Cell contacting system

Abstract

A cell contacting system for a multi-cell battery and a battery system with such a cell contacting system are proposed. An embodiment of the cell contacting system (1) comprises: a first half-shell (10) with at least one first opening (12); a second half-shell (20) with at least one second opening (22), wherein the second half-shell (20) is connected to the first half-shell (10), in particular by welding; and a plurality of cell connector elements (100). Each of the plurality of cell connector elements (100) has at least one contacting area (200).The plurality of cell connector elements (100) is positioned or positionable between the first half-shell (10) and the second half-shell (20) such that the plurality of cell connector elements (100) is received or can be received in the at least one first opening (100) and the at least one contacting area (200) of the plurality of cell connector elements (100) is received or can be received in the at least one second opening (20).

Description

[0001] The present invention relates generally to a cell contacting system and a battery system. More specifically, the present invention relates to a cell contacting system for a multi-cell battery and to a battery system comprising such a cell contacting system.

[0002] In a cell contacting system for vehicles, especially high-voltage vehicles, cell connectors and wiring harnesses or flexible circuit boards are typically fixed in large plastic frames. The frame holds the entire assembly together until the cell connectors are welded onto the cell terminals during high-voltage battery manufacturing. Furthermore, the frame ensures the correct grid spacing of the cell connectors on the cell terminals and must therefore compensate for positional and manufacturing tolerances of both the cell connectors and the batteries. Depending on the battery stack, the frame dimensions can range from approximately 30 cm to approximately 200 cm. These plastic frames are usually injection-molded. Manufacturing these large plastic parts involves complex, large, and expensive tooling, high material consumption, and long cycle times.

[0003] DE 10 2013 2218 72 A1 relates to a connector for connecting cell-shaped electrical elements. A ribbon-shaped connector for connecting cell-shaped electrical elements is described, consisting of a ribbon-shaped support element and a ribbon-shaped retaining element, wherein at least one contact element is arranged between the support element and the retaining element.

[0004] DE 10 2013 220 044 A1 relates to a cell contacting system for an electrochemical device comprising several electrochemical cells. The cell contacting system includes a power conduction system with one or more conductors for electrically connecting cell terminals of different electrochemical cells to each other or for electrically connecting a cell terminal of an electrochemical cell to a power connection of the cell contacting system, and a signal conduction system with one or more signal conductors for electrically connecting at least one signal source to a signal connection or to a monitoring device of the cell contacting system. The cell contacting system comprises a multi-layer laminate.The laminate comprises at least one conductor layer, which includes one or more conductors of the power supply system, and at least one signal conductor layer, which includes one or more signal conductors of the signal supply system.

[0005] DE 10 2023 135 262 A1 describes a traction battery assembly comprising a busbar, a support frame having a pocket for the busbar, and a cap attached to the support frame to contain the busbar within the pocket. A busbar holding method includes positioning at least one busbar with a pocket in a support frame, placing the busbar on at least one support, and attaching a cap to the support frame to hold the busbar within the pocket.

[0006] CN 2 21 126 191 U refers to a CCS assembly that is mounted on a battery module and comprises a busbar assembly, a first insulating film, and an insulating backing plate. The busbar assembly includes an output busbar and a connecting busbar, arranged longitudinally at the two ends of the battery module. The insulating backing plate is parallel to the insulating film, and the first insulating film is located on the side of the busbar assembly facing away from the battery cell and is attached to the busbar assembly. The insulating backing plate is located on the side of the busbar assembly facing the battery cell and is attached to the busbar assembly.

[0007] CN 2 21 009 173 U relates to a busbar support assembly comprising a busbar support, a measuring strip and a temperature sensor assembly, wherein the busbar support is provided with a first side surface and a second side surface opposite each other, wherein the first side surface is recessed towards the second side surface so that a receiving groove is formed in the first side surface, and wherein the measuring strip is arranged in the receiving groove.

[0008] There is a need for an improved cell contacting system and an improved battery system incorporating such a cell contacting system. In particular, there is a need for a cell contacting system that is easy to manufacture, simple in design, and / or space-saving.

[0009] According to a first aspect, a cell contacting system for a multi-cell battery is provided. The cell contacting system comprises a first half-shell and a second half-shell. The first half-shell has at least one first opening. The second half-shell has at least one second opening. The second half-shell is connected to the first half-shell, in particular by welding. The cell contacting system further comprises a plurality of cell connector elements. Each of the plurality of cell connector elements has at least one contact area.The multitude of cell connector elements is positioned or positionable between the first half-shell and the second half-shell in such a way that the multitude of cell connector elements is received or can be received in the at least one first opening and the at least one contacting area of ​​the multitude of cell connector elements is received or can be received in the at least one second opening.

[0010] The cell contacting system can also be referred to as a cell contacting unit. The at least one contacting area can have at least one contact element or contacting element, or be configured as at least one contact element or contacting element.

[0011] The wording that the plurality of cell connector elements is received or can be received in the at least one first opening can be understood, in particular, to mean that relevant areas of the plurality of cell connector elements for the connection of cells lie in the region of the at least one first opening. For example, the at least one first opening can be at least nearly congruent with these relevant areas of the plurality of cell connector elements. The relevant areas can, in particular, be areas of the cell connector elements on whose rear sides the at least one contact area of ​​the cell connector elements is arranged.For example, the wording that the plurality of cell connector elements is received or receptable in the at least one first opening can be understood to mean that the cell connector elements—except for areas provided for fixing the cell connector elements, such as those projecting from the cell connector elements—lie within the area of ​​the at least one first opening or are congruent with the at least one first opening. For example, a respective front face of the cell connector elements can be at least nearly congruent with the at least one first opening or be received or receptable at least almost completely within the at least one first opening.

[0012] Furthermore, the wording that the at least one contact area of ​​the plurality of cell connector elements is received or can be received in the at least one second opening can be understood to mean that areas of the at least one contact area relevant for the connection of cells lie within the area of ​​the at least one second opening. For example, the at least one second opening can be at least nearly congruent with these relevant areas of the at least one contact area of ​​the plurality of cell connector elements. For example, the at least one second opening can be at least nearly congruent with the at least one contact area or with the areas having the at least one contact area.For example, a respective back side of the cell connector elements can be at least almost identical to the at least one second opening, or at least almost completely received or received in the at least one second opening.

[0013] The at least one first opening can be formed by penetrating the first half-shell. In other words, the at least one first opening can penetrate the first half-shell and thus also be formed as a recess penetrating the first half-shell. The first half-shell can therefore be open in the area of ​​the at least one first opening.

[0014] The at least one second opening can be formed by penetrating the second half-shell. In other words, the at least one second opening can penetrate the second half-shell and thus also be formed as a recess penetrating the second half-shell. The second half-shell can therefore be open in the area of ​​the at least one second opening.

[0015] The first half-shell can be film-like or foil-shaped. The second half-shell can also be film-like or foil-shaped. When the first and second half-shells are joined, a flat, film-like or foil-shaped structure can be formed.

[0016] The at least one first opening can have a plurality of first openings or be configured as a plurality of first openings. The first half-shell can thus have a plurality of first openings. Additionally or alternatively, the at least one second opening can have a plurality of second openings or be configured as a plurality of second openings. The second half-shell can thus have a plurality of second openings. The number of the plurality of second openings can correspond to the number of the plurality of first openings.The multitude of cell connector elements can be positioned or positionable between the first half-shell and the second half-shell in such a way that the multitude of cell connector elements is received or received in the multitude of first openings and at least one contacting area of ​​the multitude of cell connector elements is received or received in the multitude of second openings.

[0017] The wording that the multitude of cell connector elements is received or can be received in the multitude of first openings can be understood, in particular, to mean that the relevant areas of the cell connector elements for connecting cells are located in the region of the first openings. For example, the first openings can each be at least nearly congruent with these relevant areas of the cell connector elements. The relevant areas can, in particular, be those areas of the cell connector elements on whose rear sides at least one contact area of ​​the respective cell connector elements is located.For example, the wording that the multitude of cell connector elements is received or received in the multitude of first openings can be understood to mean that the cell connector elements - except for areas provided for fixing the cell connector elements, for example, areas projecting from the cell connector elements - are each located in the area of ​​the first openings or are congruent with the first openings.

[0018] Furthermore, the wording that the at least one contact area of ​​the plurality of cell connector elements is received or received in the plurality of second openings can be understood to mean that, for the connection of cells, relevant areas of the at least one contact area are located in the region of the second openings. For example, the second openings can each be at least nearly congruent with these relevant areas of the at least one contact area. For example, the second openings can be congruent with the at least one contact area of ​​the cell connector elements or with the areas of the cell connector elements that have at least one contact area.

[0019] The openings of the plurality of first openings can each be designed to penetrate the first half-shell. In other words, the openings of the plurality of first openings can each penetrate the first half-shell and thus also be designed as recesses penetrating the first half-shell. The first half-shell can therefore be open in the area of ​​the openings of the plurality of first openings.

[0020] The openings of the plurality of second openings can each be designed to penetrate the second half-shell. In other words, the openings of the plurality of second openings can each penetrate the second half-shell and thus also be designed as recesses penetrating the second half-shell. The second half-shell can therefore be open in the area of ​​the openings of the plurality of second openings.

[0021] Each of the numerous cell connector elements can have at least two contact areas or contact elements.

[0022] The number of the plurality of second openings can be greater than the number of the plurality of first openings. The number of cell connector elements can correspond to the number of the plurality of first openings. In this way, each of the openings of the plurality of first openings can accommodate one of the cell connector elements. The number of contact areas or contact elements can correspond to the number of the plurality of second openings. In this way, each of the openings of the plurality of second openings can accommodate one of the contact areas or contact elements. Again, the relevant areas of the contact areas or contact elements for connecting cells can each lie within the region of the second openings. For example, the second openings can each be at least nearly congruent with these relevant areas of the contact areas or contact elements.For example, the second openings can be congruent with the contact areas or contact elements, or with the areas containing the contact areas or contact elements.

[0023] The at least one contact area, for example, the contact areas or contact elements, can be connected to the terminals of cells in a battery (battery cells). One section of the contact area can be connected to the positive terminal of a cell, and another section can be connected to the negative terminal of an adjacent cell. For example, one contact area / contact element of a cell connector can be connected to the positive terminal of a cell, and another contact area / contact element of the same cell connector can be connected to the negative terminal of an adjacent cell. In this way, several adjacent cells can be connected or interconnected using the cell contacting system. For example, adjacent cells can be connected in parallel or in series.According to one embodiment, at least one cell stack, each containing several cells, can be arranged in a longitudinal direction / extent of the cell contacting system. The cells of the cell stack can be connected to one another by the cell contacting system. In this way, several adjacent cells of a cell stack can be connected or interconnected by means of the cell contacting system.

[0024] In other words, the cell connector elements can be configured to connect a first cell terminal / cell connection / cell pole of a first cell to a second cell terminal / cell connection / cell pole of a second cell. The cell connector element can have a first contact area for connecting to the first cell terminal / cell connection / cell pole and a second contact area for connecting to the second cell terminal / cell connection / cell pole. By connecting the cell connector elements to the cells, a desired voltage and current can be supplied to and / or from the cells. The cell connector elements can be arranged in a modular fashion along a lengthwise direction. The length of the cell contacting system can be adjusted by simply omitting or adding one or more cell connector elements.In this way, the length of the cell contacting system can be adapted to the required length of a cell stack. For example, the length of the cell contacting system can correspond at least almost exactly to the length of the cell stack.

[0025] The multitude of initial openings can each have at least partially the same shape. In this way, cell connectors of the same shape can be accommodated, at least partially, in the initial openings. Additionally or alternatively, the multitude of initial openings can each have at least partially different shapes. In this way, cell connectors of different shapes can be accommodated, at least partially, in the initial openings.

[0026] The multitude of secondary openings can each have at least partially the same shape. In this way, contact areas or contact elements of the same shape can be accommodated, at least partially, in the secondary openings. Additionally or alternatively, the multitude of secondary openings can each have at least partially different shapes. In this way, contact areas or contact elements of different shapes can be accommodated, at least partially, in the secondary openings.

[0027] The multitude of initial openings can be designed to accommodate the multitude of cell connector elements, each at least with near-perfect fit. In other words, the multitude of initial openings can be designed to accommodate the multitude of cell connector elements at least almost exactly within the shaped areas that form the initial openings.

[0028] The multitude of secondary openings can be designed to accommodate the contact areas or contact elements at least almost perfectly. In other words, the multitude of secondary openings can be designed to accommodate the contact areas or contact elements at least almost exactly within the shaped areas forming the secondary openings.

[0029] The dimensions of the plurality of second openings can be smaller than the dimensions of the plurality of first openings. In other words, the openings of the plurality of first openings can each be larger than the openings of the plurality of second openings.

[0030] Each cell connector element of the plurality of cell connector elements can have at least one projection. This projection can be received in at least one associated receptacle or recess of the first half-shell. The projection can form a positive fit with at least one associated receptacle or recess of the first half-shell. This allows the cell connector elements of the plurality of cell connector elements to be held by the first half-shell. Simultaneously, each cell connector element can be accessed from the outside via the first openings.

[0031] The at least one projection can be received in at least one associated receptacle or recess of the second half-shell. Thus, the at least one projection can form a positive fit with at least one associated receptacle or recess of the second half-shell. This allows the cell connector elements of the plurality of cell connector elements to be held by the second half-shell. Due to the positive fit formed between the at least one projection and the first and second half-shells, the cell connector element can be held between the first and second half-shells. Simultaneously, the at least one contact area, for example, the contact elements, can be accessible from the outside via the second openings and used for contacting cells.

[0032] The cell contacting system may further comprise a third half-shell. The third half-shell may be applied to, or capable of being applied to, the first half-shell. In particular, the third half-shell may be applied to, or capable of being applied to, the first half-shell by means of a force-fit, form-fit, and / or material-fit connection. For example, the third half-shell may be welded or clipped onto, or capable of being welded or clipped onto, the first half-shell.

[0033] The third half-shell can be designed without openings. In other words, the third half-shell can be designed so that it has no openings. Alternatively, the third half-shell can have openings, but none of them are located in the area of ​​the cell connector elements when the third half-shell is connected to the first half-shell. In other words, the third half-shell can be designed so that none of its openings are located in the area of ​​the cell connector elements when the third half-shell is connected to the first half-shell. The third half-shell can, for example, serve as contact protection. Contact protection may be necessary due to the sometimes very high voltages, typically several hundred volts, especially in traction batteries for electric vehicles.

[0034] At least one receiving space can be formed in at least a subset of the cell connector elements. The receiving space can be formed in an area adjacent to the at least one contacting area, for example, next to one of the contact elements. The receiving space can be formed in an area between two contact elements.

[0035] The at least one receiving space can contain at least one connector element and / or at least one sensor element. Each connector element can be connected to or be connected to a control line and / or sensor line. Each sensor element can be connected to or be connected to a control line and / or sensor line.

[0036] A section of the first half-shell is designed, and the second half-shell is connected or connectable to the first half-shell, such that the section of the first half-shell and the second half-shell form a cable duct. The cable duct serves to accommodate one or more control cables and / or sensor cables. The cable duct can, for example, be directly connected to the at least one receiving space. This allows the at least one connector element and / or the at least one sensor element to be easily connected to the control cables and / or sensor cables routed within the cable duct.

[0037] According to one exemplary embodiment, the cable duct can form a longitudinal channel to accommodate a cable set referred to as a sensor cable set. This allows for a simple cable routing solution for the cable set. The cable set typically has a number of control lines and / or sensor lines, each of which can lead to a sensor, such as a temperature sensor, voltage sensor, etc. In a fully assembled state, the sensors can be connected via the cable set, in particular to a battery management system, which allows the battery and the individual cells to be monitored.

[0038] For example, the cell contacting system can have multiple temperature sensors. These temperature sensors can be distributed along the length of the system. Each temperature sensor can be connected to a sensor cable via a connector, for example, a plug element. This simplifies the assembly and electrical connection of the temperature sensors.

[0039] For example, the temperature sensor itself can have direct contact pins for plugging into a connector. The temperature sensor typically uses an electronic component, such as an NTC thermistor, as its sensing element. A connector can be inserted into a receptacle within a cell connector element and secured there. Generally, at least some, or even all, of the cell connector elements can have such a receptacle. The connector can be inserted into the receptacle in one direction and secured there.

[0040] The temperature sensors can be in thermally conductive contact with at least one of the cells, for example, via a cell housing. Each temperature sensor can therefore rest on the cell housing. A so-called hot-spot temperature measurement can be performed during operation using at least some of the temperature sensors. For this purpose, the corresponding temperature sensors can be positioned adjacent to a cell pole or cell connector element, since high temperatures can occur in the area of ​​the cell poles during operation due to current flow and / or ambient temperatures / conditions. At least a subset of the temperature sensors can each be designed as a cold-spot temperature sensor. In other words, at least one additional temperature sensor for a so-called cold-spot temperature measurement can be attached to or provided for on the cell contacting system.This at least one cold-spot temperature sensor can be mounted at a distance from the cell terminal or cell connector element. This additional temperature sensor allows for temperature measurement of each cell at a distance from a cell terminal during operation. The temperature sensor can be in thermal contact with the cell, particularly with a cell housing, when installed.

[0041] A crimp contact element can be provided on at least one connector element. The crimp contact element can be connected to a bond wire. An existing control line and / or sensor line can be electrically connected to a cell voltage tap (potential tap) via the bond wire and bonding. Such a voltage measurement may be required for each cell or cell stack of a battery as part of battery monitoring and a battery management system. The cell voltage can generally be measured via the voltage tap.

[0042] In one conceivable embodiment, the bond wire itself can form an overcurrent fuse with a predetermined fuse rating. The bond wire can therefore be designed as a fuse element, in particular as a fusible link. In this case, no separate fuse is required and can be omitted. A fuse rating can be defined or set by the properties of the bond wire. Specifically, the geometric properties, e.g., the length and / or the cross-sectional area, can be appropriately adjusted. For example, the bond wire can have a fuse rating in the range of 250 mA to 5 A, and particularly in the range of 750 mA to 1.5 A. The bond wire can be made of aluminum or an aluminum alloy.

[0043] The bond wire can be, in particular, a bare metal wire which is electrically connected directly to the tap point using a known bonding process. Direct bonding eliminates the need for a separate connection element to attach the sensor lead at the tap point for voltage measurement. The diameter of the bond wire can be, for example, between 25 µm and 150 µm, and particularly between 50 µm and 100 µm. Its length can be, for example, between 10 mm and 30 mm, and particularly between 15 mm.

[0044] The bond wire can be directly contacted at one end with a cell connector element. Since the cell connector element can, for example, be in direct electrical contact with a cell terminal, a voltage tap point can be defined by the cell connector element. The bond wire can be connected at its other end to a contact element, particularly a crimp contact element. It can also be connected to this contact element by bonding. The control line and / or sensor line can then be connected to the contact element, particularly by crimping. Therefore, the bond wire can be electrically contacted at both ends by bonding.

[0045] Overall, this allows for simple assembly and connection of the sensor cable(s) with integrated fuse formed by the bond wire. An advantage is that no separate fuse elements, circuit boards with fuses, etc., are required or planned. Therefore, the voltage measurement is very simple, compact, and cost-effective. Conventional components, especially standard crimp contacts, are used. Specifically, only surface-mount devices (SMDs), as known from printed circuit board assembly, are used, which can be easily and automatically mounted.

[0046] The first half-shell can have at least one gripping opening. At least one gripping element can be arranged between the first and second half-shells. This gripping element can be received or picked up in the gripping opening. The gripping element can, for example, be gripped automatically by a manufacturing robot. This allows for improved assembly. In the assembled state, the gripping elements (retaining projections) can protrude or extend into the gripping openings. The retaining openings and projections allow the elements to be mechanically held, for example, during a welding process.

[0047] The first half-shell can be made of or constructed from a plastic. This plastic can be a thermoplastic, such as polycarbonate or polyethylene terephthalate (PET). Additionally or alternatively, the second half-shell can be made of or constructed from a plastic. This plastic can also be a thermoplastic, such as polycarbonate or PET. This allows the cell contacting system to be manufactured particularly easily and cost-effectively. Using a plastic film molded part instead of an injection-molded part is simple and saves costs. Especially with larger cell contacting systems, costs can be saved by eliminating the need for injection molds.

[0048] According to a second aspect, a battery system, particularly for a vehicle, is proposed. The battery system comprises at least one stack of battery cells. In other words, the battery system comprises multiple cells / battery cells. The battery system also comprises at least one cell contacting system as described in the first aspect.

[0049] The battery cells can form a battery. The battery can be designed as a high-voltage battery.

[0050] The cell contacting system serves to electrically connect multiple cells in a battery. Depending on requirements, the cells are connected in series and / or parallel so that the battery provides a specific voltage and current. Several cells are connected in series to form a cell stack. The cells in the cell stack can each form a module of the battery. For correspondingly large batteries, such as those used in electric vehicles, a correspondingly large number of cells are required, resulting in a correspondingly large battery. For example, the battery might have a width and length ranging from 0.5 m to 2 m, necessitating contact between the cells over a considerable distance.

[0051] As described, such a cell contacting system can have a first half-shell in which individual cell connector elements are held, for example, in an opening. Each of these cell connector elements provides an electrical connection between the cell poles of adjacent cells. More precisely, the cell poles are contacted via at least one contact area, such as contact elements, of the cell connector element. During assembly, the cell contacting system is attached to a stack of cells arranged in series, and the individual cell connector elements are electrically connected to one cell pole of each cell. This is usually done by laser welding. Each cell contacting system is often at least nearly as large as the cell stack.

[0052] In an electric vehicle, several battery cells are connected together to form a cell stack or battery pack to achieve the required amount of energy. A battery pack or cell stack consists of multiple battery cells connected in series and / or parallel to achieve the necessary voltage and capacity. This allows the energy needed to power and supply the electric vehicle to be stored. A battery cell consists of an anode, a cathode, and an electrolyte, which together enable energy storage and release. During a charging phase, current flows through the cell, converting chemical energy into electrical energy, which is stored in the battery cell. During a discharging phase, the stored electrical energy is converted back into chemical energy and delivered to the consumer via the electrical circuit.

[0053] The battery system may also include a battery management system. This system may be designed, among other things, to monitor the condition of the battery and its individual cells. For this purpose, sensor lines can be routed to at least a subset of the battery cells, for example, to measure temperature, pressure, and / or voltage. The battery management system can monitor the electrochemical cells and the cell contacting system with regard to physical parameters such as voltage and temperature. This can be achieved, for example, by measuring potential differences between different conductors and / or by recording temperatures near the conductors using suitable temperature sensors.

[0054] The cell contacting system described in the first aspect provides a simple-to-manufacture cell contacting system with a small form factor. This results in a (significant) simplification of its use in a battery system as described in the second aspect.

[0055] Even though some of the aspects described above have been described in relation to the cell contacting system according to the first aspect, these aspects can also be realized in a corresponding way in the battery system according to the second aspect and vice versa.

[0056] The present revelation will be further explained using figures. These figures schematically depict: Fig. 1 a possible design of a first half-shell; Fig. 2 a possible design of a second half-shell; Fig. 3 a front side of an embodiment of a cell contacting system with a first half-shell made of Fig. 1, a second half-shell made of Fig. 2 and the cell connector elements arranged between them; Fig. 4 a rear side of an embodiment of a cell contacting system with a first half-shell made of Fig. 1, a second half-shell made of Fig. 2 and the cell connector elements arranged between them; Fig. 5 an exploded view of an embodiment of a cell contacting system with a first half-shell made of Fig. 1, a second half-shell made of Fig. 2, cell connector elements that can be arranged in between and a third half-shell; Fig. 6a and Fig. 6b a possible design of cell connector elements; and Fig. 7 a perspective view of an embodiment of a cell contacting system with a first half-shell made of Fig. 1, a second half-shell made of Fig. 2 and cell connector elements arranged in between, once with and once without a third half-shell.

[0057] Specific details are set forth below, without limitation, to provide a complete understanding of the present disclosure. However, it is clear to a person skilled in the art that the present disclosure can be used in other embodiments that may differ from the details set forth below. For example, specific configurations and embodiments of a cell contacting system are described below, which are not to be considered limiting. Although the aspects described below are related to a cell contacting system, these aspects can also be implemented analogously in a battery system with such a cell contacting system, and vice versa.

[0058] Furthermore, the following description of exemplary embodiments of a cell contacting system always includes an exemplary embodiment of a battery system that can be implemented with this cell contacting system.

[0059] Fig. Figure 1 schematically shows a possible configuration of a first half-shell 10 of a cell contacting system. The first half-shell 10 is in Fig. 1. The first half-shell 10 is designed in an exemplary foil-like or foil-shaped manner. The first half-shell 10 has, by way of example, a plurality of first openings 12 to demonstrate that at least one first opening 12 is provided in the first half-shell 10. The first half-shell 10 extends in a longitudinal direction L. In this longitudinal direction, the first openings 12 are arranged one after the other and / or next to each other. The first openings 12 are, so to speak, lined up one after the other in the longitudinal direction L. Although most of the first openings 12 have, by way of example, the same shape and size, one first opening 12 has, by way of example, a different shape and size. The different shape is shown in the example as follows: Fig. The first opening 10 is shown as an example larger, but can also be smaller than the shape of the other first openings 12. It is also conceivable that all first openings 12 have the same shape or that there are several first openings 12, each with different shapes and / or sizes. If, instead of several first openings 12, only one first opening 12 is to be provided in the first half-shell, the webs / central webs provided between the respective first openings 12 can be omitted. The first half-shell 10 can be made of a plastic, for example, a thermoplastic such as polycarbonate or PET.

[0060] Fig. Figure 2 schematically shows a possible configuration of a second half-shell 20 of a cell contacting system. The second half-shell 20 is in Fig. 2. The second half-shell 20 is designed in a foil-like or foil-shaped manner. The second half-shell 20 has, by way of example, a plurality of second openings 22 to illustrate that at least one second opening 22 is provided in the second half-shell 20. The second half-shell 20 extends in a longitudinal direction L. In the longitudinal direction L, the second openings 22 are arranged one after the other and / or next to each other, in particular at equal intervals from each other. The second openings 22 are, so to speak, arranged one after the other in the longitudinal direction L. In the example from Fig. 2. All second openings 22 have at least almost exactly the same shape. However, shapes and / or sizes that differ at least partially from one another are also possible for the second openings 22. If, instead of several second openings 22, only one second opening 22 is to be provided in the first half-shell, the webs / central webs provided between the respective second openings 22 can be omitted. The second half-shell 20 can be made of a plastic, for example, a thermoplastic such as polycarbonate or PET.

[0061] Fig. 3 and Fig. Figure 4 shows an embodiment of a cell contacting system 1. The cell contacting system 1 is particularly suitable for a battery with multiple cells. Fig. Figure 3 shows a front view of cell contacting system 1. Fig. Figure 4 shows a reverse side of cell contacting system 1. Fig. 3 and Fig. Figure 4 shows that the second half-shell 20 is connected to the first half-shell 10. For example, the first half-shell 10 and the second half-shell 20 are welded together. As in Fig. As can be seen in Figure 3, the first half-shell 10 is U-shaped in its upper section and, through its connection with the second half-shell 20, forms a channel 16 between the U-shaped section and the second half-shell 20. This channel serves as a cable duct and is therefore also referred to as cable duct 16. The cable duct 16 is used to accommodate one or more control cables and / or sensor cables.

[0062] The cell contacting system 1 has a plurality of cell connector elements 100. Each of the plurality of cell connector elements 100 has at least one contact area 200 on its back side. In the illustrated embodiment, at least two contact elements 200 are provided / arranged on the back side of each cell connector element 100 as the at least one contact area. In the section of the cell contacting system 1 from Fig. 3 and Fig. Figure 4 shows that each cell connector element 100 has exactly two contact elements 200 on its back side. Fewer or more than two contact elements 200 per cell connector element 100 are also possible. The contact elements 200 are in Fig. 4 to be recognized. The multitude of cell connector elements 100 can be positioned between the first half-shell 10 and the second half-shell 20 and, as shown in the Fig. 3 and Fig. As can be seen in section 4, the cell connector elements 100 are also positioned. They can be inserted into the first openings and, as shown in the diagram, are positioned as follows: Fig. 3. The contact elements 200 of the cell connector elements 100 can be received in the second openings 20 and, as shown in Fig. 4 can be identified, also recorded.

[0063] The cell connector elements 100 exhibit, as in Fig. 6a is easier to see, each with several projections 140, especially tabs. The in Fig. The three identifiable cell connector elements each have exactly four projections 140. Two projections 140 point upwards from the respective cell connector element 100, and two projections 140 point downwards from the respective cell connector element 100. To accommodate the projections 140, the first half-shell 10 has receptacles or recesses 14 at the corresponding positions. As in Fig. As can be seen in Figure 3, four receptacles 14 are adjacent to each of the openings 12: two receptacles 14 above the openings 12 and two receptacles 14 below the openings 12. The projections 140 form a positive fit with the receptacles 14 in a direction perpendicular to the longitudinal direction L. In this way, the cell connector elements 100 are fixed and held in this direction.

[0064] As in Fig. As can be seen in Figure 4, the second openings 22 are formed to receive the contact elements 200. The second half-shell 20 has several recesses 24 at locations corresponding to the recesses 14 of the first half-shell 10. These recesses 24 form a positive fit with the projections 140 of the cell connector elements 100 in a direction perpendicular to the longitudinal extent. In this way, the cell connector elements 100 are fixed and held in this direction. At the same time, the contact elements 200 are accessible and can be contacted through the second openings 22.

[0065] In Fig. Figure 5 shows an exploded view of the cell contacting system 1. Viewed from back to front, the cell contacting system 1 comprises a second half-shell 20, several cell connector elements 100, a first half-shell 10, and a third half-shell 30. The third half-shell 30 can be attached to the first half-shell 10, in particular by welding or clipping. In a connected state, which is shown in Fig. As can be seen in Figure 7, the third half-shell 30 is attached to the first half-shell 10 in one variant, in particular by welding or clipping. The third half-shell 30 is designed, for example, to be free of openings and forms a protective barrier against contact. When the third half-shell 30 is attached to the first half-shell 10, the cell connector elements 100 are not accessible from the front, as they are protected or covered by the third half-shell.

[0066] Optional details of the cell connector elements 100 are in Fig. 5 shown, however in the Fig. 6a and Fig. Figure 6b is easier to see. The cell connector elements 100 each form a receiving space 160 for a plug element 260. In the example shown, a receiving space 160 is formed by an area between the contact elements 200 that is convex towards the front relative to the contact elements. Fig. Figure 6a shows a reverse side of the cell connector elements 100, on which the contact elements 200 are formed. Fig. Figure 6b shows a front view of the cell connector elements 100. With respect to the front view, the area between the contact elements 200 is shaped or curved forward, thereby forming a receiving space 160. A plug element 260 is received and arranged in the receiving space 160. Fig. Figure 6a further shows a central cell connector element 100, which also forms a receiving space 160 between the contact elements 200. A plug element 260 could also be arranged in this receiving space 160; however, a sensor element 360 is arranged there as an example. The sensor element 360 is designed as a cold spot element as an example. Further plug elements 260 are provided on this central cell connector element 100, as shown in Fig. As can be seen by way of example in 6a, further receiving spaces are formed which are not between two contact elements 200 but are each adjacent or neighboring to a contact element 200.

[0067] The at least one connector element 260 can be connected to or be connected to a control line and / or sensor line. The sensor element 360 can be connected to or be connected to a control line and / or sensor line. The control line and / or sensor line can run in the cable duct 16 described above. A cable guide 280 can be connected to the cable duct 16, which can lead to and be connected to a battery management system.

[0068] The first half-shell 10 has at least one gripping opening 18. Fig. Figure 5 shows four gripping openings 18 as examples. Accordingly, in Fig. Five gripping elements 180 are provided as an example, which can be arranged and received between the first half-shell 10 and the second half-shell. Each of the gripping elements 180 can be received in a corresponding gripping opening 18.

[0069] The Fig. Figure 7 shows a front face of the cell contacting system 1, above in an embodiment without the optional third half-shell 30 and below in an embodiment with the optional third half-shell 30. Fig. Figure 7 shows the cell contacting system in its assembled state. For assembly, cell connector elements 100, as well as, if applicable, the wiring harness and temperature sensors 360, are inserted into the first half-shell 10. The cell connector elements 100 are positioned almost exactly in the formed openings 12. The wiring harness and temperature sensors 360 are also positioned almost exactly in the molded areas. A second half-shell 20 with a specific profile is then placed on top and thermally welded to the first half-shell 10. This secures and completely encloses all components between the two half-shells, ensuring fixation in all spatial directions. At the same time, the cell connector elements 100 and their contact elements 200 remain accessible from the outside through the corresponding openings. Optionally, a third half-shell can then be placed on top and welded or clipped into place.The third half-shell 30 serves as contact protection, especially as high-voltage contact protection.

[0070] Optionally, additional plastic elements are inserted between the first half-shell 10 and the second half-shell 20 as gripping elements 180, which are then partially encapsulated by the second half-shell 20. The plastic elements protrude partially through a window, which serves as a gripping opening in the first half-shell 10. These plastic elements act as gripper receptacles / elements 180 for the automated insertion and removal of the cell contacting system 1, for example, from transport containers. This improves and simplifies manufacturing.

[0071] The cell contacting system 1 can be manufactured in various ways. The first half-shell 10 and / or the second half-shell 20 can, for example, be produced using a continuous thermoforming process, also known as thermoforming. In this process, a thermoplastic is drawn into half-shells under heat and vacuum. This produces the first half-shell 10 and / or the second half-shell 20. The cell connectors 100 and cable sets are inserted into the first half-shell 10. The second half-shell 20 is then placed on top and welded to the first half-shell 10. This secures the cell connectors 100 and cable sets between the half-shells 10 and 20. Thus, two half-shells (first half-shell 10 and second half-shell 20) and, if necessary, a third half-shell 30 are manufactured using a single thermoforming process.The other components, such as cell connectors, circuit boards and / or wiring harness, are encapsulated between the first half-shell 10 and the second half-shell 20.

[0072] To produce the half-shells, a heated film can be passed through a mold. Using a vacuum, a negative of the mold is formed with the film. This allows for the continuous production of repeating patterns at high cycle times. The workpieces are then die-cut (to create the openings in the half-shells) and cut to length. The die-cut material can be recycled back into the plastics cycle. The cell connector elements (100) can later be placed in the die-cut areas to ensure direct contact with the cell poles and enable welding. The films can be approximately 0.5 mm thick. This allows for a space-optimized (height- and / or thickness-optimized) solution.

[0073] All in relation to the Fig. Details 1 to 7 described can be combined in a suitable way.

Claims

[1] Cell contacting system (1) for a battery with multiple cells, wherein the cell contacting system (1) comprises: a first hemisphere (10) with at least one first opening (12); a second half-shell (20) with at least one second opening (22), wherein the second half-shell (20) is connected to the first half-shell (10), in particular by welding; and a plurality of cell connector elements (100), wherein each of the plurality of cell connector elements (100) has at least one contacting area (200) and wherein the plurality of cell connector elements (100) is positioned or positionable between the first half-shell (10) and the second half-shell (20) such that the plurality of cell connector elements (100) is received or can be received in the at least one first opening (12) and the at least one contacting area (200) of the plurality of cell connector elements (100) is received or can be received in the at least one second opening (20);wherein a region of the first half-shell (10) is configured such that the second half-shell (20) is connected or connectable to the first half-shell (10) such that the region of the first half-shell (10) with the second half-shell (20) forms a cable duct (16) for receiving one or more control lines. [2] Cell contacting system (1) according to claim 1, wherein the first half-shell (10) and / or the second half-shell (20) is formed in a foil-like or foil-shaped manner. [3] Cell contacting system (1) according to claim 1 or 2, wherein the at least one first opening (12) has a plurality of first openings (12) or is configured as a plurality of first openings (12) and / or the at least one second opening (22) has a plurality of second openings or is configured as a plurality of second openings (22). [4] Cell contacting system (1) according to claim 3, wherein the plurality of cell connector elements (100) is received or received in the plurality of first openings (12) and the at least one contacting area (200) of the plurality of cell connector elements (100) is received or received in the plurality of second openings (20). [5] Cell contacting system (1) according to claim 3 or 4, wherein the multitude of first openings (10) each have at least partially the same shape and / or a different shape from each other, and / or the multitude of second openings (20) each have at least partially the same shape and / or a different shape from each other. [6] Cell contacting system (1) according to one of claims 1 to 5, wherein the plurality of cell connector elements (100) each has at least one projection (140) which forms a positive fit with at least one associated receptacle or recess (14) of the first half-shell (10) and / or which forms a positive fit with at least one associated receptacle or recess (24) of the second half-shell (20). [7] Cell contacting system (1) according to one of claims 1 to 6, wherein the cell contacting system (1) further comprises a third half-shell (30) which is applied or can be applied to the first half-shell (10), in particular force-fit, form-fit and / or material-fit, for example welded or clipped on. [8] Cell contacting system (1) according to claim 7, wherein the third half-shell (30) is designed without openings. [9] Cell contacting system (1) according to one of claims 1 to 8, wherein at least one receiving space (160) is formed in at least a subset of the cell connector elements (100). [10] Cell contacting system (1) according to claim 9, wherein at least one connector element (260) and / or at least one sensor element (360) is provided or can be arranged in the at least one receiving space (160). [11] Cell contacting system (1) according to one of claims 1 to 10, wherein at least one gripping opening (18) is provided on the first half-shell (10) and at least one gripping element (180) is arranged or can be arranged between the first half-shell (10) and the second half-shell (20), which is received or can be received in the at least one gripping opening (18). [12] Cell contacting system (1) according to any one of claims 1 to 11, wherein the first half-shell (10) and / or the second half-shell (20) comprises or is made of a plastic, in particular a thermoplastic, e.g. polycarbonate or polyethylene terephthalate, PET. [13] Including a battery system: at least one stack of battery cells; and at least one cell contacting system (1) according to any one of claims 1 to 12.

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