Dual-voltage battery and assembly methods for it

Abstract

Dual-voltage battery, particularly for vehicles, comprising a plurality of battery cells (41), wherein a group of battery cells (41) are connected to form battery cell blocks, comprising battery electronics with a plurality of power switching elements, which are arranged and configured in an assembled state of the dual-voltage batteries for series and / or parallel connection of at least individual battery cell blocks, wherein a first voltage is provided in a first connection arrangement of the battery cell blocks and wherein a second voltage is provided in a second connection arrangement of the battery cell blocks, wherein the battery electronics are provided in the manner of a battery electronics assembly (3) and that the battery cell blocks form a battery cell assembly (4) separate from the battery electronics assembly (3) such that the battery electronics assembly (3) is attached to the battery cell assembly (4) in the assembled state.wherein the battery electronics assembly (3) provides power interfaces (6) which are directed towards the battery cell blocks of the battery cell assembly (4) in the assembled state and via which the battery electronics assembly (3) is electrically connected to the battery cell blocks, characterized in that the dual-voltage battery comprises a multi-part housing which includes the battery cells (41) and the battery electronics in the assembled state, and that the first voltage and the second voltage are provided with reference to a ground connection that is the same for both voltages.

Description

The invention relates to a dual-voltage battery according to the preamble of claim 1. Furthermore, the invention relates to an assembly method for a dual-voltage battery according to the preamble of claim 13. Today's commercially available dual-voltage batteries feature a functional and spatial integration of the battery electronics and the battery cells or cell blocks. The two voltages of the dual-voltage batteries are provided via two different ground connections. Specifically, the power switching elements for optional series and parallel connection of the battery cells or cell blocks are spatially located directly adjacent to and distributed with the battery cells or cell blocks. The same applies to the cell monitoring circuitry, which is part of the battery electronics. Due to this spatial integration, the design of these modern dual-voltage batteries is complex and their assembly is expensive.In particular, separate pre-assembly of the battery electronics on the one hand and the battery cells or battery cell blocks on the other, and consequently also a functional test of the battery electronics or the battery cells / battery cell blocks before the complete assembly of the dual-voltage battery, is not possible. Furthermore, individual components of the dual-voltage battery cannot be replaced, for example during maintenance or repair, or only with considerable effort. A dual-voltage battery of this type and an assembly method for it are known from DE 10 2014 201 348 A1. DE 10 2009 012 176 A1 describes a battery with integrated monitoring electronics. DE 10 2008 010 808 A1 describes another battery and a manufacturing method for it. The object of the present invention is therefore to provide a modular and structurally simplified dual-voltage battery which offers advantages in terms of assembly, functional testing and / or maintenance. To solve the problem, the invention has the features of claim 1. The particular advantage of the invention lies in the fact that all battery electronics are integrated into a single unit, and that the battery cell blocks form a second unit which can be prefabricated or pre-assembled separately and tested for functionality before final assembly. This allows defects to be detected before the dual-voltage battery is fully assembled. A defective unit / component can therefore be identified early and replaced or repaired before the final assembly of the dual-voltage battery. Furthermore, manufacturing logistics are simplified because the battery electronics unit can be pre-assembled separately from the battery cell unit. This also simplifies the automation of the assembly process.Furthermore, maintenance allows for the relatively simple replacement of defective battery electronics or battery cell modules. For example, the entire battery cell module or individual cell blocks can be replaced early on. The power interfaces can be designed as plug-in connectors, allowing for tool-free connection and removal of the battery cell module and electronics module, respectively. In the first connection arrangement of the dual-voltage battery according to the invention, the first voltage is provided by a battery cell block or by a parallel connection of battery cell blocks. The second voltage is provided by a series connection of a predetermined number of battery cell blocks. Optionally, further series connections can be connected in parallel. Preferably, the first voltage and the second voltage are provided at two different external terminals of the dual-voltage battery with respect to a common ground terminal. While in the first connection arrangement only the first voltage is provided at a first external terminal, in the second connection arrangement of the battery cell blocks either the first voltage and the second voltage can be provided simultaneously at the two external terminals, or only the second voltage can be provided at a second external terminal.The battery cell blocks are connected either purely in series (in a line) or purely in parallel, or both in series and in parallel. According to a preferred embodiment of the invention, the battery electronics assembly includes additional power interfaces (external connections for the first voltage and the second voltage, ground connection) for connecting the dual-voltage battery to an external electrical load. In particular, the dual-voltage battery can be connected to a vehicle's electrical system via these additional power interfaces and supply power to a variety of electrical loads. Optionally, the power interfaces for the battery cell blocks and the additional power interfaces can be located on opposite sides of the battery electronics assembly. This ensures good accessibility to the additional power interfaces even when the dual-voltage battery is installed.The power interfaces for the battery cell blocks can be implemented internally and protected within the housing. Furthermore, incorrect assembly or malfunction of the dual-voltage battery is prevented. According to a further development of the invention, the battery electronics assembly provides a common circuit carrier for all power switching elements and for the power interfaces, which are configured to connect the battery electronics assembly to the battery cell blocks of the battery cell assembly. Optionally, further power interfaces can also be integrated into the circuit carrier. The assembly of the dual-voltage battery is advantageously simplified by providing a single common circuit carrier for all battery electronics. A distributed arrangement of the battery electronics across multiple circuit carriers and the associated increased logistical and assembly effort can be avoided with this advantageous implementation of the invention. According to a further development of the invention, a cell monitoring circuit is provided as part of the battery electronics assembly. This circuit is configured to perform a functional test or functional check of the battery cell blocks in the first connection arrangement or in the second connection arrangement. The cell monitoring circuit can preferably be arranged on the common circuit carrier of the battery electronics assembly. It is thus spatially separated from the battery cell assembly, with the result that the modularity of the dual-voltage battery with respect to the battery electronics on the one hand and the battery cells on the other is maintained even when the cell monitoring circuit is implemented. According to a further development of the invention, a cooling module is provided between the battery electronics assembly and the battery cell assembly in the assembled state of the dual-voltage battery. The cooling module preferably serves to cool both the battery electronics assembly and the battery cell assembly. Cooling can be active, for example via a fan, or fluidic. Alternatively, passive cooling can be provided via a heat sink with heat dissipation surfaces. Optionally, cooling fins can be provided in the case of passive cooling to further improve the cooling effect. According to a further development of the invention, the multi-part housing of the dual-voltage battery includes an upper housing section designed to accommodate the battery electronics unit. The battery electronics unit can be pre-assembled and then inserted into the upper housing section. Optionally, the battery electronics unit can be secured in the upper housing section by means of separately designed fastening components, for example, a frame component associated with the multi-part housing. Optionally, the battery electronics unit can be snapped or screwed into the upper housing section. According to a further development of the invention, the battery electronics assembly can be partially potted. For example, the potting can be implemented in the area of ​​the power switching elements or the cell monitoring circuit. Preferably, the power interfaces for connecting to the battery cell blocks, and optionally the other power interfaces, are brought out of the potting. Advantageously, the potting provides mechanical protection for the battery electronics. In particular, it is possible to produce the potting for the entire battery electronics assembly after the assembly has been completely pre-assembled. Potting of individual battery electronics components can thus be avoided.For example, the potting compound for the battery electronics assembly can be produced after the battery electronics assembly has been inserted into the housing of the dual-voltage battery and preferably into the upper part of the housing. According to a further development of the invention, the multi-part housing includes a lower housing section which, in the assembled state, covers the battery cell assembly on one side opposite the battery electronics assembly. This allows the battery cell assembly to be very advantageously attached to or inserted into the lower housing section, provided the lower housing section has a recess in the area where the battery electronics assembly is attached. In particular, during the final assembly of the dual-voltage battery, the battery cell assembly can first be attached to the lower housing section, and then the battery electronics assembly can be attached to the battery cell assembly. Optionally, the battery electronics assembly can be pre-installed in the upper housing section of the multi-part housing. A circumferential wall of the multi-part housing, encompassing the battery cell assembly on the mantle side when the dual-voltage battery is assembled, can be designed as part of the upper or lower housing section and each provide a connection geometry for joining the housing parts. Alternatively, the wall can be implemented as a separate part of the multi-part housing. To solve the problem, the invention has the features of claim 13. The particular advantage of the invention lies in the fact that the assembly of the dual-voltage battery is significantly simplified, and the spatial separation of the battery electronics from the battery cell blocks or the battery cell assembly allows for separate replacement of the components. This also improves the repair of the dual-voltage battery. A further improvement in assembly is achieved by inserting the battery electronics unit into the upper housing section of the multi-part housing. Preferably, the battery electronics unit is secured within the upper housing section. This securing can be accomplished using various methods known to those skilled in the art; for example, fastening elements such as screws can be provided to secure the battery electronics unit in the upper housing section. Alternatively, the battery electronics unit can be snapped into place within the upper housing section. Separate fastening components can also be incorporated into the housing to secure the battery electronics unit within the upper housing section. According to a further development of the invention, the battery electronics assembly is encapsulated, at least in the area of ​​the power switching elements. Preferably, the encapsulation is carried out after the battery electronics assembly has been inserted into the upper part of the housing. The battery electronics assembly can then also be secured in the upper part of the housing by means of the encapsulation. For example, undercuts can be formed between the encapsulation and the housing for this purpose. According to a further development of the invention, an electronics function test for the battery electronics assembly or a cell function test for the battery cell assembly and / or the battery cell blocks is performed after pre-assembly of the battery electronics assembly and before final assembly of the dual-voltage battery, or after pre-assembly of the battery cell blocks / battery cell assembly and before final assembly of the dual-voltage battery. Defects in the battery electronics assembly and / or the battery cell blocks and / or the battery cell assembly can thus be detected before final assembly of the dual-voltage battery. Replacing the defective component(s) is therefore possible in a simple manner and with minimal effort. Further advantages, features, and details of the invention can be found in the dependent claims and the following description. Features mentioned therein can be essential to the invention, either individually or in any combination. Features and details of the dual-voltage battery described in the invention naturally also apply in connection with the assembly method according to the invention, and vice versa. Thus, the disclosure relating to the individual aspects of the invention can always be referred to reciprocally. The drawings serve only as examples to clarify the invention and are not intended to be limiting. Figure 1 shows an exploded view of a first embodiment of a dual-voltage battery according to the invention, comprising a multi-part housing, a battery electronics assembly, and a battery cell assembly; Figure 2 shows the dual-voltage battery according to Figure 1, wherein the battery electronics assembly is arranged in an upper part of the multi-part housing; Figure 3 shows the dual-voltage battery according to Figure 2, wherein the battery electronics assembly is fixed in the upper part of the housing via a fastening component of the multi-part housing; Figure 4 shows a second embodiment of the invention, which provides an additional cooling module; and Figure 5 shows a third embodiment of the invention with a modified upper part of the housing. A dual-voltage battery according to a first embodiment as shown in Figures 1, 2 to 3, comprises a multi-part housing with an upper housing part 1 and a lower housing part 2, as well as battery electronics designed as a module 3 and a plurality of battery cells 41 combined into a module 4. Groups of battery cells 41 are connected to form battery cell blocks. The battery cell blocks are not shown separately in the figures. For example, four battery cells 41 form a battery cell block. The battery electronics module 3 comprises a single common circuit carrier 5 for all electronic components. Power switching elements are provided on the common circuit carrier 5 of the battery electronics unit 3, allowing the battery cell blocks to be selectively connected or wired in series or parallel. In a first connection arrangement of the battery cell blocks, a first voltage is provided, and in a second connection arrangement, both the first voltage and a second voltage are supplied. The voltages are supplied at external terminals (not shown) of the dual-voltage battery, referenced to a common ground terminal. Furthermore, the circuit carrier 5 provides a plurality of power interfaces 6 for connecting the battery electronics assembly 3 to the battery cell blocks of the battery cell assembly 4. All power interfaces 6 are located on one side of the battery electronics assembly 3 facing the battery cell assembly 4, such that, in the assembled state, the battery electronics assembly 3 is electrically connected to the battery cell blocks of the battery cell assembly 4 via the power interfaces 6. Corresponding electrical contacts (not shown) are arranged on the battery cell assembly 4 for this purpose. The circuit carrier 5 of the battery electronics unit 3 also includes a cell monitoring circuit and additional power interfaces (external connections, ground connection) not shown. The cell monitoring circuit is designed to perform a functional check of the battery cell blocks in the first connection arrangement and / or in the second connection arrangement. The additional power interfaces are preferably arranged on a side of the battery electronics unit 3 opposite the power interfaces 6 for the battery cell blocks. They serve to connect the dual-voltage battery to an external electrical load. In particular, the dual-voltage battery can be connected to a vehicle electrical system via the additional power interfaces and supply a multitude of electrical loads. The battery cell assembly 4 comprises a total of 32 battery cells 41 arranged regularly in an 8 x 4 matrix, with the battery cells 41 being connected, for example, to eight battery cell blocks of four battery cells 41 each. Furthermore, two carriers 42, 43 are provided, assigned to the battery cells 41 or battery cell blocks on opposite end faces. The battery cells 41 or battery cell blocks are held by the carriers 42, 43 and combined to form the battery cell assembly 4. According to the invention, the battery electronics assembly 3 and the battery cell assembly 4 are manufactured as separate units. The battery electronics assembly 3 can therefore be prefabricated or pre-assembled independently of the battery cell assembly 4, both spatially and functionally. During final assembly, which is shown in two intermediate steps in Figures 2 and 3, the battery electronics assembly 3 is inserted into the upper housing part 1 of the multi-part housing of the dual-voltage battery and fixed there by means of a fastening component 11 designed like a support frame (frame component of the housing). Optionally, the battery electronics assembly 3 can be provided with a potting compound in the upper housing part 1, at least partially and preferably in the area of ​​the power switching elements and the cell monitoring circuit, which protects the electronic components from contamination and damage. After the battery electronics assembly 3 is secured in the upper housing part 1, the battery cell assembly 4 is inserted into the lower housing part 2. The lower housing part 2, which covers the battery cell assembly 4 on an underside opposite the battery electronics assembly 3 when assembled, has a circumferential wall 7 that surrounds the battery cell assembly 4. The wall 7 provides a connection geometry for the upper housing part 1 in the area of ​​a free edge facing the upper housing part 1 when assembled. For example, the upper housing part 1 is snapped into place with the wall 7. According to a second embodiment of the invention as shown in Fig. 4, the dual-voltage battery additionally includes a cooling module 8. The cooling module 8 serves to cool the battery electronics assembly 3 and the battery cell assembly 4. The cooling module 8 is spatially located between the battery electronics assembly 3 and the battery cell assembly 4. It is enclosed by the multi-part housing of the dual-voltage battery. The cooling module 8, which is shown schematically in Fig. 4, can be configured for active cooling of the battery electronics assembly 3 and the battery cell assembly 4. For this purpose, a fan or a cooling fluid circuit can be provided, for example. Likewise, the cooling module 8 can serve for passive cooling of the aforementioned components 3 and 4. In this respect, it can, for example, be designed as a heat sink or incorporate one. According to a third embodiment of the invention as shown in Fig. 5, the battery cell assembly 4, in its assembled state, has a wall 7 that encompasses the outer shell of the upper housing part 1. The wall 7 has a connection geometry in the area of ​​its free edge, which in this case faces the lower housing part 2. The wall 7 is attached to the lower housing part 2 (not shown) at its free edge. The examples of the dual-voltage battery shown in the figures merely illustrate the invention. Those skilled in the art will find further embodiments of the dual-voltage battery according to the invention, retaining the core of the invention, namely the realization of the battery electronics in a first common assembly and the connection of the battery cells to form a common battery cell assembly. For example, connecting means such as screws or clips can be provided to secure the battery cell assembly 3 in the housing top 1, or the battery electronics assembly 3 can be snapped into the housing top 1 or secured solely by potting in the housing top 1. For example, it may be planned that during final assembly, the pre-assembled battery electronics unit 3 is attached to the battery cell assembly unit 4, and only then is the housing top part 1 mounted. Therefore, it is not mandatory to fix the battery electronics unit 3 in the housing top part 1 prior to connecting it to the battery cell assembly unit 4. For example, it can be provided that the battery cell blocks produced during pre-assembly are directly connected to the battery electronics assembly 3. In this case, individual carriers 42, 43 can be dispensed with. For example, the wall 7 can be divided. The wall 7 can be formed as a split wall, for instance, partially on the upper housing part 1 and partially on the lower housing part 2. Likewise, the wall 7 can be realized as a separate part of the multi-part housing. The wall 7 then preferably has a connection geometry for connecting the wall 7 to the upper housing part 1 and another connection geometry for connecting the wall 7 to the lower housing part 2. Identical components and component functions are identified by the same reference numerals. Reference symbol list 1 Upper housing part 2 Lower housing part 3 Battery electronics assembly 4 Battery cell assembly 5 Circuit carrier 6 Power interface 7 Wall 8 Cooling module 11 Mounting component 41 Battery cell 42 Carrier 43 Carrier

Claims

Dual-voltage battery, particularly for vehicles, comprising a plurality of battery cells (41), wherein a group of battery cells (41) are connected to form battery cell blocks, comprising battery electronics with a plurality of power switching elements, which are arranged and configured in an assembled state of the dual-voltage batteries for series and / or parallel connection of at least individual battery cell blocks, wherein a first voltage is provided in a first connection arrangement of the battery cell blocks and wherein a second voltage is provided in a second connection arrangement of the battery cell blocks, wherein the battery electronics are provided in the manner of a battery electronics assembly (3) and that the battery cell blocks form a battery cell assembly (4) separate from the battery electronics assembly (3) such that the battery electronics assembly (3) is attached to the battery cell assembly (4) in the assembled state.wherein the battery electronics assembly (3) provides power interfaces (6) which are directed towards the battery cell blocks of the battery cell assembly (4) in the assembled state and via which the battery electronics assembly (3) is electrically connected to the battery cell blocks, characterized in that the dual-voltage battery comprises a multi-part housing which includes the battery cells (41) and the battery electronics in the assembled state, and that the first voltage and the second voltage are provided with reference to a ground connection that is the same for both voltages. Dual-voltage battery according to claim 1, characterized in that the battery electronics assembly (3) provides, in addition to the power interfaces (6) for the battery cell blocks, further power interfaces which are designed to connect the dual-voltage battery to an external electrical consumer and / or an on-board power supply. Dual-voltage battery according to claim 1 or 2, characterized in that the power interfaces (6) for the battery cell blocks and the further power interfaces are provided on opposite sides of the battery electronics assembly (3). Dual-voltage battery according to one of claims 1 to 3, characterized in that the battery electronics assembly (3) provides a common circuit carrier (5) for the power switching elements and the power interfaces (6) for the battery cell blocks and optionally for the further power interfaces. Dual-voltage battery according to one of claims 1 to 4, characterized in that a cell monitoring circuit is provided as part of the battery electronics assembly (3), which is configured to perform a functional check for the battery cell blocks in the first connection arrangement and / or in the second connection arrangement. Dual-voltage battery according to one of claims 1 to 5, characterized in that a cooling module (8) is arranged between the battery electronics assembly (3) and the battery cell assembly (4) in the assembled state, which is designed for active or passive cooling of the battery electronics assembly (3) and the battery cell assembly (4). Dual-voltage battery according to one of claims 1 to 6, characterized in that the battery electronics assembly (3) is encapsulated at least sectionally and preferably at least in the area of ​​the power switching elements and / or the cell monitoring circuit. Dual-voltage battery according to claim 7, characterized in that the battery electronics assembly (3) is encapsulated in such a way that only the power interfaces (6) for connecting to the battery cell blocks and optionally the other power interfaces are brought out of the encapsulation. Dual-voltage battery according to one of claims 1 to 8, characterized in that the multi-part housing provides a housing upper part (1) in which the battery electronics assembly (3) is provided in the assembled state, wherein optionally a fastening component (11) is provided for fixing the battery electronics assembly (3) in the housing upper part (1), and / or that the multi-part housing provides a housing lower part (2) which covers the battery cell assembly (4) in the assembled state at least on one side opposite the battery electronics assembly (3). Dual-voltage battery according to claim 9, characterized in that the battery cell assembly (4) in the assembled state is surrounded on the mantle side by a circumferential wall (7) and / or that the wall (7) projects from the upper housing part (1) towards the lower housing part (2) or from the lower housing part (2) towards the upper housing part (1). Dual-voltage battery according to one of claims 1 to 10, characterized in that in the second connection arrangement of the battery cell blocks, in addition to the second voltage, the first voltage is also provided. Dual-voltage battery according to one of claims 1 to 10, characterized in that the first voltage is provided at a first external terminal of the dual-voltage battery and that the second voltage is provided at a second external terminal of the dual-voltage battery. Assembly method for a dual-voltage battery, in particular for a dual-voltage battery according to one of claims 1 to 12, comprising a plurality of battery cells (41), wherein a group of battery cells (41) are connected to form battery cell blocks, comprising battery electronics with a plurality of power switching elements, which are arranged and configured for series and parallel connection of at least individual battery cell blocks, wherein a first voltage is provided in a first connection arrangement of the battery cell blocks and the first voltage and a second voltage are provided in a second connection arrangement of the battery cell blocks.wherein, in a pre-assembly step, firstly, a battery electronics assembly (3) comprising the power switching elements and, secondly, a plurality of battery cell blocks, each comprising a group of battery cells (41), and / or a battery cell assembly (4) comprising the plurality of battery cell blocks are prefabricated, and wherein, in a final assembly step, the prefabricated battery cell blocks and / or the prefabricated battery cell assembly (4) are attached to the prefabricated battery electronics assembly (3), wherein power interfaces (6) provided on the battery electronics assembly (3) are electrically connected to the battery cell blocks, characterized in that the dual-voltage battery comprises a multi-part housing which includes the battery cells (41) and the battery electronics.and that in the second connection arrangement of the battery cell blocks, the first voltage and the second voltage are provided with reference to a ground connection that is the same for both voltages. Assembly method according to claim 13, characterized in that the battery electronics assembly (3) is inserted into a housing upper part (1) of the multi-part housing, wherein the battery electronics assembly (3) is preferably fixed in the housing upper part (1), and that the battery electronics assembly (3) is then connected to the battery cell blocks and / or the battery cell assembly (4). Assembly method according to claim 13 or 14, characterized in that the battery electronics assembly (3) with the power switching elements is encapsulated at least section by section. Assembly method according to one of claims 13 to 15, characterized in that the majority of the battery cell blocks and / or the battery cell assembly (4) are attached to a lower housing part (2) of the multi-part housing before being connected to the battery electronics assembly (3), wherein the lower housing part (2) covers the battery cell assembly (4) at least on one underside opposite the battery electronics assembly (3) in the assembled state. Assembly method according to one of claims 13 to 16, characterized in that after the pre-assembly step and before the final assembly step an electronics function test for the battery electronics assembly (3) and / or a cell function test for the battery cell assembly (4) is carried out.

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