[0063] The bend in axial direction A allows the contacts of two adjacent cells to cross, thus connecting them in series. The height difference makes it particularly easy to insert insulation in the intermediate area. This has the particular advantage of allowing the use of multiple identical, compactly designed busbars for connection. These compact busbars can then be connected with reduced insertion force, increasing installation tolerances and ensuring long-term stability of the contact system, as the flat busbars, for example, reduce the effects of vibrations.

[0064] An eighth example relates to a busbar according to example seven, wherein the central terminal has a plurality of individual contact wings that protrude axially from the central contact opening. Additionally or alternatively, the peripheral terminals have a plurality of individual contact wings that protrude axially from the peripheral contact openings. The individual contact wings enable easy manufacture as stamped and bent parts. Furthermore, the contact wings enable a compact design, as they can be arranged on the inside of the opening. Furthermore, the individual contact wings enable adjustment of requirements such as clamping force and insertion force.

[0065] A ninth example relates to the busbar according to any one of examples seven to eight, wherein the busbar further comprises a contact ring, wherein the contact ring is arranged axially at the central contact opening and / or the peripheral contact opening. The contact ring can increase the contact surface in the axial direction. The larger surface area reduces the contact resistance.

[0066] Advantageously, the central terminal and / or the peripheral terminals surround the contact ring, for example, using contact wings as described in the eighth embodiment. This further reduces contact resistance because the terminals can be made of a highly conductive material, such as a busbar, and / or can be integrally formed with the busbar.

[0067] The tenth example relates to the busbar according to Example 9, wherein the contact ring is composed of a harder material than the busbar. Typically, the busbar and the two parts of the contact adapter are made of a highly conductive but soft material, such as copper. The contact ring can be made of a harder material, thereby increasing the frictional connection, also known as force closure. This reduces contact resistance by enabling greater contact force. Furthermore, the rigid contact ring facilitates the removal of oxide layers, either directly through the contact ring or indirectly via the contact terminals, as described above in Examples 8 and 9.

[0068] An eleventh example relates to a busbar according to one of the ninth and tenth examples, wherein the contact ring has a groove. The groove allows the contact force of the contact ring to be set. In this case, the groove extends in the radial direction.

[0069] A twelfth example relates to a busbar according to any one of examples seven to eleven, wherein the diameter of the central contact opening is smaller than the diameter of the peripheral contact openings. This increases the contact surface, as both openings are adapted to the diameter of the corresponding contact adapter. The diameters are measured in the radial direction.

[0070] A thirteenth example relates to a bus bar according to any one of Examples 7 to 11, wherein the central bus bar portion, the bent bus bar portion, and the peripheral bus bar portion together follow the shape of a ball bar in a plane perpendicular to the axial direction, wherein the peripheral bus bar portion forms a wider end portion of the ball bar that tapers toward the central bus bar portion at the bent bus bar portion. Thus, the bus bar can be made compact, and the force required to compensate for height differences by bending the bus bar portion can be minimized.

[0071] A fourteenth example relates to a contact system comprising a plurality of contact adapters according to any one of Examples 1 to 6, a bus bar according to any one of Examples 7 to 13, and an insulator, wherein the insulator has an insulator portion extending perpendicular to the axial direction, wherein the insulator portion completely covers at least a peripheral bus bar portion to prevent a short circuit between the peripheral contact adapters and the center contact adapter of one of the plurality of batteries. In this manner, the contact system allows two batteries to be connected in series.

[0072] A fifteenth example relates to a method for contacting a plurality of batteries, the method comprising:

[0073] attaching a contact adapter according to one of Examples 1 to 6 to each of a plurality of batteries;

[0074] connecting two battery cells in series to a bus bar according to one of Examples 7 to 13;

[0075] The peripheral bus bar portion of the battery cell is covered with an insulator.

[0076] A sixteenth example relates to an assembly method for producing a plug-in battery pack including a plurality of batteries, the assembly method comprising:

[0077] providing a carrier structure having cell contacts for contacting a plurality of batteries, each battery having two concentric terminals arranged together on one end face of the battery extending in the axial direction, and

[0078] A plurality of batteries are inserted into the carrier structure so that at least two batteries are electrically connected via the cell contacts.

[0079] Therein, before a plurality of batteries are inserted to form a plug-in battery pack, a carrier structure with cell contacts is provided.

[0080] A battery pack (or battery module) is an arrangement of battery cells that work together to provide greater capacity and power than a single battery could provide.

[0081] The carrier structure allows the components of the battery pack to be held. These components include, in particular, the batteries. For a description of the batteries, reference is made to Examples 1 to 15 above.

[0082] Furthermore, the carrier structure includes cell contacts, for example, the carrier structure is made of an insulating material such as plastic, and the cell contacts are made of a conductive material such as metal for electrically contacting the cells.

[0083] The carrier structure is provided with the cell contacts before the cells are inserted. This allows the cells to be contacted solely by friction connection, without the need for material connections such as welding or soldering.

[0084] In a friction connection, components are held together by frictional forces. These frictional forces are generated when the components are pressed against each other. In a material connection, components are joined by molecular or atomic forces, resulting in a strong, non-detachable connection. This connection is created by combining the materials, typically through melting or chemical processes.

[0085] This means that instead of attaching the cell contacts to the preassembled battery, the battery is inserted into the cell contacts. The battery is thus removably held in the carrier structure.

[0086] Inserting the battery into the carrier structure makes assembly, maintenance and disassembly easier for the user.

[0087] A seventeenth example relates to the assembly method according to example sixteen, wherein at least the battery cell has a contact adapter according to one of examples 1 to 6 and / or the cell contact includes a bus bar according to one of examples 7 to 13.

[0088] An eighteenth example relates to an assembly method according to example sixteen or seventeen, wherein a plurality of cells are inserted into the carrier structure one after the other. This simplifies assembly, in particular because tolerances in cell alignment can be more easily maintained.

[0089] Example 19 relates to an assembly method according to any of Examples 16 to 18, wherein each battery cell has a bottom surface opposite the end surface, and the assembly method further comprises covering the bottom surfaces of the plurality of batteries with a cell retainer to secure the batteries in the battery pack. This prevents the batteries from accidentally coming loose when inserted into the battery pack. The cell retainer may be, for example, a housing that encloses the battery pack and, in particular, seals it against the medium. Advantageously, the cell retainer is retained on a carrier structure. Alternatively or additionally, the batteries may be secured by screws.

[0090] In the nineteenth example, it is particularly preferred to cover the bottom surface after inserting the bottom surface into the carrier structure.

[0091] A twentieth example relates to an assembly method according to any one of Examples 16 to 19, wherein the carrier structure further comprises a thermal coupling element and / or a heat conducting element for thermally coupling the cell contact to the heat conducting element, the heat conducting element for transferring heat out of the battery pack including the cell contact. This allows for efficient heat dissipation from the plug-in battery pack, which has a higher contact resistance due to the frictional connection than a material-locked connection.

[0092] In the twentieth example, it is particularly preferred that the thermal coupling element comprises an electrically insulating material. Thus, it can be connected to the battery in thermally conductive contact. Additionally or alternatively, the thermally conductive element may have a higher thermal conductivity than the thermal coupling element. For example, the conductive element may be composed of metal, or the thermally conductive element may include active cooling, such as a liquid cooling system. Additionally or alternatively, the conductive element may include cooling fins.

[0093] Figure 1 A contact adapter is shown having a center contact adapter 110 and a peripheral contact adapter 120. The center contact adapter 110 and the peripheral contact adapter 120 are made of a conductive material, such as copper.

[0094] The center contact adapter 110 is adapted to be attached to the bottom surface 112 at the center terminal 1110 of the battery 1100. The peripheral contact adapter 120 is adapted to be arranged with a bottom plate 122 at the ring terminal 1120 of the battery 1100. In particular, the center contact adapter 110 and the peripheral contact adapter 120 can be arranged on the terminals 1110, 1120 of the battery 1100 by welding, gluing or similar connection techniques. Alternatively, they can be manufactured integrally with the battery. Arrangement state, for example, Figure 2 Shown in.

[0095] The peripheral contact adapter 120 is arranged around the center contact adapter 110. In other words, the peripheral contact adapter 120 is positioned opposite to at least two opposite side surfaces of the center contact adapter 110. Figure 1 and Figure 2 In the cross-sectional view in FIG, the extent of the contact adapter in the circumferential direction U is not shown. The central contact adapter 110 and the peripheral contact adapter 120 can have the same symmetry as the battery in the circumferential direction U. In particular, if the battery is as Figure 10 For cylindrical batteries as shown, they can be rotationally symmetric about the axial direction A.

[0096] like Figure 1 and Figure 2As shown, the bottom surface 112 of the center contact adapter 110 can cover a surface area equivalent to that of the center terminal 1110 of the battery. Specifically, the dimensions in the radial direction R can be the same or similar. However, this is not required. For example, as shown in the figure, for the bottom plate 122 of the peripheral contact adapter 120, the surface area of the bottom plate 122 can be larger than that of the ring terminal 1120.

[0097] like Figure 1 and Figure 2 As shown, the inner radius of the bottom plate 122 of the peripheral contact adapter 120 in the radial direction is larger than the outer circumference of the bottom surface 112 of the center contact adapter 110. Therefore, it is possible to avoid a short circuit between the center contact adapter 110 and the peripheral contact adapter 120. The radial dimensions of the bottom surface 112 and the bottom plate 122 are determined by the size of the battery terminals 1110 and 1120, the required insulation distance, and the available contact surface.

[0098] To attach the contact adapter 100 to the battery cell 1100, the center contact adapter 110 and the peripheral contact adapter 120 can be held by a socket (not shown) and thus attached in a single process step to corresponding terminals of the battery 1100. The socket can also be held in place, for example, to serve as additional insulation.

[0099] Alternatively, the two parts 110 and 120 of the contact adapter 100 may be attached to the battery cell 1100 one after the other in two process steps.

[0100] In both cases, the configuration shown is preferred because the process steps for attaching the contact adapters are performed at the unit level. This allows high tolerances to be maintained and allows the center contact adapter 110 to be aligned to the peripheral contact adapters 120 with high precision.

[0101] In addition to the radial direction R, the center contact adapter 110 and the peripheral contact adapter 120 also extend in an axial direction A.

[0102] The center contact adapter 110 is pin-shaped in the axial direction and is also referred to as a pin, ie, it has a columnar structure. The center contact adapter 110 includes the aforementioned bottom surface 112 , which may be formed as a base plate having a thickness in the axial direction A.

[0103] Adjacent the bottom surface 112, the center contact adapter 110 includes a shoulder portion having a shoulder element 116. The shoulder portion is adjacent one end of the bottom surface 110, and the shoulder element 116 may have a smaller diameter than the bottom surface 110 in a radial direction.

[0104] The tip portion having the tip 114 abuts the shoulder member 116 of the center contact adapter 110. The tip 114 may have a smaller diameter in the radial direction R than the tip portion, and the tip portion may have a smaller diameter in the radial direction than the shoulder member 116.

[0105] In the contact system 10, for example Figure 5 As shown, the shoulder member 116 limits movement of the bus bar 200 in the axial direction A.

[0106] like Figure 1 and Figure 2 As shown, the peripheral contact adapter 120 includes the aforementioned base plate 122. From the base plate 122, a hollow contact barrel 124 extends in the axial direction A. Figure 1 It is not visible in the cross-sectional view in FIG, but the base plate 122 can be annular. The hollow contact barrel 124 can follow the edge of the base plate 122 in the form of a strip, or can be composed of multiple contact webs. Thus, the peripheral contact adapter 120 can be manufactured particularly easily as a stamped and bent part.

[0107] The bottom plate 122 may be annular. It has an inner diameter R1 and an outer diameter R2. The hollow contact cylinder 124 may be arranged on the inner diameter R1. Figure 1 and Figure 2 In the embodiment shown, the hollow contact cylinder 124 is arranged at a right angle to the base plate 122. However, the hollow contact cylinder can also be arranged at an acute angle 124 to the axial direction A on the base plate.

[0108] In the assembled state, Figure 2 As shown, the center contact adapter 110 has a center contact portion 118 on a side surface that extends between the tip 114 and the bottom surface 112. In particular, the center contact portion 118 is disposed between the shoulder element 116 and the tip 114. Similarly, the peripheral contact adapter 120 has a peripheral contact portion 128 disposed on the hollow contact barrel 124. Figure 2 As shown, the peripheral contact portion 128 and the central contact portion 118 are separated from each other in the radial direction. In addition, the contact adapter 100 increases the contact area of the battery in the axial direction A.

[0109] In addition, from Figure 2 As can be seen in FIG, the hollow contact tube 124 extends all the way to the peripheral contact height Hp. The end 114 extends upward to the center contact height Hz. The center contact height Hz is farther away from the battery installation distance in the axial direction A than the peripheral contact height Hp. Due to these different heights, it is possible to use Figures 3 to 5Furthermore, alignment of the bus bar 200 with the contact adapter is facilitated because the bus bar 200 is first aligned with the pin-shaped ends of the center contact adapter.

[0110] As mentioned above, Figure 1 and Figure 2 The contact adapter 100 contacts the battery and the bus bar 200, which Figures 3 to 5 Shown in detail.

[0111] Figure 3 The bus bar 200 includes a central bus bar portion 210, a peripheral bus bar portion 220, and a bent bus bar portion 230 disposed between the central bus bar portion 210 and the peripheral bus bar portion 220. The bus bar 200 extends perpendicular to the axial direction A, that is, in the radial direction R and in the circumferential direction U.

[0112] Here, the busbar 200 includes a plurality of 2×13 center busbar sections 210, 210′, 210″, a plurality of 2×13 peripheral power busbar sections 220, 220′, 220″, and a plurality of 13 bent busbar sections 230, 230″. This plurality of sections allows a plurality of 2×13 cells to be contacted in parallel at one terminal and 2×13 cells to be contacted in parallel at another terminal. Each of the terminals is then contacted in series to the other terminal via the busbar 200.

[0113] In other examples not shown, the central bus bar portion includes only one central bus bar portion 210 and one peripheral bus bar portion 220. Each pair of the central bus bar portion 210 and the peripheral bus bar portion 220 allows two adjacent terminals to be connected in series.

[0114] Each center busbar portion 210 of the busbar 200 includes a center contact opening 212 defined by side surfaces. The center contact opening 212 is larger than the diameter of the distal end 114 of the center contact adapter in the radial direction R. A center terminal 218 extends from one side surface of the center contact opening 212. Here, the center terminal 218 is composed of a plurality of five individual contact wings. As will be described later in Figure 4 As described in , the wings are curved. This increases the contact surface in the axial direction A.

[0115] Similar to the central busbar portion 210, each of the peripheral busbar portions 220 has a peripheral contact opening 222. The peripheral contact opening 222 is larger than the diameter of the hollow contact barrel 124 of the peripheral contact adapter 120 in the radial direction R. The peripheral terminals 228 extend from the peripheral contact opening 222. In this case, the peripheral terminals 218 are composed of a plurality of five individual contact wings. As will be discussed later with respect to Figure 4As mentioned above, the wings are curved. This increases the contact surface in the axial direction A.

[0116] The bent bus bar portion 230 is disposed between the central bus bar portion 210 and the peripheral bus bar portion 220. Figure 5 As shown, the bus bar 200 is bent in the axial direction A at the bent bus bar portion. The arrangement at the bent bus bar portion 230 enables serial contact at different heights in the axial direction A. Therefore, the bent portion enables the height difference in the axial direction A between the height of the peripheral contact portion 128 and the peripheral contact height Hp of the adjacent cell to be compensated.

[0117] In such Figure 10 In the case of the arrangement of multiple battery cells shown, a hexagonal arrangement is particularly space-saving for cylindrical cells, and the central bus bar portion 210, the curved bus bar portion 230 and the peripheral bus bar portion 220 are club-shaped in a plane perpendicular to the axial direction A, as shown in FIG. Figure 3 As shown. The peripheral bus bar portion forms the wider end of the club that tapers to the central bus bar portion at the curved bus bar portion. This allows for easy manufacture of bus bar 200 because the bend at curved bus bar portion 230 does not affect the bend at curved bus bar portion 230" due to the recess between central bus bar portion 210 and central bus bar portion 210".

[0118] Figure 4 The busbar 200 is shown to further include a contact ring 250 for each central busbar portion and each peripheral busbar portion, respectively. The contact rings 250 are arranged over each of the central contact openings and each of the peripheral contact openings 222 in the axial direction A. The contact rings 250 may have slots 252 that separate the contact rings 250 in the radial direction R.

[0119] The wings of the center terminal and the wings of the peripheral terminals 228 are bent around the contact ring 250. Thus, as Figure 5 As shown, the contact surface between the busbar 200 at the peripheral terminal 228 and the peripheral contact portion 128 at the peripheral contact adapter 110 is maximized in the axial direction A. The same applies to the center terminal 218 and the center contact portion 118 .

[0120] The contact ring 250 increases the contact pressure between the peripheral terminal 228 and the peripheral contact portion 128. The contact pressure can be set by the material selection for the contact ring 250 and the slot 252. It is particularly preferred to use a harder material (such as steel) for the contact ring 250 than the busbar, which is made of copper, for example.

[0121] Figure 5A contact system 10 is shown with a plurality of contact adapters. For the description of the contact adapters, reference is made in particular to Figure 1 and Figure 2 Furthermore, the contact system comprises busbars. For the description of the busbars, reference is made in particular to Figure 3 and Figure 4 .

[0122] Furthermore, the contact system 10 includes an insulator 300. The insulator 300 has an insulator portion extending perpendicularly to the axial direction A. The insulator portion completely covers the peripheral busbar portion 220'". This prevents a short circuit through the central busbar portion 210'' of the busbar 200, i.e., a short circuit between the peripheral contact adapters 120'' and the central contact adapters 110'' of the individual battery cells of the plurality of batteries.

[0123] The series connection of the battery pack is as follows Figure 6 and Figure 7 shown. Figure 6 is similar to Figure 5 A cross-sectional view of Figure 7 Shown from Figure 6 A top view of a group of batteries.

[0124] Figure 2 、 Figure 8 and Figure 9 The assembly method is shown in FIG. Figure 2 As shown, a contact adapter 100 is attached to each battery cell. Then, a plurality of identical busbars 200, 200' are provided. Furthermore, adapted end sections 202 and 204 are provided. Furthermore, a plurality of insulators 300, 300', 300" are provided.

[0125] Then, if Figure 9 As shown, busbars 200 , 200 ′ can first be preassembled with insulators 300 , 300 ′, 300 ″ by means of a carrier structure 400 . In the preassembled busbars with the insulators received therebetween, battery cells can then be inserted with contact adapters. This enables a preferred insertion system.

[0126] Figure 9 A solution with the above-described contact adapter 100 and busbar 200 is shown. However, these are not required. Typically, an assembly method for manufacturing a plug-in battery pack, such as Figure 10 As shown, it can also be inserted without these elements.

[0127] Figure 10 is a flow chart of an assembly method for manufacturing a plug-in battery pack.

[0128] In step S2, the assembly method includes providing a carrier structure, such as carrier structure 400, wherein the carrier structure has cell contacts for contacting a plurality of cells. Each cell is Figure 11 One of the cells 1100 is shown. Each cell has two concentric terminals 1110 , 1120 , which are arranged together on an end face of the cell 1100 extending in the axial direction A.

[0129] The single contact may include Figures 3 and 4 and Figure 8 Bus bar 200 is shown.

[0130] The assembly method then includes a step (S4) of inserting the plurality of batteries into the carrier structure to electrically connect at least two batteries via cell contacts. In this manner, the two batteries are held and connected in series or parallel. Specifically, the carrier structure is provided with cell contacts before the plurality of batteries are inserted to form the plug-in battery pack.

[0131] Each battery cell may have Figure 1 and Figure 2 For plug-in battery packs, refer specifically to Figures 5 to 7 In particular, a plurality of batteries can be inserted one after another into a carrier structure, as e.g. Figure 9 shown.

[0132] Each of the batteries may have a bottom surface opposite to the end surface, and the assembling method may further include step S6. In step S6, the bottom surfaces of the plurality of batteries are covered with a cell fixing member to fix the batteries in the battery pack.

[0133] exist Figure 11 1 shows a plug-in battery pack 1. A plurality of batteries 1100 are arranged in the battery pack 1. Each battery 1100 has two concentric terminals, which are arranged together on an axially extending end face of the battery 1100. Each battery may have a plurality of contact adapters, such as the central contact adapter 110 and the peripheral contact adapter 120 described above.

[0134] Furthermore, battery pack 1 includes a cell contact, such as bus bar 200 as described above. Bus bar 200 includes a central bus bar portion 210 and a peripheral bus bar portion 220. Although not shown, another type of cell contact may be used. For example, the cell contact does not necessarily need to include a curved bus bar portion.

[0135] Furthermore, the battery pack 1 comprises a carrier structure 400. The carrier structure 400 may be can-shaped, such as Figure 11 On the other hand, the carrier structure 400 may be in the form of a plate, as in Figure 9The above-mentioned single contact, such as busbar 200, is received in a carrier structure 400. In particular, the single contact is non-detachably connected to the carrier structure 400. Non-detachably means here that the two parts cannot be separated without destroying at least one of them.

[0136] Furthermore, the carrier structure 400 may include further components, such as a thermal coupling element 410 for thermally coupling the cell contacts to the thermally conductive element 420 and / or a thermally conductive element 420 for transferring heat out of the battery pack via the cell contacts. In particular, the components 410 and 420 are non-detachably connected to the carrier structure 400. Thus, the thermal coupling element 410 may comprise an electrically insulating material in order to electrically insulate the cell contacts from the thermally conductive element 420. This also allows the thermally conductive element 420 to be made of an electrically conductive material. Although not shown in FIG. Figure 11 , but the heat conduction element 420 may include active cooling and / or include cooling fins.

[0137] Furthermore, a connecting element (not shown) may be provided on one edge of the carrier structure 400 to enclose the battery pack with the housing component 430, such as a plate-shaped bottom element. A cell holder 440 may be provided between the housing component 430 and the battery 1100 to secure the battery 1100 in the battery pack 1. For example, the cell holder 440 may comprise an elastic material, and the housing component 430 may comprise a rigid material. The rigidity of the housing component 430 compared to the cell holder 440 allows the battery 1100 to be protected from external influences, while the elasticity of the cell holder 440 compared to the housing component 430 facilitates the maintenance of tolerances and the easy positioning of the battery 1100 relative to one another.

[0138] Although not shown in the figures, the battery can have a shape other than a cylinder. Instead of a circle, any polygon can form the bottom surface of the cylinder. The opening then has a corresponding circumference that follows the polygon. The same applies to the contact ring, which then forms the contact polygon.

[0139] List of reference numerals:

[0140] 1 battery pack

[0141] 10 contact system

[0142] 100 contact adapter

[0143] 110 center contact adapter

[0144] 112 bottom surface

[0145] 114 end

[0146] 116 shoulder element

[0147] 118 center contact part

[0148] 120 peripheral contact adapter

[0149] 122 baseboard

[0150] 124 hollow contact tube

[0151] 128 peripheral contact part

[0152] 200 busbars

[0153] 202, 204 end sections

[0154] 210 center bus section

[0155] 212 center contact opening

[0156] 218 center terminal

[0157] 220 peripheral busbar part

[0158] 222 peripheral contact opening

[0159] 228 peripheral terminals

[0160] 230 bent busbar section

[0161] 250 contact ring

[0162] 252 slots

[0163] 300 insulator

[0164] 400 carrier structure

[0165] 410 thermal coupling element

[0166] 420 heat conduction element

[0167] 430 shell components

[0168] 440 single fixing parts

[0169] 1000 monomer system

[0170] 1100 battery

[0171] 1110 center terminal

[0172] 1120 ring terminal

[0173] 1130 insulation area

Claims

1. A contact adapter (100) for contacting two concentric terminals (1110, 1120), the two concentric terminals (1110, 1120) being arranged together on an end face of a battery (1100) extending in an axial direction (A), having a bus bar (200) for connecting a plurality of such batteries (1000), the contact adapter (100) comprising: A center contact adapter (110) extending in the axial direction (A), the center contact adapter (110) comprising: a bottom surface (112) for attachment to a central terminal (1110) of the battery (1100), an opposite end (114) for passing through a center contact opening of the bus bar (200), wherein the end (114) rises from the bottom surface (112) to a center contact height (Hz), and a side surface extending between the end (114) and the bottom surface (112), having a central contact portion (118) for contacting a central terminal (218) of the central contact opening (222) of the busbar (200) in a radial direction (R); A peripheral contact adapter (120) is arranged around the central contact adapter (110), the peripheral contact adapter (120) comprising: a bottom plate (122) for attaching to a ring terminal (1120) of the battery (1100), and a hollow contact cylinder (124) rising from the base plate (122) to a peripheral contact height (Hp) in the axial direction (A), the hollow contact cylinder (124) having a peripheral contact portion (128) for contacting a peripheral terminal (228) of a peripheral contact opening (220) of the busbar (200) in the radial direction (R); The central contact height (Hz) is greater than the peripheral contact height (Hp).

2. The contact adapter (100) according to claim 1, wherein the center contact adapter (110) further comprises a shoulder element (116), wherein the shoulder element (116) protrudes from the side surface in the radial direction (R).

3. The contact adapter (100) according to any of the preceding claims, wherein the center contact adapter (110) is rotationally symmetrical with respect to the axial direction (A), in particular wherein the center contact adapter (110) forms a pin.

4. The contact adapter (100) according to any of the preceding claims, wherein the hollow contact cylinder (124) is integrally connected to the base plate (122) and / or wherein the hollow contact cylinder (124) and the base plate (122) have an L-shaped profile.

5. The contact adapter (100) according to any of the preceding claims, wherein the base plate (122) and / or the hollow contact cylinder (124) are configured to be rotationally symmetrical about the axial direction (A), in particular wherein the base plate (122) is annular and / or the hollow contact cylinder (124) comprises a separate contact web.

6. A busbar (200) for contacting a plurality of batteries (1100) in series via a contact adapter (100) according to any one of the preceding claims, each battery (1100) having two concentric terminals (1110, 1120), the two concentric terminals (1110, 1120) being arranged together on an end face of the battery (1100) extending in the axial direction (A), the busbar (200) comprising: A central bus bar portion (210) having: a center contact opening (212) for passing a center contact adapter (110), said center contact adapter (110) having a side surface extending in said axial direction (A), and a center terminal (218) for contacting the side surface of the center contact adapter (110) in a radial direction (R); A peripheral bus bar portion (220) having: a peripheral contact opening (222) for passing a hollow contact barrel (124) of a peripheral contact adapter (220) extending in an axial direction (A) up to the peripheral contact height, and a peripheral terminal (228) for contacting the peripheral contact portion (128) of the hollow contact cylinder at a peripheral contact portion height in the radial direction (R); A bent bus bar portion (230) is arranged between the central bus bar portion (210) and the peripheral bus bar portion (220) to compensate for a height difference between the peripheral contact portion height and the peripheral contact height (Hp) in the axial direction (A).

7. The busbar (200) according to claim 6, wherein the central terminal (218) and / or the peripheral terminal (228) comprises a plurality of individual contact wings, wherein the contact wings protrude from the central contact opening (212) or the peripheral contact opening (222) in the axial direction (A).

8. The busbar (200) according to any one of claims 6 to 7, further comprising a contact ring (250), wherein the contact ring (250) is arranged on the central contact opening (212) and / or the peripheral contact opening (222) in the axial direction, in particular wherein the contact ring (250) is made of a harder material than the busbar (200), and / or wherein the contact ring (250) has a groove (252).

9. The busbar (200) according to claim 6 , wherein the diameter of the central contact opening (212) is smaller than the diameter of the peripheral contact opening (222), and / or wherein the central busbar portion (210), the curved busbar portion (230) and the peripheral busbar portion (220) together follow the shape of a ball shaft in a plane perpendicular to the axial direction (A), wherein the peripheral busbar portion (220) forms the wider end of the ball shaft, the ball shaft tapering towards the central busbar portion (210) at the curved busbar portion (230).

10. A contact system (10) comprising a plurality of contact adapters (100) according to any one of claims 1 to 5, a bus bar (200) according to any one of claims 6 to 9, and an insulator (300), wherein the insulator has an insulator portion extending perpendicular to the axial direction, wherein the insulator portion completely covers the peripheral bus bar portion (220) to prevent a short circuit between the peripheral contact adapter (120") and the center contact adapter (110") of one of the plurality of batteries.

11. A method for contacting a plurality of batteries (1100), the method comprising: attaching a contact adapter (100) according to any one of claims 1 to 5 to each of the plurality of batteries (1100); connecting two battery cells (1100) in series to a bus bar (200) according to any one of claims 6 to 10; and The peripheral bus bar portion (220) is covered with an insulator (300).

12. An assembly method for manufacturing a plug-in battery pack (1) having a plurality of batteries (1100), the assembly method comprising: A carrier structure (400) is provided having a single-cell contact for contacting the plurality of batteries, each battery (1100) having two concentric terminals (1110, 1120), the two concentric terminals (1110, 1120) being arranged together at an end face of the battery (1100) extending in the axial direction (A), and inserting the plurality of batteries (1100) into the carrier structure (400) to electrically connect at least two batteries (1100) via the cell contacts, Before inserting the plurality of batteries (1100) to form the plug-in battery pack (1), the carrier structure (400) having the cell contacts is provided.

13. Assembly method according to claim 12, wherein the plurality of batteries are inserted into the carrier structure one after another, in particular wherein at least the battery comprises a contact adapter (100) according to any one of claims 1 to 6 and / or the cell contact comprises a busbar (200) according to any one of claims 7 to 13.

14. The assembly method according to one of claims 12 to 13, wherein each battery (1100) has a bottom surface opposite to the end surface, and the assembly method further comprises: covering bottom surfaces of the plurality of batteries with a cell fixing member to fix the batteries in the battery pack, In particular, the covering of the bottom surface is achieved after insertion into the carrier structure (400).

15. The assembly method according to any one of claims 12 to 14, wherein the carrier structure (400) further comprises a thermal coupling element and / or a heat conducting element, wherein the thermal coupling element is used to thermally couple the cell contact to a heat conducting element, and the heat conducting element is used to transfer heat out of the battery pack having the cell contact. In particular, wherein the thermal coupling element comprises an electrically insulating material and / or the thermal conduction element has a higher thermal conductivity than the thermal coupling element, optionally wherein the thermal conduction element comprises active cooling and / or comprises cooling fins.

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