Battery assembly, method for repairing the battery assembly and method for manufacturing the battery assembly

Abstract

The invention relates to a battery arrangement (100) in which, for example, battery cells (400) are arranged in a tray structure and a contact element (600) rests on these battery cells (400), which electrically connects the battery cells (400) to each other and is designed to be cut through at predefinable limits (640), namely the limits (640) of a cell pack contact element (630), so that a separated area is created which corresponds to at least one cell pack contact element (630), so that it is possible to replace those battery cells (400) which are comprised of a cell pack (430) on which the cell pack contact element (630) rests.

Description

[0001] The invention relates to a battery arrangement, a method for repairing the battery arrangement, and a method for manufacturing the battery arrangement.

[0002] To manufacture a battery assembly with at least one predefined property, such as a predefined capacity, specific energy, and / or power output, individual battery cells, for example, cylindrical cells, prismatic cells, and / or pouch cells, are connected together so that the at least one predefined property is fulfilled. Various architectures can be used for this purpose, such as the prior art C2M (cell to module) architecture or the prior art C2P (cell to pack) architecture. The advantage of the C2P architecture over the C2M architecture is more efficient space utilization, i.e., an increase in energy density, and / or cost savings in production.In C2P architectures, since the battery cells are integrated into a tray structure that forms, for example, the housing of the battery assembly, repairs or rework during production are more complex than in C2M architectures, where the battery cells are assembled into modules and the modules are integrated into the tray structure. The modules allow for the replacement of battery cells at the module level. The integration of a part into the tray structure specifically refers to a direct integration of the part into the tray structure; that is, no structures are formed encompassing the part and the structure is integrated into the tray structure.

[0003] DE 10 2013 220 845 A1 discloses a flexible module connector for electrically connecting a first module and a second module of an energy storage device, wherein the module connector is formed from a plurality of stacked layers of a metallic foil.

[0004] DE 10 2016 210 204 B4 discloses a wiring module used in a battery, in particular where no separation (cutting) is provided.

[0005] DE 10 2015 010 989 B4 discloses a busbar module arranged on one end of each battery in a battery group consisting of a plurality of batteries, the batteries having connections at their ends in an axial direction. The busbar module comprises electrically connecting the battery connections and having an insulating material arranged between the busbars. A separation of the busbars is not mentioned.

[0006] The invention is based on the objective of providing a reworkable battery arrangement which is designed to enable the replacement of a predetermined number of battery cells.

[0007] The problem is solved by the subject matter of the independent patent claims. Advantageous further developments of the invention are described by the dependent patent claims, the following description, and the figures.

[0008] The invention is based on a battery arrangement in which, for example, battery cells are arranged in a tray structure and a contact element rests on these battery cells, which electrically connects the battery cells to each other and is designed to be cut at predefinable boundaries (boundaries of a cell pack contact element), so that a separated area (corresponding to at least one cell pack contact element) is created, enabling the replacement of those battery cells on which the separated area rests (battery cells of at least one cell pack).

[0009] The invention relates to a battery arrangement comprising at least two cell packs, each cell pack comprising at least two battery cells. Preferably, at least one cell pack, and in particular each cell pack, comprises between 7 and 81 battery cells. In particular, each cell pack comprises the same number of battery cells. In other words, at least two battery cells are grouped together to form a cell pack, with each battery cell being assigned to exactly one cell pack. Alternative terms for cell pack are battery group or cell group or group, since each refers to a plurality of battery cells grouped together as a group or unit. The cell type of the battery cells can be cylindrical cells and / or prismatic cells and / or pouch cells, with preferably all battery cells being of the same cell type.

[0010] Each battery cell comprises at least one cell contact surface, the cell contact surface being configured to transfer electrical charge from the battery cell to a conductor electrically connected to the cell contact surface and / or to receive electrical charge from a conductor electrically connected to the cell contact surface. This means that each battery cell has at least one cell contact surface configured to perform a charge exchange with a conductor electrically connected to the cell contact surface. This means that the cell contact surfaces are configured to allow charging and / or discharging of the respective battery cell.

[0011] Each battery cell has at least one active cell contact surface, wherein an active cell contact surface is a cell contact surface that points in a predefinable spatial direction common to all active cell contact surfaces. This means that at least a true portion of the cell contact surfaces, preferably all cell contact surfaces, point in a predefinable direction. This portion (a true portion or all) of the cell contact surfaces that point in the predefinable direction are referred to here as active cell contact surfaces. The predefinable direction is a predefinable spatial direction, preferably relative to a coordinate system common to all battery cells.

[0012] All active cell contact surfaces lie in a common cell contact plane. This means that a plane exists, the cell contact plane, which preferably has no curvature and which is characterized in particular by the fact that when a conductive material is placed on the cell contact plane, all active cell contact surfaces touch the conductive material.

[0013] For each cell pack, all battery cells of at least that cell pack are electrically connected to each other via a contact element. For this purpose, the respective active cell contact surfaces of each battery cell in the respective cell pack are electrically connected to the contact element. To establish an electrically conductive connection, the contact element has at least two contact surfaces. These contact surfaces are electrically connected to the active cell contact surfaces, with each active cell contact surface being electrically connected to at least one contact surface. This means that the contact element has at least one contact surface for each active cell contact surface, with which the respective active cell contact surface has an electrically conductive connection.Additionally, the contact element comprises electrical conductors configured to electrically connect the contact surfaces, or at least a portion thereof, to one another, particularly in a predefinable manner. These electrical conductors are, for example, conductive traces running within or on the surface of a material. Preferably, the contact element is a flexible printed circuit (FPC).

[0014] To conductively connect the battery cells of each cell pack, the contact element is arranged to rest on the battery cells and / or on the cell contact plane, thereby contacting all active cell contact surfaces of the respective cell pack. The contact element comprises at least two cell pack contact elements. In particular, the contact element consists of a plurality of cell pack contact elements. Each cell pack contact element is a region of the contact element that rests on all battery cells of the respective cell pack. Each point of the contact element corresponds to a point on at most one, preferably exactly one, cell pack contact element. Exactly one cell pack contact element rests on each battery cell.This means that each cell pack has a region of the contacting element, referred to in this application as a cell pack contacting element, resting on it. Preferably, adjacent cell pack contacting elements share a portion of their respective boundaries. A cell pack contacting element can, for example, have a rectangular, square, triangular, pentagonal, or hexagonal shape.

[0015] The contacting element is designed to be more easily separated along the boundaries (edges) of at least one cell pack contacting element. Separation along these boundaries is characterized, for example, by the fact that less pressure and / or force is required and / or less material resistance must be overcome than if the contacting element were separated along boundaries other than those of at least one cell pack contacting element. These boundaries are primarily geometric. This means that the contacting element is designed such that separation (cutting) along predefined lines corresponding to the boundaries of the cell pack contacting elements is possible.In particular, separation means that the contact element is separated along the boundaries of the respective cell pack contact element in such a way that the cell pack contact element, along whose boundaries a separation has occurred, can be detached from the remaining contact element. Specifically, after separation, there is no longer any electrical connection between the electrical conductors of the cell pack contact element, along whose boundaries a separation has occurred, and the remaining contact element.

[0016] This battery arrangement offers the advantage of providing a battery configuration in which the battery cells are interconnected via a single unit that can be separated along predefined boundaries. This results in a battery arrangement where the battery cells are placed in a tray structure, particularly analogous to a C2P architecture, leading to a higher energy density compared to the C2M architecture. Simultaneously, the integrated contact element simplifies manufacturing, as the electrically conductive connection between the battery cells is achieved by placing a single element on top.Additionally, the separability of the contact element allows for the removal of individual battery cells without removing the entire contact element, meaning that when replacing individual battery cells, the entire conductor structure, i.e. the entire contact element, does not have to be replaced.

[0017] The battery arrangement is preferably a battery arrangement for a motor vehicle. In particular, it is a battery arrangement for a motor vehicle as used to operate at least one electric motor to propel the motor vehicle.

[0018] The invention also includes further developments that result in additional advantages.

[0019] One further development step involves ensuring that the electrical conductors are arranged identically within each cell pack contact element. This means that the electrical conductors in the contact element exhibit a repeating pattern across all cell pack contact elements. This simplifies the manufacturing process of the contact element, as the electrical conductors do not need to be arranged differently for two cell pack contact elements. Specifically, the cell pack contact elements can have the same shape, resulting in a repeating pattern for both the contact elements and the electrical conductors, further simplifying the manufacturing process.

[0020] A further development includes the electrical conductive connection of all battery cells, and in particular all active cell contact surfaces, of the battery assembly. This is achieved by electrically connecting the conductors of each cell pack contact element, which rests on the respective cell pack, to the conductors of at least one other cell pack contact element via cell pack-spanning conductors. This means that the conductors of the cell pack contact elements are each electrically connected by cell pack-spanning conductors. These cell pack-spanning conductors electrically connect all battery cells of the battery assembly. The number of cell pack-spanning conductors originating from a cell pack contact element is limited to a maximum of the number of cell packs adjacent to that cell pack.A cell pack adjacent to a first cell pack shares at least part of its boundary or delimitation with the first cell pack. Preferably, an electrical connection via inter-cell pack electrical conductors occurs only between adjacent cell packs. In particular, it is provided that each cell pack has exactly one inter-cell pack electrical conductor for each adjacent cell pack. This ensures an electrical connection between the cell pack and its respective adjacent cell packs with a minimal number of inter-cell pack electrical conductors.

[0021] The advantage of this further development is that there is a minimal number of conductors spanning multiple cell packs between the cell pack contact elements. This means that when a contact element is cut along its boundaries (edge), as few of these conductors, and therefore electrical connections, need to be severed. Simultaneously, it ensures that all cell pack contact elements remain electrically connected to one another, thus maintaining an electrical connection between all battery cells. Furthermore, it is advantageous to ensure that when a contact element is cut along the boundaries (edge) of one cell pack contact element, all other cell pack contact elements remain electrically connected to one another.

[0022] A further development comprises all battery cells, in particular all active cell contact surfaces, of the battery assembly being electrically connected to one another by means of electrical conductors. This is achieved by connecting the electrical conductors of each cell pack contact element, which rests on the respective cell pack, to the electrical conductors of at least one other, preferably adjacent, cell pack contact element via electrical conductors spanning across the cell pack. Additionally, each cell pack contact element has connector contact surfaces that are electrically connected to the electrical conductors of the cell pack contact element.The connector contact surfaces are designed to replace at least one cell pack-spanning electrical conductor between a first cell pack contact element and a second cell pack contact element by electrically connecting at least one connector contact surface of the first cell pack contact element to at least one connector contact surface of the second cell pack contact element via a connector.

[0023] This means that the electrical conductors of one cell pack contact element are electrically connected to the electrical conductors of another cell pack contact element via cross-cell pack electrical conductors. If at least one cross-cell pack electrical conductor is cut and / or the electrical connection established by a cross-cell pack electrical conductor is interrupted, the cross-cell pack electrical conductor and / or the electrical connection established by the cross-cell pack electrical conductor can preferably be replaced by an equivalent connector.Equivalent means that the difference between the electrical connection via the cell pack-spanning electrical conductor and via the connector when measuring at least one electrical, electromagnetic, electro-optical and / or electrostatic quantity lies within a predefinable interval, preferably with no difference.

[0024] An electrical connection via the cell-pack-spanning electrical conductor between the first cell-pack contact element and the second cell-pack contact element, which electrically connects the battery cells of a first cell-pack, on which the first cell-pack contact element rests, to the battery cells of a second cell-pack, on which the second cell-pack contact element rests, can be replaced by the connector. To replace this electrical connection and / or this cell-pack-spanning electrical conductor, the connector can establish an electrical connection between at least two, preferably exactly two, connector contact surfaces. At least one of the connector contact surfaces is encompassed by the first cell-pack contact element, and at least one other connector contact surface is encompassed by the second cell-pack contact element.This means that the connector electrically connects at least one, preferably exactly one, connector contact surface of the first cell pack contact element with at least one, preferably exactly one, connector contact surface of the second cell pack contact element. The connector is therefore an electrically conductive connection between at least two connector contact surfaces. The connector contact surface of a cell pack contact element is electrically connected to the electrical conductors, preferably all electrical conductors or a definable portion of the electrical conductors.

[0025] The further development offers the advantage of providing a means to electrically connect the electrical conductors of one cell pack contact element to the electrical conductors of at least one other cell pack contact element. Furthermore, when the contact element is cut along its boundaries (edge), the at least one severed cell pack-spanning electrical conductor originating from the cell pack contact element can be replaced by at least one connector. This advantageously results in easy replacement of the electrical connections established by the cell pack-spanning electrical conductors.

[0026] A further development includes ensuring that the number of connector contact surfaces of each cell pack corresponds to at least a minimum number of connectors, where the minimum number of connectors corresponds to the number of cell pack-spanning electrical conductors originating from the cell pack. This means that each cell pack contact element comprises at least one connector contact surface for each cell pack-spanning electrical conductor originating from the cell pack contact element. This advantageously ensures that at least one connection point for at least one connector is provided for all cell pack-spanning electrical conductors originating from the cell pack contact element. Thus, each cell pack-spanning electrical conductor originating from the cell pack contact element can be replaced by at least one connector.Preferably, the number of connector contact surfaces corresponds exactly to the number of cell pack-spanning electrical conductors originating from the cell pack contact element. This allows each cell pack-spanning electrical conductor originating from the cell pack contact element to be replaced by a connector, while simultaneously avoiding redundancy in the connector contact surfaces, which can lead to cost savings in production. A cell pack-spanning electrical conductor originating from the cell pack contact element is defined as a cell pack-spanning electrical conductor that is electrically connected to at least one electrical conductor of the respective cell pack contact element.

[0027] A further development includes the electrically conductive connection between the connector and the at least one connector contact surface being a welded or soldered connection, or a plug connection. An additional or alternative development includes the electrically conductive connection between the active cell contact surface and the contact surface being a welded or soldered connection. The production of a welded, electrically conductive connection is preferably carried out by laser welding. The advantage of a welded or soldered electrically conductive connection is that a particularly robust, electrically conductive connection can be produced in a simple manner.In this case, a secure connection means that the connection cannot be interrupted by the forces acting on a vehicle battery under normal circumstances, which supplies energy to at least one electric motor to power a motor vehicle. The advantage of a plug connection is its replaceability, which allows a connector attached to a connector contact surface to be removed very easily and, if necessary, replaced with a new connector, especially compared to, for example, a welded or soldered connection.

[0028] One further development involves mechanically weakening the contact element along the boundaries of each cell pack contact element. This makes it easier to separate the contact element along the boundaries of at least one cell pack contact element than would be the case without mechanical weakening. Additionally or alternatively, it makes it more difficult to separate the contact element along lines other than those defining the boundaries of the respective cell pack contact element. This is achieved, for example, by ensuring that when a force or pressure is applied to separate the contact element, the mechanical weakening causes the separation to occur along the boundaries of the cell pack contact element, since the contact element can withstand less pressure and / or force, particularly along these boundaries.The mechanical weakening can, for example, be due to a predetermined breaking point and / or a perforation, and / or the contacting element may have a reduced thickness and / or be made of a different material at the boundaries of the cell pack contacting element. In particular, the contacting element has reduced stability at the point of mechanical weakening, especially with regard to a force acting on this point and / or a pressure exerted on the contacting element.

[0029] A further development includes the contacting element being a single element resting on all battery cells of each cell pack, and / or the contacting element being a planar and / or flexible element. Planar means, for example, that the contacting element has a significantly smaller extent in one spatial direction than in the other two directions. For example, the extent in one spatial direction can differ from the extent of the contacting element in at least one other spatial direction by a factor greater than 50, in particular greater than 100, preferably greater than 1000. The spatial direction in which the contacting element resting on the battery cells has the smallest extent preferably corresponds to the spatial direction in which all active cell contacting surfaces point.Flexibility is synonymous with shape instability and can be characterized by a low modulus of elasticity, which can mean, for example, that the contacting element can be rolled up.

[0030] This can be achieved, for example, by using a film with additional conductive elements, such as electrical conductors and / or a flexible printed circuit (FPC).

[0031] The advantage of this is that the contact element can be easily placed on the battery cells, for example by rolling the contact element onto the battery cells.

[0032] A further development involves integrating the battery cells into a tray mold, specifically by bonding them in place, and ensuring that the dimensions of the contact element correspond to the dimensions of the tray mold at the cell contact plane. This means that the dimensions of the contact element are adapted to the tray mold and, in particular, do not extend beyond its boundaries. Specifically, this means that the entire contact element is located within the tray mold and rests on all battery cells within the tray mold. The tray mold corresponds, in particular, to the housing of the battery assembly. This has the advantage that the contact element does not need to be resized after being placed on the battery cells within the tray mold, thus simplifying production.

[0033] Integrating the battery cells into the tray shape means, in particular, that the battery cells are arranged within the tray shape analogously to a C2P architecture; that is, the battery cells are not formed as modules that are then integrated into the tray structure. This allows for a high energy density, especially compared to the C2M architecture.

[0034] Further development involves distinguishing the cell pack from a battery module in a cell-to-module (C2M) architecture by eliminating the need for individual cell packs to be separated by a separate housing for at least one cell pack, and / or by using a single cooling system for all battery cells in the battery assembly, and / or by a cell pack consisting of multiple battery cells. This means that the architecture differs from the C2M architecture. The C2M architecture is characterized, for example, by grouping the battery cells into battery modules, with each module including a housing and / or its own cooling system. In the C2M architecture, the modules are integrated into the tray-like structure. In contrast to the C2M architecture, in this battery assembly, the battery cells are divided into cell packs.A cell pack is characterized by the fact that its battery cells are electrically connected to one another via the electrical conductors of the cell pack contact element. Additionally, a cell pack can be distinguished by the fact that, unlike a battery module, it does not have a housing; that is, the battery cells of one cell pack are not separated from the battery cells of another by a housing and / or a material layer. Alternatively, or in addition, a cell pack is characterized by the fact that, unlike a battery module, it does not have its own cooling system; that is, the battery assembly has a single cooling system responsible for cooling all the battery cells of the battery module. This results in the advantages of a C2P architecture compared to a C2M architecture.

[0035] The invention comprises a method for repairing a battery assembly, comprising at least the following steps: a. Identifying a defective cell pack. This means determining which cell pack contains at least one defective battery cell. A defective battery cell is characterized by poorer performance in at least one property than the average of all other battery cells. The following assumes a single defective cell pack. If there are multiple defective cell packs, the repair procedure can be repeated for each one. b. Cutting the contact element along the boundaries of the cell pack contact element resting on the defective cell pack. This allows the cell pack contact element to be detached from the remaining contact element. In particular, the cell pack-spanning electrical conductors originating from the cell pack contact element resting on the defective cell pack are severed. c. Removal of the cell pack contact element and the defective cell pack itself. For this purpose, the battery cells of the defective cell pack, connected to the cell pack contact element, can be detached from the tray. d. Inserting a new cell pack which, apart from the defect, is structurally identical to the defective cell pack. For this purpose, battery cells, in particular different from those of the defective cell pack, can be integrated into the tray structure of the battery assembly. e. Placing a second cell pack contact element, which is identical in construction to the cell pack contact element on the defective cell pack, onto the new cell pack. f. Establishing an electrical connection between the active cell contact surfaces of the battery cells of the new cell pack and the contact surfaces of the second cell pack contacting element. This can be done, for example, by welding, especially laser welding, or soldering. g. Establishing at least one electrical connection between the electrical conductors of the second cell pack contact element and the electrical conductors of at least one other cell pack contact element. Preferably, an electrical connection is established to cell pack contact elements adjacent to the second cell pack contact element. The electrical connection between two cell pack contact elements refers in particular to an electrical connection between the electrical conductors of the respective cell pack contact elements. Establishing the electrical connection between the second cell pack contact element and at least one other cell pack contact element is particularly necessary to replace the severed electrical conductors spanning the cell pack. This can be achieved, for example, via at least one connector.

[0036] Preferably, the repair results in a battery arrangement according to the invention.

[0037] The battery assembly offers the advantage that, despite its C2P architecture, a simple repair procedure is provided, while retaining the benefits of a C2P architecture. This means that if at least one battery cell fails, the entire battery assembly does not need to be replaced, and the cost of repairing the assembly does not exceed the cost of the assembly itself. Additionally or alternatively, the electrical connections between the contacting element's contact surfaces and the active cell contact surfaces of the battery cell do not need to be severed for repair, which would be a complex and costly process.

[0038] The invention further comprises a method for manufacturing the battery assembly, comprising performing at least the following steps: a. Integrating the battery cells into a tray structure. This means that some of the battery cells of the battery assembly, in particular all battery cells of the battery assembly, are integrated, in particular glued, into a tray structure, which may be a housing of the battery assembly. b. Unrolling the contact element onto the battery cells arranged in the tray structure, so that the contact element rests on all battery cells. Before being placed onto the battery cells, the contact element is preferably coiled or rolled up. Particularly in the case of an FPC or a film with conductive elements such as wires, the contact element is coiled, especially coiled on a cylindrical form. To place the contact element onto the battery cells, it can be unrolled. Preferably, the shape of the contact element is adapted to the tray shape, so that no adjustment of the shape, for example by cutting the contact element, is necessary. The contact element is particularly a single piece. c. Establishing electrical connections between the active cell contact surfaces and the contact surfaces. This can be done, for example, by welding, especially laser welding, or soldering.

[0039] Preferably, after the repair, a battery arrangement according to the invention or a battery arrangement equivalent to the battery arrangement according to the invention is obtained, which has the same electrical properties.

[0040] The advantage of this battery arrangement is that its manufacture can be achieved very simply and therefore cost-effectively by integrating, for example by gluing, the battery cells and / or by rolling the finished contact element onto the battery cells.

[0041] The invention also includes further developments of the methods according to the invention, which have features already described in connection with the further developments of the battery arrangement according to the invention. For this reason, the corresponding further developments of the methods according to the invention are not described again here.

[0042] The motor vehicle according to the invention is preferably designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle.

[0043] The invention also includes combinations of the features of the described embodiments. The invention therefore also includes realizations that each exhibit a combination of the features of several of the described embodiments, provided that the embodiments have not been described as mutually exclusive.

[0044] The following are exemplary embodiments of the invention described. This is illustrated by: Fig. 1 a schematic representation of the inventive method for manufacturing the battery arrangement; Fig. 2 a schematic representation of the inventive method for repairing the battery assembly; Fig. 3 a schematic representation of the battery arrangement according to the invention.

[0045] The exemplary embodiments described below are preferred embodiments of the invention. In these exemplary embodiments, the described components each represent individual features of the invention, which can be considered independently of one another and each further develops the invention independently. Therefore, the disclosure is intended to include combinations of features of the embodiments other than those shown. Furthermore, the described embodiments can also be supplemented by further features of the invention already described.

[0046] In the figures, identical reference symbols denote functionally equivalent elements.

[0047] Fig. Figure 1 shows an exemplary process for manufacturing the battery assembly 100. In a first manufacturing step S10, at least one tray mold 200, at least two battery cells 400, and one contacting element 600 can be provided. The tray mold 200 can define the shape of the battery assembly 100. Examples are shown in Fig. 1 only a few battery cells 400 are shown. Furthermore, an example is shown in Fig. Figure 1 shows a battery cell 400, which can be classified as a cylindrical cell. Alternatively, the battery cell 400 could also be a pouch cell or a prismatic cell, as shown in Figure 1. Fig. 1 is not shown.

[0048] In an installation step S11, the battery cells 400 can be integrated into the tray-shaped form 200. This can be done, for example, by gluing the battery cells 400 into the tray-shaped form 200. The battery cell 400 comprises at least one cell contact surface 410. Fig. In Figure 1, the battery cell 400 comprises, for example, two cell contact surfaces 410. The cell contact surface 410 is designed to enable charge exchange between the battery cell 400 and, for example, a conductor. Thus, charging and / or discharging of the battery cell is possible via the cell contact surface 410. The battery cells 400 are integrated into the tray-shaped housing 200 such that each battery cell 400 has at least one active cell contact surface 420. In the exemplary case in Fig. Each battery cell 400 has two active cell contact surfaces 420. The active cell contact surface 420 is a cell contact surface 410 which points in a predefinable spatial direction 110 when the battery cell 400 is integrated into the tray 200. After the battery cells 400 are integrated into the tray 200, all active cell contact surfaces 420 lie in a common cell contact plane.

[0049] The contact element 600 is placed on the battery cells 400 integrated into the tray 200. Preferably, the contact element 600 is a flexible element, for example, a flexible printed circuit or a film onto which, for example, conductive elements are applied. The contact element 600 is preferably planar and / or monolithic and / or can, for example, be rolled up, as shown in Fig. The contact element 600 is shown schematically in Figure 1 and can be placed onto the battery cells 400, for example, by rolling it onto the battery cells 400. The contact element 600 is placed onto the battery cells so that it rests on the battery cells 400 and / or rests on the cell contact plane. Preferably, the extent of the contact element 600 corresponds to the extent of the tray 200 in the cell contact plane, so that after rolling, the contact element 600 is flush with the walls of the tray 200 and / or the extent of the contact element 600 does not need to be adjusted after rolling. The contact element 600 has contact surfaces 610 and electrical conductors 620. The contact element 600 is placed onto the battery cells 400, for example, by rolling it onto the battery cells 400 such that the contact surfaces 610 rest on the active cell contact surfaces 420.The contact surfaces 610 are electrically connected to the active cell contact surfaces 420. The electrical connection between the active cell contact surfaces 420 and the contact surfaces 610 can be established by welding, in particular laser welding, or soldering.

[0050] The contacting element 600 comprises at least one cell pack contacting element 630. In particular, the contacting element 600 consists of at least one cell pack contacting element 630. A cell pack contacting element 630 is characterized by the fact that it represents a region of the contacting element 600. The contacting element 600 is thus divided into several regions, the cell pack contacting elements 630. A cell pack contacting element can have various shapes, for example, triangular, rectangular, square, pentagonal, or hexagonal. Fig. Figure 1 shows, for example, a zigzag-shaped cell pack contacting element 630. Preferably, all cell pack contacting elements 630 have the same shape. In particular, all cell pack contacting elements 630, except for those at the edge of the contacting element 600, have the same shape. The latter case is shown by way of example in Figure 1. Fig. 1 shown.

[0051] Adjacent cell pack contacting elements 630 can be characterized by sharing at least part of the boundary 640 of the cell pack contacting element 630. Fig. 1. Cell pack contact elements 631 and 632 are examples of adjacent cell pack contact elements 630.

[0052] The battery cells 400, on which the same cell pack contact element 630 rests, are assigned to a cell pack 430. This means that the battery cells 400 of the battery assembly 100 are subdivided into cell packs 430, specifically according to the subdivision of the contact element 600 into the cell pack contact elements 630. The cell packs 430 represent a grouping of the battery cells 400; that is, the battery cells are integrated into the tray 200 and then assigned to groups, the cell packs 430. This contrasts with the C2M architecture, in which the battery cells 400 are first integrated into modules, which may include, for example, a housing and / or their own cooling system, and the modules are then integrated into the tray 200. In the case of the battery assembly 100, the cell packs 430 do not include their own housing and / or cooling system.In particular, the cell packs 430 consist of a plurality of battery cells 400.

[0053] The battery cells 400 of each cell pack 430 are electrically connected to one another. For this electrically conductive connection of the battery cells 400 of the cell pack 430, the contacting element 600 comprises electrical conductors 620. The electrical conductors 620 electrically connect the contact surfaces 610 or a portion thereof. In particular, each cell pack contacting element 630 comprises at least one, preferably exactly one or exactly two, electrical conductors 620. The electrical conductors 620 connect the contact surfaces 610 such that all battery cells 400 of the respective cell pack 430 are electrically connected to one another via the at least one electrical conductor 620 of the respective cell pack contacting element 630.Preferably the electrical conductors 620 of each cell pack contacting element 630 are identical, i.e., the cell pack contacting elements 630 do not differ in the course of the respective electrical conductors 620.

[0054] To achieve an electrically conductive connection between all battery cells 400 of the battery assembly 100, cell pack-spanning electrical conductors 650 can be provided. An example of a cell pack-spanning electrical conductor 650 is shown in Fig. Figure 1 is shown. For the sake of clarity, the representation of further cell pack-spanning electrical conductors 650 has been omitted. Fig. 1. A cell pack-spanning electrical conductor 650 connects at least one electrical conductor 620 of a cell pack contact element 630 to another electrical conductor 620 of another, preferably an adjacent, cell pack contact element 630. The electrical connection between two cell pack contact elements 630 is referred to here as a cell pack-spanning electrical conductor 650. Preferably, the number of cell pack-spanning electrical conductors 650 originating from a cell pack contact element 630, i.e., those electrically conductive connections that are electrically connected to at least one electrical conductor 620 of the respective cell pack contact element 630, is equal to the number of cell pack contact elements 630 adjacent to the respective cell pack contact element 630. Preferably, each cell pack contact element 630 has at least one electrical connection to all adjacent cell pack contact elements 630.

[0055] For example, during the manufacture of the battery assembly 100 or after the manufacture of the battery assembly 100, for example when using the battery assembly 100 in a motor vehicle 120, a repair of the battery assembly 100 may be provided. Fig. Figure 2 shows an embodiment of the repair method according to the invention. The repair of the battery arrangement 100 comprises, as a first repair step S20, identifying at least one defective cell pack 431. This means determining in which cell pack 430 at least one defective battery cell 400 is located, i.e., a battery cell 400 in which at least one electrical property deviates from the average of this electrical property of all battery cells 400. Preferably, the deviation is greater than a predefinable threshold value. In the following, we will assume a defective cell pack 431 in which at least one defective battery cell 400 is located. The defective cell pack 431 is in Fig. 2 is exemplified by a lightning bolt 432. In the case of several defective cell packs 431, the procedure for repairing a battery assembly can be repeated according to the number of defective cell packs 431.

[0056] In a second repair step S21, the contact element 600 is cut S641 along the boundaries 640 of the cell pack contact element 630 resting on the defective cell pack 431. Fig. Figure 2 schematically represents the cutting operation S641 using symbolic scissors. Cutting operation S641 can be equated with separation; that is, the contact element 600 is processed such that the cell pack contact element 630, along whose boundaries 640 the cutting operation S641 takes place, can be separated from the remaining contact element 600 after the cutting operation S641. This means that after cutting operation S641, two independent parts can exist: the separated cell pack contact element 630, i.e., the cell pack contact element 630 along whose boundaries 640 the cutting operation S641 took place, and the remaining contact element 600, i.e., the contact element 600 without the separated cell pack contact element 630.

[0057] To ensure a particularly simple and therefore advantageous cutting S641, the contacting element 600 can be mechanically weakened along the boundaries 640 of each cell pack contacting element 630. This allows the contacting element to be cut (separated) along the boundaries 640 of each cell pack contacting element 630. This can be achieved, for example, by a predetermined breaking point and / or a perforation. Mechanical weakening means, in particular, that the contacting element 600 is not as resistant to at least one mechanical force at the points of mechanical weakening as at the other points. This means, in particular, that when this at least one mechanical force is applied, the contacting element 600 will cut S641 along the mechanical weakening if the mechanical force exceeds a predefinable value.In particular, the cutting S641 of the contact element 600 along the boundaries of the cell pack contact element 630 resting on the defective cell pack 431 can be effected by exerting at least one mechanical force, especially on the cell pack contact element 630 resting on the defective cell pack 431. When the contact element 600 is cut S641 along the boundaries of the cell pack contact element 630 resting on the defective cell pack 431, at least one cell pack-spanning electrical conductor 650 is cut. Specifically, all cell pack-spanning electrical conductors 650 originating from the cell pack contact element 630 resting on the defective cell pack 431 are cut. This means that the electrical connections that existed based on the cut cell pack-spanning electrical conductors 650 are interrupted.As a result, after cutting S641, there is no longer an electrically conductive connection between the battery cells 400 of the defective cell pack 431 and the battery cells of the other cell packs 430 of the battery arrangement 100.

[0058] In a third repair step S22, the defective cell pack 431 and the cell pack contact element 630 resting on the defective cell pack 431 are removed. This can result in at least two parts: the defective cell pack 431 with the cell pack contact element 630 resting on it, and the remaining battery assembly 101.

[0059] In a fourth repair step S23, a new cell pack 433 is inserted, which, apart from the defect, is identical in construction to the defective cell pack 431. A second cell pack contact element 633, identical in construction to the cell pack contact element 630 on the defective cell pack 431, is then placed onto the new cell pack 433. Thus, the battery cells 400 of the new cell pack 433 are integrated into the tray 200 at the locations where the battery cells 400 of the defective cell pack 431 were integrated. Subsequently, the second cell pack contact element 633 is placed onto the new cell pack 433, establishing an electrically conductive connection between the active cell contact surfaces 420 of the battery cells 400 of the new cell pack 433 and the contact surfaces 610 of the second cell pack contact element 633.This allows all battery cells 400 of the new cell pack 433 to be electrically connected to each other via the second cell pack contacting element 633.

[0060] To electrically connect the battery cells 400 of the new cell pack 433 with the battery cells 400 of the remaining battery arrangement 101, an electrically conductive connection is established in a fifth repair step S24 between the at least one electrical conductor 620 of the second cell pack contact element 633 and the at least one electrical conductor 620 of at least one other cell pack contact element 630. Preferably, an electrical connection is established between the at least one electrical conductor 620 of the second cell pack contact element 633 and the respective at least one electrical conductor 620 of each cell pack contact element 630 adjacent to the second cell pack contact element 633.

[0061] To establish the electrical connection between the second cell pack contact element 633 and at least one other cell pack contact element 630, each cell pack contact element can have at least one connector contact surface 660. The connector contact surface 660 is electrically connected to the at least one electrical conductor 620 of the cell pack contact element 630 and can be electrically connected to at least one connector 651. The connector 651 can electrically connect two connector contact surfaces 660 to each other, such that the at least one electrical conductor 620 of one cell pack contact element 630 is electrically connected to the at least one electrical conductor 620 of at least one other cell pack contact element 630. In particular, the connector 651 is configured to replace at least one, preferably exactly one, cell pack-spanning electrical conductor 650.This can mean that the number of connector contact surfaces 660 corresponds to the number of cell pack-spanning electrical conductors 650 originating from the respective cell pack contact element 630. In the case of the second cell pack contact element 633, the number of connector contact surfaces 660 can correspond to the number of cell pack-spanning electrical conductors 650 that were severed in the second repair step S21 during the cutting operation S641. Preferably, the number of connectors 651 used for the electrical connection of the second cell pack contact element 633 with at least one other cell pack contact element 630 corresponds to the number of connector contact surfaces 660 of the second cell pack contact element 633 and / or the number of cell pack contact elements 630 adjacent to the second cell pack contact element 633.The at least one connector 651 preferably establishes exactly one electrical connection between the second cell pack contacting element 633 and each cell pack contacting element 630 adjacent to the second cell pack contacting element 633.

[0062] In particular, the connector 651 has the same electrical properties as the respective cell pack-spanning electrical conductor 650 that the connector 651 replaces. The connector 651 is, in particular, an electrically conductive connection between at least two connector contact surfaces 660. The connector 651 can be electrically connected to a connector contact surface 660, for example, by welding, in particular laser welding, and / or soldering and / or via a plug connection.

[0063] The battery arrangement 100 can, for example, be installed in a motor vehicle 120. In particular, the battery arrangement can provide the power required to operate at least one electric motor in the motor vehicle. Preferably, the at least one electric motor is an electric motor that provides the power to drive the motor vehicle.

[0064] The following is a particularly preferred embodiment: Switching from C2M to C2P architecture, that is, from C2M to C2P battery concepts, results in more efficient space utilization and / or multifunctionality and / or greater battery storage capacity. Additionally or alternatively, this leads to greater difficulties regarding repairability and / or rework during manufacturing.

[0065] In a battery with a C2P architecture, battery cells 400 are integrated into a tray 200, primarily by bonding. This means the battery cannot be reworked, so if at least one cell 400 fails, the entire battery must be replaced. The disadvantages of the C2M architecture are the complex secondary structure, resulting particularly from the use of modules, and the structural integrity issues and the need for additional connection technology to integrate the modules into the tray 200.

[0066] Fig. Figure 3 shows an exemplary embodiment of a battery arrangement 100. In particular, it shows Fig.3. A reworkable battery assembly 100 comprising a reworkable contact element 600, which may, for example, comprise a flexible plastic carrier film or consist of the plastic carrier film. The plastic carrier film can be rolled over the battery cells 400 integrated in the tray-shaped housing 200. The battery cells 400 may be prismatic cells, cylindrical cells, or pouch cells. The contact element 600 may be subdivided into cell pack contact elements 630. The cell pack contact elements 630 are preferably identical. The contact element 600 is thus repeated modularly, i.e., at the level of the cell pack contact elements 630.Each cell pack contact element can have at least one low-voltage contact 801 (LV contact), at least one high-voltage contact 802 (HV contact), at least one electrical conductor 620, for example in the form of an FPC (flexible printed circuit), and / or at least one connector contact surface 660 to which a connector 651 can be electrically connected. The connector can establish an electrical connection between the electrical conductors 620 of two cell pack contact elements 630. The contact element 600 can be pre-perforated in the region of the boundaries 640 of the cell pack contact elements 630 and / or have a mechanical weakening, whereby the cell packs 430 and the respective cell pack contact element 630 resting on them are reversibly interchangeable. That is, the battery assembly 100 can be reversibly interchangeable at the stack level.By laser welding, a cell contact 803 can be created after unwinding the contact element 600, i.e., an electrically conductive connection between the battery cells 400 of the respective cell pack 430 and the respective at least one electrical conductor 620 of the respective cell pack contact element 630. The cell pack contact elements 630 can be electrically connected to each other by means of at least one connector 651. Alternatively, the cell pack contact elements 630 can be electrically connected to each other by means of cell pack-spanning electrical conductors 650. The connectors 651 can be used in the event of repair and replace the cell pack-spanning electrical conductors 650. This would have the advantage that the electrical conductors 620, preferably the FPC, run continuously over the entire contact element 600, i.e., over the entire carrier film, and are only cut in the event of repair.Electrical and sensory connections are re-established via connectors 651.

[0067] Overall, the examples show how a reworkable cell contacting unit can be provided.

Claims

[1] Battery arrangement (100) comprising at least two cell packs (430), wherein • each of the cell packs (430) comprises at least two battery cells (400), ◯ wherein each of the battery cells (400) comprises at least one cell contacting surface (410), wherein the cell contacting surface (410) is configured such that a charging and / or discharging of the respective battery cell (400) takes place via the cell contacting surface (410), and ◯ each battery cell (400) has at least one active cell contact area (420), ◯ wherein an active cell contacting surface (420) is a cell contacting surface (410) which points in a predeterminable spatial direction (110) common to all active cell contacting surfaces (420), and ◯ all active cell contact surfaces (420) lie in a common cell contact plane, and • for each of the cell packs (430), all battery cells (400) are electrically connected to one another via a contacting element (600) in that ◯ the contacting element (600) is arranged resting on the battery cells (400) and / or resting on the cell contacting plane, ◯ the contacting element (600) comprises at least two cell pack contacting elements (630), • wherein each cell pack contacting element (630) is the area of ​​the contacting element (600) which rests on all battery cells (400) of the respective cell pack (430), • and each point of the contacting element (600) corresponds to a point on a maximum of one cell pack contacting element (630), • and exactly one cell pack contact element (630) rests on each battery cell (400), and ◯ the contacting element (600) has contacting surfaces (610) which are electrically conductively connected to the active cell contacting surfaces (420), wherein each active cell contacting surface (420) is electrically conductively connected to at least one contacting surface (610), and ◯ the contacting element (600) has electrical conductors (620) which are designed to electrically connect the contacting surfaces (610) to one another and ◯ the contacting element (600) is designed to be more easily separated along the boundaries (640) of at least one cell pack contacting element (630). [2] Battery arrangement (100) according to claim 1, wherein the course of the electrical conductors (620) in the region of each cell pack contacting element (630) is identical. [3] Battery arrangement (100) according to one of the preceding claims, wherein all battery cells (400) of the battery arrangement (100) are electrically conductively connected to one another in that the electrical conductors (620) of each cell pack contacting element (630) resting on the respective cell pack (430) are each electrically connected via cell pack-spanning electrical conductors (650) to the electrical conductors (620) of at least one other cell pack contacting element (630), and the number of cell pack-spanning electrical conductors (650) originating from a cell pack contacting element (630) is limited in that it corresponds at most to the number of cell packs (430) adjacent to the respective cell pack (430). [4] Battery arrangement (100) according to one of the preceding claims, wherein all battery cells (400) of the battery arrangement (100) are electrically connected to one another in that the electrical conductors (620) of each cell pack contacting element (630) resting on the respective cell pack (430) are each electrically connected via cell pack-spanning electrical conductors (650) to the electrical conductors (620) of at least one other cell pack contacting element (630), and each cell pack contacting element (630) has connector contacting surfaces (660) which are electrically connected to the electrical conductors (620) of the cell pack contacting element (630), wherein the connector contacting surfaces (660) are configured to replace at least one cell pack-spanning electrical conductor (650) between a first cell pack contacting element (630) and a second cell pack contacting element (630).by electrically connecting at least one connector contacting surface (660) of the first cell pack contacting element (630) to at least one connector contacting surface (660) of the second cell pack contacting element (630) via a connector (651). [5] Battery arrangement (100) according to claim 4, wherein the number of connector contact surfaces (660) of the respective cell pack (430) corresponds to at least a minimum number of connectors, wherein the minimum number of connectors corresponds to the number of cell pack-spanning electrical conductors (650) originating from the cell pack (430). [6] Battery arrangement (100) according to one of claims 4 to 5, wherein the electrically conductive connection between the connector (651) and the at least one connector contact surface (660) is a welded or soldered connection or a plug connection. [7] Battery assembly (100) according to one of the preceding claims, wherein the electrically conductive connection between the active cell contacting surface (420) and the contacting surface (610) is a welded or soldered connection. [8] Battery arrangement (100) according to one of the preceding claims, wherein the contacting element (600) is mechanically weakened along the boundaries (640) of the respective cell pack contacting elements (630). [9] Battery arrangement (100) according to one of the preceding claims, wherein the contacting element (600) is a single element resting on all battery cells (400) of each cell pack (430) and / or the contacting element (600) is a flat and / or flexible element. [10] Battery arrangement (100) according to one of the preceding claims, wherein the battery cells (400) are integrated into a trough shape (200) and the extension of the contacting element (600) corresponds to the extension of the trough shape (200) in the cell contacting plane. [11] Battery arrangement (100) according to one of the preceding claims, wherein the cell pack (430) differs from a battery module of a cell-to-module architecture in that a delimitation of the individual cell packs (430) by a respective housing for at least one cell pack (430) is dispensed with and / or a single cooling system is used for all battery cells (400) of the battery arrangement (100) and / or the cell pack (430) consists of a plurality of battery cells (400). [12] A method for repairing a battery assembly (100) according to any one of the preceding claims, comprising at least the following steps: a. Detecting a faulty cell pack (430), b. Severing the contacting element (600) along the boundaries (640) of the cell pack contacting element (630) resting on the defective cell pack (430) c. Removal of the cell pack contact element (630) resting on the defective cell pack (430) and the defective cell pack (430), d. Inserting a new cell pack (430) which, apart from the defect, is identical to the defective cell pack (430), e. Placing a second cell pack contacting element (633), which is identical in construction to the cell pack contacting element (630) resting on the defective cell pack (430), on the new cell pack (430), f. Establishing an electrical connection between the active cell contact surfaces (420) of the battery cells (400) of the new cell pack (430) and the contact surfaces (610) of the second cell pack contact element (633), and g. Establishing at least one electrical connection between the electrical conductors (620) of the second cell pack contacting element (633) to the electrical conductors (620) of at least one other cell pack contacting element (630). [13] A method for producing a battery assembly (100) according to any one of claims 1 to 11, wherein the following steps are carried out: a. Integrating the battery cells (400) into a tray structure, b. rolling the one contacting element (600) onto the battery cells (400) arranged in the tray structure, so that the contacting element (600) rests on all battery cells (400), and c. Establishing electrical connections between the active cell contact surfaces (420) and the contact surfaces (610).

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