Cell contact arrangement for an energy storage module and method for contacting energy storage cells of an energy storage module

Abstract

Cell contact arrangement (10) for an energy storage module (1) comprising at least one energy storage cell (2), wherein each energy storage cell (2) has at least two connection terminals (4), the cell contact arrangement (10) comprising a carrier plate (12) that can be arranged on the energy storage module (1), a cable harness (14) with several signal lines (16) supported by the carrier plate (12), and several cell connectors (20) inserted into or integrated into the carrier plate (12), which are designed to connect one of the connection terminals (4) of the energy storage cell (2) and one of the signal lines (16) of the cable harness (14), further comprising a connecting element (24) having a first end (26) that can be connected to one of the signal lines (16) and a second end (28) that can be connected to the cell connector (20).wherein the carrier plate (12) and / or the cell connector (20) has at least one spatial orientation element (32; 34, 42) which defines the spatial orientation between the connecting element (24) and the cell connector (20) and / or the carrier plate (12), characterized in that the spatial orientation element (32; 34, 42) is designed as a section (42) projecting from the cell connector (20) which can be connected to the second end (28) of the connecting element (24), wherein the connecting element (24) can be slid or plugged onto the projecting section (42) at its second end (28), wherein the connecting element (24) further comprises a housing-like receiving element (36) in which a temperature sensor (18) is received, and wherein the first end (26) of the connecting element (24) is made of a first material and the second end (28) of the connecting element (24) consists of a second material.

Description

[0001] The present invention relates to a cell contacting arrangement for an energy storage module comprising at least one energy storage cell, wherein each energy storage cell has at least two connection terminals and the cell contacting arrangement has a carrier plate that can be arranged on the energy storage module, a cable harness carried by the carrier plate and having a plurality of signal lines, and a plurality of cell connectors inserted into the carrier plate or integrated into the carrier plate, which are designed to connect a connection terminal of the energy storage cell and a signal line of the cable harness.

[0002] In electric and / or hybrid vehicles, energy modules consisting of individual battery cells, such as lithium-ion cells, are preferred. However, lithium-ion cells are not intrinsically safe, and thus the electrical voltage of each individual cell and their temperature must be monitored. This monitoring or electrical connection of the temperature sensor is achieved by means of a cable harness, which is attached to a carrier plate for easy installation. The carrier plate, in turn, is arranged on the energy storage module. Integrated into the carrier plate or arranged on the carrier plate are also cell connectors, which are intended to enable a connection to a connection terminal of the energy storage cell on the one hand and to the signal line on the other. Such a cell connection arrangement is described, for example, in DE 102011087040 A1.

[0003] A disadvantage of this state-of-the-art technology, however, is that, on the one hand, the connection between the signal line and the cell connector must be prepared manually, and, on the other hand, anti-corrosion measures are necessary to connect the copper signal line to the aluminum cell connectors. For this purpose, a corrosion protection coating is typically applied to the connection point between the signal line and the cell connector after the copper signal line has been attached to the cell connector using ultrasonic welding. Once a corrosion-resistant connection between the signal line and the cell connector has been achieved, the carrier plate on the cell connectors is typically connected to the connection terminals using fusion welding. The application of the anti-corrosion coating can also require manual intervention, making the manufacturing process expensive and error-prone.But even if the anti-corrosive coating is applied automatically, the manufacturing process remains expensive, as, among other things, a large amount of anti-corrosive coating must be used to compensate for manufacturing tolerances. Furthermore, the automated process carries the risk of high reject rates, as the poor positional tolerance often results in only incomplete coverage of the joint during automated application.

[0004] DE 10 2014 110 211 A1 discloses a cell contacting system. At least one signal line of the signal line system is electrically connected to a positioning element on the signal line system side. The positioning element is secured to the signal line on the one hand and to a cell connector on the other. Particularly during assembly, the positioning element on the signal line system side is connected to an associated positioning element on the carrier element side. The positioning element on the signal line system side is held in a desired position relative to the cell connector by the positioning element on the carrier element side. A similar cell contacting system is known from DE 10 2017 112 125 A1.

[0005] Further contact elements or cell connectors for battery systems are known from DE 10 2013 201 556 A1, DE 10 2010 031 380 A1, US 2015 / 0372354 A1, DE 10 2013 207 358 A1, DE 10 2016 221 643 A1 or US 2015 / 0064524 A1.

[0006] The object of the present invention is therefore to achieve a simplified connection of the signal line to the cell connector.

[0007] This object is achieved by a cell contacting arrangement according to patent claim 1.

[0008] The following describes a cell contacting arrangement for an energy storage module, which comprises at least one energy storage cell having at least two connection terminals. Furthermore, the cell contacting arrangement comprises a carrier plate that can be arranged on the energy storage module, a cable harness supported by the carrier plate and having a plurality of signal lines, and a plurality of cell connectors inserted into or integrated into the carrier plate, which are designed to connect a connection terminal of the energy storage cell and a signal line of the cable harness.

[0009] To achieve an optimized connection of the signal line to the cell connector, a connecting element is further provided, which has a first end that can be connected to the signal line and a second end that can be connected to the cell connector. Furthermore, the carrier plate and / or the cell connector have at least one spatial orientation element that defines the spatial orientation between the connecting element and the cell connector and / or the carrier plate. The additional connecting element and the orientation element enable a quick, simple, and precisely positioned arrangement between the signal line and the cell connector, thus enabling an automated fastening process. This, in turn, reduces the susceptibility to errors and is cost-effective.

[0010] The spatial orientation element is designed as a section projecting from the cell connector, which can be connected to the second end of the connecting element. The second end of the connecting element is designed such that it can be pushed or plugged onto the projecting section of the cell connector. This allows for very quick and easy spatial orientation between the signal line and the cell connector.

[0011] Alternatively or additionally, the spatial orientation element can be a fixing element formed on the carrier plate, for example a snap-in connection or a fixing pin, which cooperates with the connecting element and which fixes the connecting element in a predefined spatial orientation on the carrier plate and / or the cell connector.

[0012] Furthermore, the first end of the connecting element is made of a first material, in particular copper, and the second end of the connecting element is made of a second material, in particular aluminum. The transition between the two materials in the connecting element can be produced, for example, by roll bonding, so that no additional corrosion protection needs to be applied. The seamless transition between the two materials in the connecting element itself can provide a corrosion-free transition between the two materials. The connecting element itself is then preferably welded to the cell connector at its second end by means of fusion welding, while the connection between the first element and the signal line can be made, for example, by crimping. This provides a particularly simple and corrosion-free connection option between the signal line and the cell connector.

[0013] In addition to the welding and / or crimping mentioned above, other connection options between the second end of the connecting element and the cell connector or the first end of the connecting element and the signal line are also possible. Suitable joining processes such as form-fitting, force-fitting, and / or material-fit connections can be used.

[0014] Furthermore, the connecting element has a housing-like receiving element in which a temperature sensor is accommodated. Here, too, the connection between the temperature sensor and the housing-like element can be made in particular by force-fitting or material-fitting.

[0015] For example, it is possible for the temperature sensor to be glued into the housing-like receiving element. For this purpose, an opening can be provided on the housing-like receiving element through which a binding agent, in particular an adhesive, is introduced to create a physical connection between the temperature sensor and the receiving element. Alternatively, the housing-like receiving element can also be dimensioned such that a temperature sensor can be fixed therein with frictional engagement. In this case, the housing-like receiving element is arranged at the first end of the connecting element or is formed by the first end of the connecting element.

[0016] A frictional connection is particularly advantageous because it allows heat to be introduced into the temperature sensor without any adhesive material in between, making temperature measurement more accurate and faster.

[0017] A further aspect of the present invention relates to a method for contacting a connection terminal of an energy storage cell in an energy storage module. The method preferably comprises the step of preassembling a cell contacting arrangement, as described above, wherein the cell contacting arrangement comprises a carrier plate, a cable harness connected to the carrier plate and having a plurality of signal lines, and at least one cell connector suitable for contacting the connection terminals of the energy storage cells and which are integrated into the carrier plate or arranged on the carrier plate.

[0018] In a second step, the pre-assembled cell contact arrangement is then placed on the energy storage module and subsequently the cell connectors are welded to the connection terminals and the connecting elements are welded to the cell connectors.

[0019] This allows for a particularly fast process for connecting the individual cell storage units, as an additional welding process is eliminated and no additional corrosion protection is required. This results in lower costs and a shorter process time.

[0020] Furthermore, the step of pre-assembling the carrier plate may comprise the optional steps of positioning the cell connectors on / at the carrier plate, arranging connecting elements on a wiring harness and / or on the carrier plate, and connecting the signal lines of the wiring harness to the connecting elements and / or connecting the cell connectors to the connecting elements attached to the wiring harness.

[0021] The embodiments and features described for the proposed device apply accordingly to the proposed method.

[0022] Further possible implementations of the invention also include combinations of features or embodiments described above or below with respect to the exemplary embodiments that are not explicitly mentioned. In this case, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the invention.

[0023] Further advantages and advantageous embodiments are set forth in the description, the drawings, and the claims. In particular, the combinations of features set forth in the description and the drawings are purely exemplary, so that the features may also be present individually or in other combinations.

[0024] The invention will be described in more detail below with reference to exemplary embodiments illustrated in the drawings. The exemplary embodiments and the combinations shown in the exemplary embodiments are purely exemplary and are not intended to define the scope of the invention. This scope is defined solely by the appended claims.

[0025] They show: Fig. 1: schematic, perspective view of an energy storage module with a cell contact arrangement arranged thereon according to a first embodiment; Fig. 2a, Fig. 2b: schematic perspective views of details of the Fig. 1 shown energy storage module; Fig. 3a, Fig. 3b: schematic perspective views of other details of the Fig. 1 shown energy storage module; Fig. 4a - 4c: schematic perspective views of an alternative fastening option; and Fig. 5a - 5g: schematic representation of a manufacturing process of the Fig. 1 shown energy storage module.

[0026] In the following, identical or functionally equivalent elements are identified by the same reference symbols.

[0027] Fig. 1 shows an energy storage module 1, which has several energy storage cells 2 each with 2 connection terminals 4 (more precisely in Fig. 2 to 5). Furthermore, Fig. 1, that a cell contact arrangement 10 is arranged on the energy storage module 1, which cell contact arrangement has a carrier plate 12, a cable harness 14 carried by the carrier plate 12 with a plurality of signal lines 16, and a plurality of cell connectors 20 inserted into the carrier plate 12 or integrated into the carrier plate 12. The cell connectors 20 are designed to interconnect the connection terminal 4 of each energy storage cell 2 and the signal line 16 of the cable harness 14. The signal lines 16 are designed, on the one hand, to monitor the voltage of each energy cell 2 and, at specific locations, to create a connection to a temperature sensor 18 that measures the temperature of the energy storage cell. Thus, in Fig. 1 the signal line 16-1 is responsible for voltage monitoring, while the signal line 16-2 transmits temperature values.

[0028] The various connection options are described below with regard to voltage monitoring, especially in the Fig. 2a and Fig. 2b and regarding the temperature sensor in the Fig. 3a and Fig. 3b is explained in more detail. In the Fig. 4a to 4c show another connection option that is possible for both the signal line and the temperature sensor.

[0029] Fig. 2a shows a spatial side view of a detail of the energy storage module 1 from Fig. 1 and Fig. Figure 2b shows a spatial plan view of a detail of the energy storage module 1.

[0030] In both Fig. 2a and Fig. 2b, voltage monitoring of the energy cell 2 is possible by means of a signal line 16-1. As the Fig. 2a and Fig. 2b, a cell connector 20 is arranged on the connection terminal 4 of the energy storage cell 2 on the carrier plate 12, which in the illustrated embodiment is fastened by means of hook elements 22 which are formed integrally with the carrier plate 12. As Fig. 2a, the cell connector 20 contacts the connection terminal 4 of the energy storage cell 2. Furthermore, Fig. 2a and Fig. 2b that for the connection between the signal line 16-1 and the cell connector 20, a connecting element 24 is further arranged, which has a first end 26 and a second end 28, wherein the first end 26 is designed for a connection to the signal line 16-1, while the second end 28 is designed for a connection to the cell connector 20. In the Fig. In the embodiment shown in Figure 2, the first end 26 is equipped with crimping elements 30 which enable crimping of the connecting element 24 to the signal line 16-1.

[0031] The second end 28 of the connecting element 24 is typically connected to the cell connector 20 in a materially bonded manner, for example by welding. In order to avoid having to perform this welding manually during assembly of the carrier plate 12, but rather to enable the welding process to run automatically, a fixed spatial orientation of the connecting element 24 on the carrier plate 12 is necessary. For this purpose, orientation elements 32 are also formed on the carrier plate 12, which in the illustrated embodiment are designed as latching or snap-in hooks 34, which enable a fixed spatial orientation of the connecting element 24 on the carrier plate 12 and the cell connector 20. The orientation elements 32 can achieve a spatial arrangement of the connecting element 24, so that the welding of the second end 28 of the connecting element 24 to the cell connector 20 can take place in an automated process.

[0032] In the same way, a temperature sensor 18 can also be attached to the cell connector 20, as in particular Fig. 3a and Fig. 3b. Here, too, the connecting element 24 is fixed in its spatial position on the cell connector 20 via the orientation elements 32 designed as locking lugs 34. While the second end 28 for connection to the cell connector 20 is analogous to the Fig. 3, the connecting element 24, which is suitable for connection to a temperature sensor 18, further comprises a housing-like receiving element 36 at the first end 26, in the interior 38 of which the temperature sensor 18 is received. In this case, the secure connection of the temperature sensor 18 in the interior of the housing-like receiving element 36 can be provided, for example, via close tolerances and the resulting frictional engagement between the housing-like receiving element 36 and the temperature sensor 18, but it is also possible to glue the temperature sensor 18 into the housing-like receiving element 36. For this purpose, as in particular the embodiment of Fig. 3b shows, an elongated hole 40 can be provided in the housing-like receiving element 36, through which a binding agent, in particular an adhesive, can be introduced into the interior 38 of the housing. Since in this case, too, the spatial orientation of the connecting element 24 is determined by the orientation elements 32, the connection process between the connecting element 24 and the cell connector 20 can also be carried out in an automated process.

[0033] Instead of providing locking lugs 34 as orientation elements 32 on the carrier plate 12, the spatial orientation can be carried out as shown in the Fig. 4a to 4c, can also be achieved by attaching the connecting element 24 to the cell connector 20. Fig. 4a a spatial plan view, Fig. 4b a spatial view from below, and Fig. 4c a spatial side view of the cell connector 20 with the connecting element 24 attached thereto. As shown, the cell connector 20 has projecting sections 42 which can be connected to the second end 28 of the connecting element 24. For this purpose, in particular the second end 28 of the connecting element 24 is bent into spring tabs 44, 46 which, as can be seen in particular from the Fig. 4b and Fig. 4c, resiliently enclose the projection 42 of the cell connector. This also allows a spatial pre-fixation of the connecting element 24 to the cell connector 20 in order to firmly fasten the connecting element 24 to the cell connector 20 in a subsequent, for example, material, joining step.

[0034] As can be seen schematically in particular in the Fig. 4a and Fig. As shown in Figure 2b, the connecting element 24 is designed as a hybrid sheet, wherein the material of the first end 26 is adapted to the material of the signal line 16, i.e., in particular, made of copper, while the material of the second end 28 is adapted to the material of the cell connector 20, i.e., in particular, made of aluminum or an aluminum alloy. Such hybrid sheets are typically produced by roll bonding and provide a gap-free transition between the materials, in this case, copper and aluminum. As a result, corrosion protection is directly applied via the connecting element 24, eliminating the need for an additional corrosion protection coating to prevent the penetration of liquid or moisture into the connection point between the copper signal line 16 and the aluminum cell connector 20.

[0035] In Fig. 5 with the Fig. 5a to 5g schematically illustrate the manufacturing process for connecting an energy storage module to a cable harness.

[0036] In a first step (see Fig. 5a - Fig. 5d) the cell contact arrangement 10 is assembled before the assembled cell contact arrangement 10 is attached to the energy storage module 1 (see Fig. 5e - 5g). The assembly of the cell contact arrangement 10 comprises the first step of arranging cell connectors 20 on the carrier plate 12 ( Fig. 5a, Fig. 5b). Then, the cable harness 14 is crimped at the ends of the signal lines 16 to the first ends 26 of the connecting units 24 ( Fig. 5c). Subsequently, the thus pre-assembled cable harness 14 is spatially arranged on the cell connectors 20, in the embodiment shown here by plugging the connecting elements 24 onto projections 42 on the cell connector 20 ( Fig. 5d).

[0037] The pre-assembled cell contact arrangement 10 is then placed on an energy storage module 1 ( Fig. 5e) and subsequently, in an automated process, the connections between cell connector 20 and connection terminal 4 are provided by welding using a welding device 50 ( Fig. 5f), as well as the spatial fixation of the connecting elements 24 to the cell connectors 20 by welding using a welding device 50 ( Fig. 5g). In particular, the same welding process can be used.

[0038] Since the spatial position of the connecting elements 24 on the cell connectors 20 is clearly defined by the orientation elements 32, an automated process can also be used for the connection between the cell connector 20 and the connecting element 24.

[0039] This eliminates the additional welding or assembly process required in the prior art for signal line 16 and cell connector 20, which, moreover, usually had to be performed manually. Applying corrosion protection to the welded joint is also no longer necessary, since the use of a hybrid sheet for the design of the connecting element 24 provides integrated corrosion protection. Thus, a cost-effective and easy-to-assemble cell contact arrangement 10 can be provided overall. Reference symbol 1 energy storage module 2 energy storage cells 4 connection terminal 10 Cell contact arrangement 12 carrier plate 14 Wiring harness 16 Signal line 18 Temperature sensor 20 cell connectors 22 Fastening element 24 connecting element 26 first end of the connecting element 28 second end of the connecting element 30 crimping elements 32 Orientation element 34 locking hooks 36 housing-like receiving element 38 Interior 40 slot 42 overhang 44.46 spring noses 50 welding device

Claims

[1] Cell contact arrangement (10) for an energy storage module (1) comprising at least one energy storage cell (2), each energy storage cell (2) having at least two connection terminals (4), the cell contact arrangement (10) comprising a carrier plate (12) which can be arranged on the energy storage module (1), a cable harness (14) carried by the carrier plate (12) and having a plurality of signal lines (16), and a plurality of cell connectors (20) which are inserted into or integrated into the carrier plate (12) and are designed to connect one of the connection terminals (4) of the energy storage cell (2) and one of the signal lines (16) of the cable harness (14), a connecting element (24) being further provided which has a first end (26) which can be connected to the one signal line (16) and a second end (28) which can be connected to the cell connector (20),wherein the carrier plate (12) and / or the cell connector (20) has at least one spatial orientation element (32; 34, 42) which determines the spatial orientation between the connecting element (24) and the cell connector (20) and / or the carrier plate (12), characterized by in that the spatial orientation element (32; 34, 42) is designed as a section (42) projecting from the cell connector (20) and connectable to the second end (28) of the connecting element (24), wherein the connecting element (24) can be pushed or plugged onto the projecting section (42) with the second end (28), wherein the connecting element (24) further comprises a housing-like receiving element (36) in which a temperature sensor (18) is received, and wherein the first end (26) of the connecting element (24) consists of a first material and the second end (28) of the connecting element (24) consists of a second material. [2] Cell contacting arrangement (10) according to claim 1, wherein additionally the spatial orientation element (32; 34, 42) is a fixing element formed on the carrier plate (12), in particular a snap-in connection (34) and / or a fixing pin, which cooperates with the connecting element (24) and fixes the connecting element (24) in a predefined spatial orientation either on the carrier plate (12) or on the carrier plate (12) and the cell connector (20). [3] Cell contact arrangement (10) according to one of the preceding claims, wherein the first material is copper and wherein the second material is aluminum. [4] Cell contact arrangement (10) according to one of the preceding claims, wherein the connection between the connecting element (24) and the cell connector (20) and / or between the connecting element and the one signal line (16) is positively locking and / or non-positively locking and / or materially locking. [5] Method for contacting one or more energy storage cells (2) of an energy storage module (1) with a respective signal line (16) of a cable harness (14) with the following steps - Pre-assembling a cell contact arrangement (10) according to one of the preceding claims; - arranging the pre-assembled cell contact arrangement (10) on the energy storage module (1); and - Welding the cell connectors (20) of the cell contact arrangement (10) to the connection terminals (4) of the energy storage cell (2) and welding the connecting elements (24) to the cell connectors (20). [6] The method according to claim 5, wherein the step of pre-assembling the cell contacting arrangement (10) comprises the following steps: - fixing, in particular crimping, the first end (26) of the connecting element (24) to each signal line (16) of the cable harness (14); - Spatial pre-fixing of the connecting elements (24) to the cell connectors (20) by means of the orientation elements (32; 34, 42), in particular by plugging or snapping them in. [7] Method according to claim 5 or 6, wherein the step of pre-assembling the cell contacting arrangement (10) comprises the following step: Spatial pre-fixing of the connecting elements (24) with housing-like receiving elements (36) on the cell connectors (20) by means of the orientation elements (32; 34, 42), in particular by plugging or snapping in; wherein the temperature sensor (18) is inserted into the housing-like receiving element (36) of the connecting element (24) and is fastened by means of frictional engagement or material engagement.

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