Methods for repairing a battery system and battery system

Abstract

The invention relates to a method for repairing a battery system (A), wherein the battery system (A) comprises at least one cell (1) with at least one cell terminal (2) and a cell connector (3), characterized by the following steps: - Identifying and locating a defect affecting the tap and its connection, or where a foil element is at least partially separated, - Disconnecting a defective surge arrester (4) at a defined location (5), - Attaching a new probe (6) to a second contact point (7) on the cell terminal (2) and connecting it to the cell potential, and - Prepare a mounting point for a connector beforehand, if necessary. Furthermore, the invention relates to a battery system (A).

Description

[0001] The invention relates to a method for repairing a battery system according to the preamble of claim 1. Furthermore, the invention relates to a battery system.

[0002] Modern battery systems typically feature cell voltage taps and cell temperature sensor leads connected by a wiring harness, for example, in the form of a flexible printed circuit board (FPC) with associated evaluation electronics. These FPCs are used due to numerous advantages over conventional round conductors. They are relatively lightweight, require little installation space, are comparatively inexpensive, and all conductor tracks are precisely defined.

[0003] One disadvantage, however, is that they can be sensitive to bending and impacts at the edges, as the conductor tracks themselves are usually very thin. Furthermore, pre-existing damage from production, as well as thermal shrinkage over time, can lead to breakage. Additionally, the need for repairs to the battery system elsewhere may require partial removal of the flexible film. Similarly, defects in the wiring and connections can occur with different cell voltage tap designs. Generally, plug connectors are not used, as these are expensive to produce and more prone to failure.

[0004] If the voltage taps are welded to the connection points, they cannot be removed or repaired unless the weld itself can be renewed, for example, due to its inaccessibility. Depending on the application, such a seemingly inexpensive component can lead to high downtime costs in the event of a defect, as the entire battery system must be replaced.

[0005] CN 214849442 U discloses an integrated female arrangement of a flexible pinboard for a detachable battery system of a new energy vehicle, including a wired plastic support board, a plurality of electrically conductive busbar rows used for the mutual electrical connection of each battery group, the signal line FPC used for voltage and temperature sensing of the battery group, and the output connector with the signal line being collected. The arrangement is characterized in that the FPC sensing wiring and the plurality of conductive busbars are arranged separately on the plastic wiring board, and the output end of the FPC sensing wiring is connected to the output connector.The voltage and temperature sensing signals are acquired between each conductive bus strip and the FPC sensing cabling via a detachable connector. Therefore, only a standard plug-in connection is suggested for repairs. However, the connection is also plug-in in the standard case.

[0006] The object of the invention is to provide a method and a battery system by which a repair solution for cell voltage taps is provided.

[0007] This problem is solved by means of a method with the features of claim 1 and by means of a battery system according to the invention. Advantageous embodiments of the battery system according to the invention are to be regarded as advantageous embodiments of the method according to the invention, wherein the means of the battery system are used to carry out the method steps. Furthermore, advantageous developments of the invention are described by the dependent claims, the following description, and the figures.

[0008] One aspect of the invention relates to a method for repairing a battery system for a motor vehicle or motor vehicles. Such a battery system can, however, also be intended for other applications. The battery system comprises at least one cell with at least one cell terminal and one cell connector. The method is characterized by the following technical steps: Identifying and locating a defect affecting the tap and its connection, or where a foil element is at least partially separated. Disconnecting a defective current collector at a defined point. Attaching a new current collector to a second contact point on the cell terminal and connecting it to the cell potential. Preparing a mounting point for a connector, if necessary. This procedure enables reliable repair of defects in battery systems for motor vehicles, among other applications, with a high level of safety ensured by the structured approach.

[0009] The object of the invention is therefore to create a repair or rework solution for defects in the battery system that affect the voltage taps and their connection, or where the flexible foil needs to be partially removed. To implement this solution, the cell connectors to which the voltage taps are usually welded, or the cell contacts to which the cell connectors are welded, must be equipped with or include receptacles for a connector. If necessary, the welded voltage tap can be separated from the affected cell, and a new voltage tap can be connected to the cell potential at a different location. It is irrelevant whether this contact is located on the cell contact itself, the cell connector, or even on the welding pad of the cell connector; however, welding defects of the component cannot be repaired.One solution is to use a standardized flat connector to keep costs to a minimum. Another advantage is that this repair solution is also repairable.

[0010] The advantages of the invention arise from the fact that such plug-in devices can be easily integrated into existing busbars or cell connectors, and existing series production processes can be used to create a cost-effective product. This allows for high repairability with minimal effort during production. However, it is important that the material properties enable the shaping of the plug-in devices.

[0011] Another option is to make the cell connectors or cell contacts oversized so that the connector shape can be shaped for repairs later.

[0012] Further aspects of the invention relate to the method with different embodiments, in which, for example, various further steps are possible for repairing a battery system for motor vehicles. The method is characterized, for example, by the identification and localization of a defect affecting the tap and its connection, or in which a foil element is partially separated. Subsequently, the connection of a defective current collector can be disconnected at a defined point using an automated tool and / or a robot, enabling separation without damaging the surrounding components. The attachment of a new current collector to the second contact point on the cell terminal using a standardized connector, in particular a flat connector, and connection to the cell potential can also be carried out in this way.

[0013] Furthermore, updating the software of the battery system may also be necessary to define the new contact point or points.

[0014] In yet another embodiment, the connection of the new surge arrester to the cell potential is achieved by simply inserting it, with or without locking elements, into the prepared mounting point on the cell terminal. The introduction of locking elements would offer greater safety but also increase the complexity of the installation.

[0015] This process enables reliable repair of defects in battery systems for motor vehicles, with a high level of safety and quality ensured through the structured approach.

[0016] Further advantages, features, and details of the invention will become apparent from the following description of a preferred embodiment and from the drawings. The features and combinations of features mentioned above in the description, as well as those mentioned below in the figure description and / or shown in the figures alone, can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the invention.

[0017] This shows: Fig. 1. A schematic top view of a battery system to illustrate a possible embodiment of a method according to the invention; and

[0018] Fig. Figure 1 shows a schematic top view of a battery system A to illustrate a possible embodiment of a method according to the invention.

[0019] The assembly consists of at least one cell 1 with at least one cell terminal 2 and one cell connector 3. During repair, the defective current collector 4 is first cut at a defined point 5. A new current collector 6 is then plugged into the second contact point 7 on the cell terminal 2 and thus connected to the cell potential. To define the new contact point, the repair may need to be recorded in the battery system A's software. In addition to a contact point 7 on the cell connector 3, a variant with a contact point 7 on another cell connector 8 can also be selected.

[0020] In an alternative design option, it may be necessary to create the insertion point for the plug beforehand. Reference symbol list A battery system 1 cell 2-cell terminal 3 cell connectors 4 drains 5 Defined Position 6 New drain 7 Second point of contact 8 cell connectors QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] CN 214849442 U

[0005]

Claims

[1] Method for repairing a battery system (A) wherein the battery system (A) comprises at least one cell (1) with at least one cell terminal (2) and a cell connector (3), characterized by the following steps: - Identifying and locating a defect affecting the tap and its connection, or where a foil element is at least partially separated, - Disconnecting a defective surge arrester (4) at a defined location (5), - Attaching a new probe (6) to a second contact point (7) on the cell terminal (2) and connecting it to the cell potential, and - Prepare a mounting point for a connector beforehand, if necessary. [2] Method according to claim 1, characterized by , that an update of the battery system software (A) is performed to define the new contact point. [3] Method according to claim 1 or 2, characterized bythat the defect is identified by visual and / or machine inspection or by measurements. [4] Method according to any one of the preceding claims, characterized by , that the disconnection of the defective conductor (4) is carried out using an automated tool and / or a robot that enables the separation without damaging the surrounding components. [5] Method according to any one of the preceding claims, characterized by , that the new surge arrester (6) is attached to the second contact point (7) on the cell terminal (2) by means of a standardized connector, in particular a flat connector. [6] Method according to any one of the preceding claims, characterized by , that the connection of the new probe (6) to the cell potential is carried out by simply inserting it with or without locking elements into the prepared receiving point on the cell terminal (2). [7] Method according to any one of the preceding claims, characterized by , that the variant with a contact point on the cell connector (8) is chosen when the repair conditions require it. [8] Battery system (A) for a motor vehicle, comprising at least one battery cell (1) for storing electrical energy, at least one cell terminal (2) for connecting the battery cell (1) to external circuits, at least one cell connector (3) for electrically connecting several battery cells (1), with a signal line FPC designed to detect the voltage and temperature of the battery cells (1), and with at least one output connector for outputting signals.

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