Battery pack, contact device for battery pack

Abstract

The invention relates to a battery pack, in particular a replaceable battery pack, comprising an electrical interface for releasably connecting the battery pack to an electrical appliance, in particular an electric bicycle, an electronic device having at least one circuit board, and a contact device having at least one contact element, the contact element is designed to connect an electrical interface of the battery pack to electronics of the battery pack. According to the invention, the at least one contact element can be electrically connected to the electrical interface by means of at least one connection element, in particular a cable element.

Description

Technical Field

[0001] The present invention relates to a battery pack, particularly a replaceable battery pack, and a contact device for the battery pack. Background Technology

[0002] A battery pack with electronic components connected to a plug is described in DE 10 2022 211 713 A1. Summary of the Invention

[0003] This invention relates to a battery pack, particularly a replaceable battery pack, comprising an electrical interface for releasably connecting the battery pack to an electrical device, particularly an electric bicycle, an electronic device having at least one circuit board, and a contact device having at least one contact element configured to connect the electrical interface of the battery pack to the electronic device of the battery pack. It is proposed that at least one contact element is electrically connected to the electrical interface via at least one connecting element, particularly a cable element. Advantageously, this provides a battery pack with an optimized and secure electrical interface for attachment to electronic devices.

[0004] In the context of this application, an electric bicycle should be understood in particular as a bicycle having a drive unit for assisting the rider. Electric bicycles are preferably constructed as electric-assisted bicycles (E-Bikes), pedicab-assisted electric bicycles (Pedelec), high-speed pedicab-assisted electric bicycles (S-Pedelec), cargo bicycles, folding bicycles, etc. The drive unit has a motor, which can be configured, for example, as a mid-mounted motor or a hub motor. The motor is preferably configured as an electric motor. The drive unit is connected to a battery pack for powering the drive unit. The battery pack has a battery housing, which is preferably detachably connected to the housing of the electrical device, particularly to the frame of the electric bicycle. The electric bicycle preferably has a control unit, wherein the control unit of the electric bicycle is equipped with electronic components.

[0005] The electronic device preferably includes a sensor unit, which may include, for example, a motion sensor, a torque sensor, a speed sensor, a Global Navigation Satellite System (GNSS) receiver, a magnetic sensor, etc. Furthermore, the electronic device particularly includes at least one communication interface for wireless connection between the electric bicycle and mobile terminal devices and / or servers. The communication interface may be configured as a short-range communication interface, particularly a Bluetooth interface or a WiFi interface, for connection to the mobile terminal device.

[0006] Alternatively, the electrical equipment can be constructed as other light electric vehicles, such as electric scooters or electric motorcycles. It is also possible to consider constructing the electrical equipment as gardening tools, household appliances, or handheld machine tools.

[0007] The replaceable battery pack is preferably designed to be detachable from the electrical equipment without tools. Alternatively, the battery pack may be fixedly mounted or integrated into the casing of the electric bicycle. Tool-free detachment is also understood here to mean detachment via a lock, such as a bicycle lock. The lock is configured to be operable, for example, by a key or electric actuator. The battery pack is particularly configured to be able to connect to a charging device for charging. Alternatively or additionally, the battery pack may also be configured to be able to be charged while connected to the electric bicycle.

[0008] The battery pack particularly includes a housing. At least one battery cell is arranged within the housing of the battery pack. The housing of the battery pack is preferably constructed as an outer casing. The battery pack, and particularly the housing, can be configured to be releasably or securely connected to electrical equipment, particularly to an electric bicycle and / or charging device, via a mechanical interface. The housing preferably has at least one casing component constructed as an outer casing component. This outer casing component isolates the battery pack externally and allows it to be accessed by the user.

[0009] The battery pack is configured to be electrically connected to electrical equipment via an electrical interface. This electrical connection allows for, for example, charging and / or discharging of the battery pack. Alternatively or additionally, it may be considered that information can be transmitted from the battery pack to the electrical equipment, and vice versa, via the electrical interface. The electrical equipment or charger has an electrical interface corresponding to the electrical interface of the battery pack.

[0010] The electrical interface is preferably constructed as a contact interface, in which electrical connection is achieved through physical contact between at least two conductive components. The electrical interface preferably includes at least two electrical contact elements. In particular, one of the electrical contact elements is constructed as a positive contact, and the other as a negative contact. Additionally, the electrical interface may have at least one additional contact configured to transmit additional information to the electric bicycle and / or charging device. The additional contact may be configured as a signal contact, an encoded contact, a temperature contact, a bus contact, etc. The electrical contact element may, for example, be configured as a resilient contact element in the form of a contact tulip or a flat contact element in the form of a contact blade. Alternatively or additionally, the electrical interface may have a secondary charging coil element for inductive charging. The mechanical interface and the electrical interface may be constructed integratedly or separately from each other.

[0011] In addition to circuit boards, the electronic components of a battery pack may also include computing units, control units, transistors, capacitors, and / or storage units. Information may also be retrieved from the electronic components, either additionally or alternatively. The electronic components are configured to control or regulate the battery pack and / or electrical equipment. The electronic components particularly include a battery management system (BMS) configured to monitor the battery pack. The BMS is particularly configured to prevent overcharging and / or deep discharging of the battery pack. The BMS is preferably configured for proper cell balancing. The electronic components may also have one or more sensor elements, such as temperature sensors for determining the temperature within the battery pack or motion sensors for determining motion. The electronic components may alternatively or additionally have encoding elements, such as encoded resistors. In the context of this application, a circuit board should be understood as a circuit carrier having an organic or inorganic substrate, such as an insulating metal substrate (IMS). The circuit board can be configured as a rigid circuit board or a flexible circuit board. Furthermore, the circuit board can be mounted or unmounted. The circuit board can be constructed with a single layer or multiple layers.

[0012] A single battery cell can be constructed as a primary cell, having one electrode at one end and the other at the opposite end. In particular, the battery cell has a positive electrode at one end and a negative electrode at the opposite end. The battery cell is preferably constructed as a nickel-cadmium (NiCd) or nickel-metal hydride (NiMH) battery, and particularly preferably as a lithium-based or lithium-ion (Li-Ion) battery. Alternatively, for example, the battery cell can be constructed as a pouch cell or a prismatic cell. The battery voltage of a battery pack is typically a multiple of the voltage of a single battery cell and is determined by the connection method of the battery cells (parallel or series). Thus, in the case of a common battery cell with a voltage of 3.6V, battery pack voltages such as 3.6V, 7.2V, 10.8V, 14.4V, 18V, 36V, 54V, and 108V are obtained. The battery cell is preferably constructed as a cylindrical cell, at least substantially cylindrical, with the electrode arranged at the cylindrical end.

[0013] The contact elements of the contact device are configured for electrically connecting the contact device to a circuit board. The contact elements are configured as electrical contact elements and are therefore made of conductive material. The contact elements are preferably made of metal, such as steel, aluminum, or copper. The contact elements can be configured as integral, one-piece, or multi-piece. In the context of this application, "integral" should be understood in particular as a component made of a single member and thus of a single material. In the context of this application, "one-piece" should be understood in particular as a component that can also consist of multiple members, wherein these members are substantially inseparably connected to each other by material locking and cannot be released from each other without damage.

[0014] Furthermore, it is proposed that the contact element has a first connection area for connection with a connecting element and a second connection area for connection with electronic devices, particularly circuit boards. The connection areas are preferably made of the same material. Alternatively, the connection areas may be made of different materials. The connection areas may have surface modifications or surface markings to aid the connection, such as at least one or more protrusions in the case of soldered connections. The connection areas of the contact elements may be arranged adjacent to each other or on different sides of the contact element.

[0015] Furthermore, it is proposed that the battery pack has at least one battery cell and at least one cell connector, wherein the battery cell is connected to electronic devices via the cell connector. The cell connector may be made of, for example, a metal sheet, cable, or wire. The cell connector is preferably made of a metal sheet, wherein the cell connector partially or substantially completely covers at least one battery cell, preferably multiple battery cells, on its end side. The cell connector is preferably constructed as a single piece or integral unit. The cell connector is preferably made of aluminum, copper, or nickel, or an alloy of at least one of these materials. The cell connector may also be made of the same material as the contact elements of the contact device.

[0016] Furthermore, it is proposed that contact elements and individual connectors are connected to the circuit board using the same connection technology. Advantageously, this reduces assembly complexity and improves component connectivity. Connection technologies can be configured, for example, as brazing or fusion welding, particularly resistance welding or laser welding.

[0017] Furthermore, it is proposed that the contact elements and individual connectors be arranged adjacent to each other on the circuit board of the electronic device. Advantageously, this allows for further optimization of the assembly. In particular, the contact elements of the contact device and the individual connectors that connect to the battery cells are arranged on the same side of the circuit board and connected to the circuit board.

[0018] Furthermore, it is proposed that the contact element and the base of the contact device be connected in a shape-locking manner. Advantageously, this provides reliable fixation of the contact element. The base can be constructed as a single piece, a one-piece, or multiple pieces. The base is preferably made of plastic, especially hard plastic. Alternatively, the contact element can be connected to the base by force locking or material locking.

[0019] Furthermore, it is proposed that the contact element has an assembly aid structure configured to deform the contact element during assembly. Advantageously, this can further optimize the assembly process. The assembly aid structure can be configured, for example, as a mark for indicating assembly operations or a material weakening section.

[0020] Furthermore, it is proposed that the contact device has at least one retaining element for retaining at least one cable element. Advantageously, this can effectively ensure the correct positioning of the cable element and prevent cable breakage. The retaining element can, for example, be configured to force-lock and / or form-lock the base to the cable element. The retaining element can be integrally or one-piece constructed with the base of the contact device. The retaining element can be configured to be rigid or movable relative to the base.

[0021] Furthermore, the present invention relates to a contact device for a battery pack, particularly a replaceable battery pack, having at least one contact element configured to connect an electrical interface of the battery pack to the electronic components of the battery pack, wherein the contact element is electrically connected to the electrical interface via at least one cable element. It is proposed that the contact device has at least one retaining element for retaining at least one cable element. Advantageously, this effectively ensures the correct positioning of the cable element and prevents cable breakage.

[0022] Furthermore, it is proposed that the component be constructed as a locking device. Advantageously, this allows for a simple and releasable fixation.

[0023] Furthermore, it is proposed that the contact device has at least one guiding element for guiding the connecting element. Advantageously, this allows for further optimization of the positioning and protection of cable elements. Attached Figure Description

[0024] Further advantages are illustrated in the following figures, which depict embodiments of the invention. The figures, description, and claims contain multiple combinations of features. Those skilled in the art may also consider the stated features individually and summarize them into other meaningful combinations.

[0025] The attached diagram shows:

[0026] Figure 1 A perspective view of an electric bicycle having a battery pack according to the present invention;

[0027] Figure 2 :according to Figure 1 A perspective view of a battery pack used in an electric bicycle;

[0028] Figure 3 :according to Figure 2 A perspective view of the contact device used for a battery pack;

[0029] Figure 4 :according to Figure 2 A partial perspective view of the battery pack without its casing. Detailed Implementation

[0030] exist Figure 1The diagram shows a perspective view of an electrical device 10 having a power supply device 100 in the form of a battery pack 102. The electrical device 10 is configured, for example, as an electrically driven propulsion device 12, particularly an electric bicycle 14. The electric bicycle 14 can be configured, for example, as a pedal-assisted electric bicycle (Pedelec) or an electric-assisted bicycle (E-Bike).

[0031] The electric bicycle 14 has a frame 18, or bicycle frame. Two wheels 20 are connected to the frame 18. Furthermore, the electrical device 10 has a drive unit 22, which includes an electric motor. The electric motor is preferably constructed as a permanent magnet driven brushless DC motor. The electric motor may be constructed as a mid-mounted motor, and hub motors, etc., are also possible.

[0032] The drive unit 22 includes a control unit (not shown) configured to control or regulate the electric bicycle 14, particularly the electric motor. The electric bicycle 14 has pedal cranks 24. The pedal cranks 24 are connected to pedal crank shafts (not shown).

[0033] The control unit and the drive unit 22, which has an electric motor and a pedal crankshaft, are arranged in the drive housing 26 connected to the frame. The drive motion of the electric motor is preferably transmitted to the pedal crankshaft via a transmission (not shown), wherein the degree of assistance via the drive unit 22 is controlled or adjusted by means of the control unit.

[0034] The electric bicycle 14 is electrically and mechanically connected to a battery pack 102 configured to power the drive unit 22. The battery pack 102 is configured, for example, as a replaceable battery pack. In the connected state, the battery pack 102 is, for example, fully housed within the frame 18 of the electric bicycle 14. This connection can be achieved by axially inserting the battery pack 102 into the lower tube of the frame 18 or by pivoting the battery pack 102 into the frame 18 from the side. Alternatively, the battery pack 102 can be configured to be secured to the outside of the frame 18.

[0035] exist Figure 2 The battery pack 102 is shown in a perspective view. The battery pack 102 has a housing 104 in which, for example, 20 individual battery cells 130 are arranged (see...). Figure 4The housing 104 is constructed in multiple parts and has a tubular base 110, which is made of metal, for example. The housing 104 has two end plates 108 at its ends, which are configured as attachment plates 112 and each has at least one connecting element 116. The connecting element 116 is associated with a mechanical interface of the battery pack 102, configured for mechanically connecting the battery pack 102 to the electric bicycle 14. The connecting element 116 is configured, for example, as a notch in the attachment plate 112 into which a corresponding connecting element (not shown) of the electric bicycle 14 can be inserted. Furthermore, the tubular base 110 has, for example, two longitudinal grooves 105 on its sides, which may also be associated with the mechanical interface or used, for example, for connection to a cover.

[0036] In addition, the battery pack 102 has a charging status indicator 106. The charging status indicator 106, along with the electronic components 107 arranged in the housing 104 of the battery pack 102 (see [link to documentation]), further contributes to this functionality. Figure 4 The charging status display 106 can be configured to be operated by a user via a button or to be operated automatically, for example, by signal-driven electronics based on motion sensors.

[0037] The battery pack 102 also includes an electrical interface 114 for electrically connecting the battery pack 102 to the electric bicycle 14. The electrical interface 114 is configured, for example, as a socket 115. The electrical interface 114 includes, for example, four electrical contact elements, wherein two electrical contact elements are configured as power contacts and at least one electrical contact element is configured for exchanging information between the battery pack 102 and the electric bicycle 14.

[0038] The electronics 107 of the battery pack 102 are associated with a control unit having a monitoring system, such as a battery management system (BMS), for monitoring the battery pack 102, particularly the individual battery cells 130. Here, the individual battery cells 130 are monitored for voltage via cell monitoring and for temperature via temperature sensors (not shown). The electronics 107 of the battery pack 102 are connected to the electronics or control unit of the electric bicycle 14 via an electrical interface 114.

[0039] To connect the electrical interface 114 to the electronic device 107, the battery pack 102 has a contact device 200, which... Figure 3 It is shown in a three-dimensional view.

[0040] The contact device 200 has a substrate 202, which is made of, for example, plastic, especially hard plastic. The substrate 202 is constructed substantially in a plate shape and has an upper side 204 and a lower side 206.

[0041] The contact device 200 includes, for example, four contact elements 208 configured to electrically connect the contact device 200 to the electronics 107 of the battery pack 102. The number of contact elements 208 in the contact device 200 corresponds to the number of electrical contact elements in the electrical interface 114 of the battery pack 102. The contact elements 208 are connected to the base 202 of the contact device 200, for example, by thermal locking. For this purpose, each of the four contact elements 208 has at least one notch 210 into which a thermal locking element 212, in particular in the form of a pin to the base 202 of the contact device 200, is inserted and at least partially melted during assembly.

[0042] The four contact elements 208 each have a first connection area 214 for connecting to the connection element 216 to connect to the electrical interface 114 of the battery pack 102, and a second connection area 218 for connecting to the electronic devices 107 of the battery pack 102, especially to the circuit board 109.

[0043] The first connection region 214 is, for example, arranged on the upper side 204 of the contact device 200. The first connection region 214 is, for example, constructed as the plane 220 of the contact element 208. The connection element 216 is, for example, constructed as a cable element 222, wherein the cable element 222 is, for example, made of copper wire with insulation. The cable element 222 here has different cross-sections, wherein the cross-section of the cable element used for power transmission is constructed to be larger. In the first connection region 214, the cable element 222 is attached to the contact element 208 without insulation and is connected by material locking, for example by brazing, ultrasonic welding or crimping.

[0044] The second connecting region 218 is arranged, for example, spaced apart from the first connecting region 214, particularly on the opposite ends of the contact element 208. The contact element 208 is shaped, for example, such that it extends around the base 202 of the contact device 200. Therefore, the contact element 208 has, for example, two curved edges 224, at which it is bent at approximately 45°. Through this bending, a notch 210 of the contact element 208 is arranged on the side and thus, particularly, between the first connecting region 214 and the second connecting region 218.

[0045] The second connection region 218 of the contact element 208 has, for example, at least one solder point 226, particularly a single solder point 226 or two solder points 226. The solder point 226 is configured, for example, as a raised portion. The solder point 226 is configured to securely connect the contact element 208 to the circuit board 109 of the battery pack 102 by a soldering method. The contact element 208 has an assembly aid structure 228 in the form of a slot 230 in the second connection region 218. The assembly aid structure 228 ensures that the second connection region 218 can be bent during assembly, such that after bending, the second connection region 218 is positioned on the lower side 206 of the contact device 200, as shown in... Figure 4 As shown in the diagram.

[0046] exist Figure 4 The diagram shows a partial perspective view of a battery pack 102 without a casing. The battery cells 130 of the battery pack 102 are received in cell holders 132, which are made of plastic and receive the battery cells 130 individually, for example. Electronic components 107, particularly circuit boards 109, of the battery pack 102 are arranged, for example, outside the cell holders 132 between two battery cells 130.

[0047] Circuit board 109 has a number of electronic components not described in detail. Furthermore, electronic devices 107, particularly circuit board 109, are electrically connected to battery cells 130 via individual connectors 134. The individual connectors 134 are configured such that they connect to the battery cells 130 at one end. Additionally, the individual connectors 134 are locked to the circuit board material on the side of circuit board 109 opposite to the battery cells 130. The connection between circuit board 109 and individual connectors 134 is achieved via a soldering method, such as resistance soldering. Here, individual connectors 134 are soldered to circuit board 109 individually or to each other.

[0048] In the assembled state, the contact device 200 is arranged between the electronic components 107 of the battery pack 102, particularly the circuit board 109, and the individual cell holders 132 of the battery pack 102. Here, the contact device 200 is preferably configured such that it can be force-locked and / or form-locked connected to the individual cell holders 132 and / or the circuit board 109. Therefore, during the assembly process after assembling the circuit board 109, the second connection area 218 is bent so that it abuts against the circuit board 109 of the battery pack 102. The second connection area 218 of the contact element 208 abuts against the same side of the circuit board 109 where the individual cell connectors 134 are also abutted. Advantageously, this allows both the electrical contact element 208 of the contact device 200 and the individual cell connectors 134 to be electrically connected to the circuit board 109 of the battery pack 102 using the same connection method, such as resistance welding.

[0049] To optimize the positioning and securing of the connecting element 216, and especially the cable element 222, during assembly, the contact device 200 has a retaining element 232 and a guiding element 234. The guiding element 234 is configured, for example, as a partition wall 236 that extends outward from the base 202 and has, for example, a height substantially corresponding to the height of the connecting element 216.

[0050] The contact device 200 has, for example, two different retaining elements 232. The first retaining element 232 is configured, for example, as a locking clip 238, which is configured to forcefully lock, for example, all connecting elements 216. Here, the locking clip 238 has a hinge on one side and a locking protrusion 240 on the other side.

[0051] Furthermore, the contact device 200 has, for example, two second retaining elements 232, which are in the form of press-fit portions 242. The second retaining elements are configured to force-lock a single connecting element 216.

Claims

1. A battery pack, particularly a replaceable battery pack, comprising: An electrical interface (114) is provided for releasably connecting the battery pack (102) to an electrical device (10), particularly to an electric bicycle (14). Electronic device (107), said electronic device having at least one circuit board (109), and A contact device (200) having at least one contact element (208) configured to connect an electrical interface (114) of the battery pack (102) to electronic components (107) of the battery pack (102). Its features are, The at least one contact element (208) can be electrically connected to the electrical interface (114) via at least one connecting element (216), in particular a cable element (216).

2. The battery pack according to claim 1, characterized in that, The contact element (208) has a first connection area (214) for connection with the connection element (216) and a second connection area (218) for connection with the electronic device (107), especially with the circuit board (109).

3. The battery pack according to any one of the preceding claims, characterized in that, The battery pack (102) has at least one battery cell (130) and at least one cell connector (134), wherein the battery cell (130) is connected to the electronic device (107) through the cell connector (134).

4. The battery pack according to claim 3, characterized in that, The contact element (208) and the single connector (134) are connected to the circuit board (109) using the same connection technology.

5. The battery pack according to claim 4, characterized in that, The connection technology is constructed as a welding method, especially a resistance welding method.

6. The battery pack according to any one of claims 3 to 5, characterized in that, The contact element (208) and the single connector (134) are arranged adjacent to each other on the circuit board (109) of the electronic device (107).

7. The battery pack according to any one of the preceding claims, characterized in that, The contact element (208) is form-locked to the base (202) of the contact device (200).

8. The battery pack according to any one of the preceding claims, characterized in that, The contact element (200) has an assembly aid structure (228) configured to deform the contact element (208) during assembly.

9. The battery pack according to any one of the preceding claims, characterized in that, The contact device (200) has at least one retaining element (232) for retaining the at least one cable element (222).

10. A contact device for a battery pack (102), particularly a replaceable battery pack, having at least one contact element (208) configured to connect an electrical interface (114) of the battery pack (102) to electronic components (107) of the battery pack (102), wherein, The contact element (208) can be electrically connected to the electrical interface (114) via at least one cable element (222). Its features are, The contact device (200) has at least one retaining element (232) for retaining the at least one cable element (222).

11. The contact device according to claim 10, characterized in that, The retaining element (232) is configured as a locking device (238).

12. The contact device according to any one of claims 10 to 11, characterized in that, The contact device (200) has at least one guide element (234) for guiding the connecting element (216).

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