Installation unit for a high-voltage battery

Abstract

The invention relates to an installation unit (100) for a high-voltage battery with a battery housing having an interior in which battery cell modules are arranged, particularly for an electric and / or hybrid vehicle. The installation unit (100) comprises a battery cover (10) and a battery frame (40); wherein the battery cover (10) has an inner side facing the interior of the battery housing and an outer side facing away from the interior of the battery housing, wherein a Battery Management Controller extended (BMCe) (20) is mounted on the inner side, and wherein the battery cover (10) is screwed to the battery frame (40) from the inside, thereby ensuring a mechanically stable and corrosion-resistant connection;wherein the BMCe (20) has contact elements (28) for automatic self-contacting between the contact elements (28) on the BMCe (20) and high-voltage battery contacts of the high-voltage battery, thereby enabling an electrical connection without manual intervention; and wherein a sealing line (50) is provided between the battery cover (10) and the battery frame (40) for a watertight seal between the battery cover (10) and the battery frame (40).

Description

[0001] The invention relates to an installation unit for a high-voltage battery with a battery housing having an interior in which battery cell modules are arranged, in particular for an electric and / or hybrid vehicle.

[0002] A high-voltage battery (HV battery) is a type of battery used in electric vehicles and other applications such as autonomous vehicles, boats, and drones. In automotive engineering, the term "high voltage" refers to alternating voltages in the range of 30 V to 1 kV (or direct voltages above 60 V to 1.5 kV). This voltage range is called "high voltage" because it is significantly higher than the usual vehicle electrical system voltages (typically 12 V) and places special demands on safety and technology.

[0003] The high-voltage battery in an electric vehicle is a central element of the electric drive system for storing and providing electrical energy. It consists of many individual battery cells connected in series and / or parallel to achieve the required voltage and capacity. These cells are often lithium-ion batteries, which are characterized by high energy density and good charging and discharging properties. The battery cells are grouped into battery stacks and arranged in a battery module. This design ensures stability, safety, and thermal insulation.

[0004] The battery casing of the high-voltage battery is robust and often consists of aluminum or special plastics to protect the battery from mechanical influences, moisture and other environmental influences.

[0005] High-voltage batteries are equipped with an effective cooling system that ensures they operate within their optimal temperature range to prevent overheating and guarantee consistent performance. Excessive temperatures can negatively impact cell performance and lifespan, while excessively low temperatures can reduce power output. Additional safety features such as fuses, temperature sensors, and fire protection mechanisms are employed to minimize risks like overheating, short circuits, and mechanical damage.

[0006] An integrated battery management system monitors the temperature, state of charge, cell voltages, and overall battery health. It ensures balance between individual cells, protects against overcharging and overheating, and optimizes battery performance and lifespan.

[0007] The size and capacity of the high-voltage battery determine the range of the electric vehicle. Modern high-voltage batteries are characterized by a high energy density, meaning they can store a lot of energy without being too heavy or too large.

[0008] The battery casing is typically made of a lightweight yet durable material such as aluminum or specialized plastics. A battery cover seals the casing and protects the battery from external elements like water, dust, and vibrations. The cover is usually made of robust plastic or metal to securely close the battery and features seals to prevent the ingress of moisture or other harmful substances. It also provides a mounting point for other electrical components. Often, the battery cover includes openings for routing cables or connecting electrical components, such as a battery management controller (BMC).

[0009] A battery frame serves as a supporting and protective structure, connecting the battery cover to the high-voltage battery. The battery frame ensures that the battery and battery cover remain securely and firmly connected, even under vibrations and impacts during driving, thus protecting the battery from external influences and damage. In many cases, the battery frame is also part of the battery's thermal management system and may contain heat dissipation or insulation elements.

[0010] A battery management system (BMC) is the core component of a vehicle's battery management system (BMS). It monitors and controls essential functions to ensure safe and efficient battery operation. The primary tasks of a BMC are monitoring battery voltage, state of charge (SoC), and temperature. The BMC measures the voltage of each individual battery cell and calculates the overall SoC. It also ensures that the battery does not overheat or get too cold, as extreme temperatures can negatively impact battery lifespan and performance. Furthermore, the BMC ensures that the cells are charged and discharged evenly, preventing any single cell from being overloaded and allowing the battery to function optimally. In this way, the BMC protects the battery from overcharging, deep discharging, short circuits, and other potentially damaging conditions.

[0011] The Battery Management Controller extended (BMCe) is an enhanced version of the BMC, offering additional functions beyond the standard BMC tasks. These enhancements are particularly relevant for more complex or larger battery systems. For example, the BMCe can interact with other systems in the vehicle via advanced communication protocols such as CAN bus, LIN, or Ethernet. This enables better integration of battery management into the overall vehicle. Furthermore, the BMCe can perform more detailed fault diagnostics and collect comprehensive battery health data, which can be transmitted in real time to other control units or external systems. In addition to monitoring, the BMCe often also handles control functions for the charging infrastructure, such as optimizing charging behavior based on the availability and condition of the power grid (vehicle-to-grid functions).The BMCe features improved hardware and software to process more complex algorithms for optimizing battery performance and usage. In vehicles with high-performance batteries, such as electric or hybrid vehicles, the BMCe thus enables more precise management and optimization of the high-voltage batteries.

[0012] The battery cover of a high-voltage battery not only protects the battery but also serves as a mounting point for the extended battery management control unit (BMCe). The battery cover, with the mounted BMCe, is securely bolted to the battery frame. The connection is made via screw connections that are recessed into the sheet metal of both the battery cover and the battery frame to ensure a secure and stable installation.

[0013] The term "wet area" refers to a region in a vehicle that is constantly or regularly exposed to water, whether from rain, road spray, condensation, or other liquids. In the case of vehicle batteries, this wet area is often located in the underbody where the battery is installed. Here, the likelihood of water or dirt ingress is increased, especially when the vehicle drives through puddles or in bad weather. This moisture can impair both the function and lifespan of the vehicle battery in this area.

[0014] Due to constant exposure to moisture, the wet room is an area where corrosion of metallic components (such as fasteners, connectors, and the battery itself) poses a significant risk. Corrosion can compromise electrical connections and the mechanical stability of the components. Special seals, protective housings, and moisture- and corrosion-resistant materials are used to protect the components installed in this area, such as the battery and the Battery Management System (BMS).

[0015] Bolted connections represent a potential weak point, especially in environments subject to constant temperature fluctuations, humidity, and vibration. In humid environments, moisture can penetrate the bolted connections and cause corrosion. Corrosion impairs the strength and tightness of the connection and, in the worst case, can lead to failure of the bolted connection.

[0016] German patent application DE 10 2018 109 328 A1 discloses a battery unit comprising a battery housing base body, a cell assembly arranged therein, and a cell management controller. The battery housing base body has an installation opening through which the cell assembly can be inserted into the housing during assembly. This installation opening is closed by a cover element, thus creating a closed battery housing. A cell management controller is arranged through an opening in the battery housing base body that can be closed with a cover. The cell management controller is provided in a corresponding frame, which is screwed to the battery housing base body from the inside.

[0017] DE 10 2022 206 575 A1 relates to a cover for battery modules of a battery system with a contacting module which has a first contacting terminal for electrically contacting a first battery module and at least a second contacting terminal for contacting a second battery module, wherein the at least two contacting terminals are arranged such that in an attached state of the cover on the battery system the at least two battery modules are electrically contacted simultaneously.

[0018] DE 10 2022 000 949 A1 relates to an arrangement of an electrical energy storage device on a body shell for a passenger car, in which the body shell has two side sills between which a main floor extends, wherein the entire main floor is formed by a housing cover of a housing of the electrical energy storage device which is formed separately from the body shell.

[0019] The present invention aims to develop a concept for a reliable and secure connection between a battery frame and a battery cover with a mounted Battery Management Controller extended (BMCe), suitable for use in wet areas of a vehicle. This connection must be corrosion-resistant to withstand the negative effects of moisture and chemical influences. Furthermore, the concept should allow for easy assembly and disassembly of the battery cover without special tools. In particular, the solution should be flexible enough to be integrated into various vehicle models and battery configurations to facilitate adaptation to existing high-voltage battery designs.

[0020] This problem is solved according to the invention with respect to a mounting unit for a high-voltage battery with the features of claim 1, and with respect to a method for manufacturing a mounting unit for a high-voltage battery with the features of claim 8. The remaining claims relate to preferred embodiments of the invention.

[0021] The present invention provides a corrosion-resistant connection between a battery cover, on which a Battery Management Controller extended (BMCe) is mounted, and a battery frame for installing a high-voltage battery in the wet compartment of an electric or hybrid vehicle. An efficient electrical connection without manual intervention is ensured by automatic self-contacting between the contact elements of the BMCe and the high-voltage battery contacts.

[0022] The installation unit according to the invention optimizes assembly and increases corrosion resistance by screwing the battery cover with the integrated BMCe to the battery frame from the inside of the battery cover. Since the battery frame acts as a load-bearing component and, together with the battery cover, forms a compact installation unit, the assembly process and the structural integrity of the high-voltage battery are improved. Overall, the invention offers a functional and durable solution that significantly increases both the performance and the service life of the electric drive system.

[0023] According to a first aspect, the invention provides an installation unit for a high-voltage battery with a battery housing having an interior in which battery cell modules are arranged, particularly for an electric and / or hybrid vehicle. The installation unit comprises a battery cover and a battery frame; wherein the battery cover has an inner side facing the interior of the battery housing and an outer side facing away from the interior of the battery housing, wherein a Battery Management Controller extended (BMCe) is mounted on the inner side, and wherein the battery cover is screwed to the battery frame from the inside, thereby ensuring a mechanically stable and corrosion-resistant connection; wherein the BMCe has contact elements for automatic self-contacting between the contact elements on the BMCe and high-voltage battery contacts of the high-voltage battery, thereby enabling an electrical connection to be established without manual intervention.and wherein a sealing line is provided between the battery cover and the battery frame to provide a watertight seal between the battery cover and the battery frame in order to prevent the ingress of moisture and chemical influences when installing the high-voltage battery in a wet area of ​​a vehicle and to allow easy assembly and disassembly of the battery cover for maintenance work without the use of special tools.

[0024] Further training stipulates that corrosion-resistant materials such as stainless steel or coated metals should be used for the screw connections between the battery cover and the battery frame to ensure the durability of the connection in a humid environment.

[0025] In an advantageous embodiment, the sealing line has a sealing groove into which a sealant or a rubber sealing ring (O-ring) is inserted, wherein the sealant or the rubber sealing ring (O-ring) is compressed from the inside during screwing to ensure a watertight seal between the battery cover and the battery frame that is resistant to chemicals and temperatures.

[0026] In another embodiment, the contact elements for self-contacting are designed as spring contacts or flexible contact elements in order to compensate for manufacturing tolerances and to reliably maintain the electrical connection even under vibrations and mechanical loads.

[0027] In particular, the Battery Management Controller extended (BMCe) has a modular design and can be easily replaced or updated as needed, without having to replace the entire battery cover or the installation unit.

[0028] Advantageously, the battery cover is provided with reinforcing ribs or structural reinforcements to withstand the mechanical stresses during driving and to improve the stability of the overall structure of the high-voltage battery.

[0029] Further training envisages that the dimensions of the installation unit be flexibly adaptable to different battery sizes and configurations to enable integration into various vehicle models.

[0030] According to a second aspect, the invention provides a method for manufacturing an installation unit for a high-voltage battery with a battery housing having an interior in which battery cell modules are arranged, particularly for an electric and / or hybrid vehicle. The method comprises the following process steps: - Providing a battery cover with an inner surface facing the interior of the battery housing and an outer surface facing away from the interior of the battery housing, wherein a Battery Management Controller extended (BMCe) is mounted on the inside of the battery cover; - Positioning and aligning self-contacting contact elements on the BMCe for automatic electrical contacting with high-voltage battery contacts during the high-voltage battery assembly process; - Providing a battery frame; - Applying a seal along a sealing line on the outside of the battery cover to ensure a watertight seal between the battery cover and the battery frame; - Screwing the battery cover to the battery frame, with the screwing being done from the inside of the battery cover to the battery frame in order to create a stable, corrosion and vibration resistant installation unit.

[0031] In a further training course, it is planned that the installation unit is designed in such a way that the BMCe can be replaced or upgraded if necessary, without having to replace the battery cover or the battery frame.

[0032] Advantageously, the dimensions of the installation unit can be flexibly adapted to different battery sizes and configurations to enable integration into different vehicle models.

[0033] The invention will now be explained in more detail with reference to exemplary embodiments shown in the drawing.

[0034] This shows: Fig. 1 a top view of the inside of a battery cover of a high-voltage battery with an advanced battery management control unit (BMCe) attached to it, in accordance with the prior art; Fig. 2 a side view of a screw connection for fastening the BMCe to the battery cover according to the state of the art; Fig. 3 a top view of the inside of a battery cover according to the invention for a high-voltage battery with an extended battery management control unit (BMCe) attached thereto; Fig. 4 an exploded view of an installation unit according to the invention with the battery cover made of Fig. 3 and a battery frame; Fig. 5 a flowchart to explain the individual process steps of a process according to the invention.

[0035] Additional features, aspects and advantages of the invention or its embodiments become apparent from the detailed description in conjunction with the claims.

[0036] Fig. Figure 1 shows an inside view of a battery cover 10 for a battery housing of a high-voltage battery, particularly for an electric and / or hybrid vehicle, with an attached extended battery management controller (BMCe, Battery Management Controller extended) 20, according to the state of the art. A battery management controller (BMC, Battery Management Controller) is a basic control unit that performs the core functions of battery management. The BMCe 20 is an extended version of a conventional BMC with additional control, communication, and diagnostic functions to meet the requirements of modern and high-performance battery systems.

[0037] The BMCe 20 monitors the voltage, current, and temperature of each battery cell, ensuring that the cells operate within safe parameters. Since not all cells in a battery module discharge or charge at the same rate, the BMCe 20 balances the cells, thereby increasing battery efficiency and lifespan. The BMCe 20 can detect deviations such as over-temperature, overcharging, or deep discharging and, in emergencies, trigger safety protocols like battery shutdown. The BMCe 20 also controls the battery's cooling system to ensure the temperature remains within the optimal range. This protects the battery from overheating and extends its lifespan. The BMCe 20 also features advanced communication capabilities and can transmit data to the vehicle's electronic control unit (ECU) in real time, such as the state of charge (SoC), state of health (SoH), and performance forecasts.Furthermore, the BMCe 20 supports remote monitoring and software updates. This allows for continuous monitoring of the battery's condition and software updates to enable future improvements or bug fixes. The BMCe 20 therefore plays a key role in the efficient operation and safety of high-voltage batteries in electric vehicles.

[0038] The battery cover 10 thus not only provides protection and sealing for the battery cells of the battery, but also serves as a base for the attachment of the BMCe 20 as the central control unit of the battery.

[0039] The battery cover 10 is large and robustly designed to protect the sensitive battery cells inside the high-voltage battery. Its surface is equipped with fasteners for securely attaching additional components such as the BMCe 20. The battery cover 10 is made of a lightweight yet durable material such as plastic (e.g., fiberglass-reinforced plastic), aluminum, or a combination of composite materials. These materials are used to stabilize the overall battery structure, providing high strength at a low weight while also ensuring external protection against environmental factors such as moisture, dust, and vibrations.

[0040] The BMCe 20 is mounted in a lateral area on the inside of the battery cover 10. Its shape is complex and adapted to the design of the battery cover 10. The BMCe 20 consists of an oval-shaped carrier module 23 with a mounting flange 24 and several individual components connected to each other via cables and plug connectors to ensure the monitoring and control of the battery cells. Furthermore, maintenance openings 27 are provided for manual electrical contacting of the BMCe 20 with the high-voltage battery.

[0041] The mounting flange 24 of the carrier module 23 can be connected to a correspondingly designed receiving flange 14. The receiving flange 14 is arranged around a receiving space for the BMCe 20 in the battery cover 10. The receiving space is designed such that the cables and connectors of the BMCe 20 can be routed as efficiently and compactly as possible to enable the electrical control of the battery cells.

[0042] The mounting flange 24 is designed to receive screws 30 with sealing washers 32. These screws 30 are screwed into rivet nuts 34, which are provided in the receiving flange 14, to ensure secure fastening and sealing. The sealing washers 32 play an important role, as they keep the area around the screws 30 watertight and dustproof. The BMCe 20 is screwed to the inside of the battery cover 10, thus forming a mounting unit with the battery cover 10, into which the BMCe 20 is firmly and securely integrated. The sealing washer 32 provides a seal for the BMCe 20 to prevent the ingress of moisture or contaminants and to protect the sensitive area of ​​the BMCe 20. Furthermore, a seal 15, in particular in the form of O-rings or a sealant, is provided between the mounting flange 24 and the receiving flange 14.

[0043] As in Fig. As shown in Figure 2, the rivet nut 34 is located in the receiving flange 14 on the outside of the battery cover 10 (i.e., on the side facing away from the inside of the battery) and serves as a threaded carrier. It is firmly connected to the battery cover 10, for example, by crimping or riveting. The screw 30 is screwed into the rivet nut 34 from the inside through the mounting flange 24 of the BMCe 20. The sealing washer 32 is located between the screw head of the screw 30 and the top of the mounting flange 24 to ensure a tight connection.

[0044] As in Fig. As shown in Figure 1, the battery cover 10 is connected to a battery frame 40. The battery cover 10 is secured using screw connections (in Fig. (1 not shown) is attached to the battery frame 40. These screw connections can consist of a screw with a sealing washer and a rivet nut. The battery cover 10 with the BMCe 20 mounted on it is placed onto the battery housing of the high-voltage battery. The electrical contact between the BMCe 20 and the battery components of the high-voltage battery is made manually through maintenance openings 27 in the BMCe 20. After manual contact, the battery frame 40 is placed onto the battery cover 10, and the battery frame 40 with the battery cover 10 is screwed to the battery housing from the outside.

[0045] The battery frame 40 serves as a supporting and protective structure that connects the battery cover 10 to the high-voltage battery. The battery frame 40 ensures that the high-voltage battery and the battery cover 10 remain securely and firmly connected, even under vibrations and shocks during driving. In many cases, the battery frame 40 is also part of the battery's thermal management system. It may contain elements for heat dissipation or insulation.

[0046] In the previous method (state of the art), the battery frame 40 is screwed to the battery cover 10 after the BMCe 20 has been manually connected to the corresponding high-voltage battery contacts of the high-voltage battery. This means that the battery cover 10 is first connected to the battery housing, and then the battery frame 40, which is placed on top of the battery cover 10, is screwed in place to establish a connection between the battery cover 10 and the battery frame 40. The rivet nuts are located on the outside of the battery cover 10, while the screws are screwed into the battery frame 40. This means that the screwing process proceeds from the battery frame 40 towards the outside of the battery cover 10.

[0047] Fig. Figure 3 shows a portion of the inner surface of a battery cover 10 according to the invention with a BMCe 20 attached to it. The BMCe 20 is fastened as in the prior art by screws 30, sealing washers 32 and rivet nuts 34. The battery cover 10 is provided with reinforcing ribs or structural reinforcements to withstand the mechanical loads during driving operation and to improve the stability of the overall structure of the high-voltage battery.

[0048] However, the BMCe 20 is equipped with contact elements 28 that enable the BMCe 20 to automatically connect to the corresponding contact elements of the high-voltage battery. These contact elements 28 are precision mechanical and electrical components that allow for a secure and reliable connection without manual intervention. These contact elements 28 typically consist of specially designed plug contacts and spring contacts that automatically make contact as soon as the battery cover 10 is placed on the battery housing.

[0049] Typical contact elements 28 are spring contacts consisting of flexible metal springs designed to establish a reliable electrical connection under slight pressure. They are located either on the BMCe 20 side or on the battery housing side. The spring contacts compensate for slight tolerance differences and misalignment. They also ensure that the contact remains stable despite vibrations or movement of the vehicle.

[0050] On the opposite side of the spring contacts are typically pin or bolt contacts that engage with the spring contacts. These are integrated into the high-voltage battery to complete the electrical connection. The pin contacts are robust and can withstand the pressure generated by fitting the battery cover.

[0051] Another type of contact element 28 is a flat connector that engages in corresponding sockets. This type of connector provides a large contact area capable of transmitting high currents. Due to their design, flat connectors can also tolerate slight misalignments and provide a stable, self-contacting connection.

[0052] Other options include spring-loaded contacts and floating contacts. These contacts can compensate for slight misalignment. The contacts have a certain amount of play to self-align when the battery cover is put into position. This ensures a reliable connection even if the battery cover is not perfectly aligned.

[0053] As soon as the battery cover 10 is placed on the battery housing, the contact elements 28 of the BMCe 20 engage with the mating contacts of the high-voltage battery. The electrical connections are automatically established through precise alignment and pressure during assembly. The contact elements 28 incorporate locking mechanisms that ensure the contacts are correctly seated only when fully assembled, thus guaranteeing a secure and stable connection.

[0054] Self-contacting therefore requires precise design on both the BMCe 20 side and the high-voltage battery side to ensure that the high-voltage battery contacts are connected securely, reliably, and without manual intervention.

[0055] Since, according to the invention, automatic or self-contacting occurs instead of manual contacting as soon as the battery cover 10 is placed on the battery housing, this allows for an alternative screwing direction of the battery cover 10 to the battery frame 40. Because the electrical contacts connect automatically, manual intervention by a technician via the maintenance openings 27 is no longer necessary. The battery cover 10 can therefore be screwed on as shown in Fig. As shown in Figure 4, the battery frame 40 is screwed to the inside. The battery frame 40, together with the battery cover 10, is then placed onto the battery housing as a single, integrated unit 100. After the BMCe contact elements 28 have automatically made contact with the high-voltage battery contacts, the unit 100 is screwed to the battery housing from the outside. This simplifies the assembly step and makes the design more efficient.

[0056] Corrosion-resistant materials such as stainless steel or coated metals are used as screw connections between the battery cover 10 and the battery frame 40 to ensure the durability and corrosion resistance of the connection in humid environments.

[0057] The seal between the battery cover 10 and the battery frame 40 is not achieved via sealing washers on screws, but rather by means of a sealing line 50. Specifically, the sealing line 50 is provided as a pre-formed sealing groove in the battery cover 10 and / or in the battery frame 40. A sealant or a rubber sealing ring (O-ring) can be inserted into the sealing groove, which is compressed from the inside when the screws are tightened to ensure a tight seal. This sealing line 50 runs along a contact surface between the battery cover 10 and the battery frame 40, so that the sealing effect along the sealing line 50 is created by the compression of the screw connection.

[0058] The internal screw connection of the battery cover 10 to the battery frame 40 and the self-contacting contact elements 28 significantly increase the efficiency of the assembly process. The time-consuming manual contacting is eliminated, saving not only time but also reducing the risk of human error. The self-contacting ensures that the electrical connection is established securely and automatically. This increases reliability and minimizes potential contact errors.

[0059] Since the battery cover 10 is screwed in from the inside, the outer skin of the battery frame 40 remains intact and forms an additional protective layer for the high-voltage battery against external influences. The use of rivet nuts and the associated screwing process are eliminated, thus reducing the number of required assembly steps and the assembly time.

[0060] The use of the sealing line 50 offers improved sealing and reduces the risk of moisture ingress, increasing the lifespan and reliability of the battery and the BMCe 20.

[0061] Furthermore, the maintenance openings 27 on the BMCe 20 and a drip protection flap can be omitted, which minimizes the number of components required and leads to a simpler and more efficient design.

[0062] A key advantage of the installation unit 100 according to the invention is that the Battery Management Controller extended (BMCe) 20 has a modular design. This modular design allows the BMCe 20 to be easily replaced or retrofitted as needed, without having to replace the entire battery cover 10 or the installation unit 100.

[0063] In the event of maintenance or replacement, the entire installation unit 100, consisting of battery cover 10, BMCe 20, and battery frame 40, can be removed from the high-voltage battery. The accessible interior of the battery cover 10 after removal allows direct access to the BMCe 20. This enables the BMCe 20 to be easily detached and replaced with an updated version or a new module without having to replace the entire installation unit 100.

[0064] This modular design contributes to efficiency and flexibility in the maintenance and upgrade of the high-voltage battery, while also offering a cost-effective solution, as only the BMCe 20 needs to be replaced or upgraded, while the other components of the installation unit 100 remain unaffected.

[0065] In particular, the dimensions of the installation unit 100 can be flexibly adapted to different battery sizes and configurations to enable integration into different vehicle models. Thus, the inventive concept of an installation unit 100 can be used for a variety of battery types.

[0066] In Fig. Figure 5 shows the process steps for manufacturing a built-in unit 100 for a high-voltage battery.

[0067] In step S10, a battery cover 10 is provided with an inside facing the interior of the battery housing and an outside facing away from the interior of the battery housing, wherein a Battery Management Controller extended (BMCe) 20 is mounted on the inside of the battery cover 10.

[0068] In step S20, self-contacting contact elements 28 are positioned and aligned on the BMCe 20 for automatic electrical contacting with high-voltage battery contacts during the assembly process of the high-voltage battery.

[0069] In step S30, a battery frame 40 is provided.

[0070] In step S40, a seal is applied along a sealing line 50 on the outside of the battery cover 10 to ensure a watertight seal between the battery cover 10 and the battery frame 40.

[0071] In step S50, the battery cover 10 is screwed to the battery frame 40, with the screwing being carried out from the inside of the battery cover 10 to the battery frame 40 in order to create a stable, corrosion and vibration resistant installation unit 100.

[0072] The present invention provides a corrosion-resistant connection between a battery cover 10, on which a Battery Management Controller extended (BMCe) 20 is mounted, and a battery frame 40 for installing a high-voltage battery in the wet compartment of an electric or hybrid vehicle. An efficient electrical connection without manual intervention is ensured by automatic self-contacting between the contact elements 28 of the BMCe 20 and the high-voltage battery contacts.

[0073] The installation unit 100 according to the invention optimizes assembly and increases corrosion resistance by screwing the battery cover 10 with the integrated BMCe 20 to the battery frame 40 from the inside of the battery cover 10. Since the battery frame 40 acts as a load-bearing component and, together with the battery cover 10, forms a compact installation unit 100, the assembly process and the structural integrity of the high-voltage battery are improved. Overall, the invention offers a functional and durable solution that significantly increases both the performance and the service life of the electric drive system. Reference sign 10 Battery covers 14 Mounting flange 15 Seal 20 Battery Management Controller extended (BMCe) 23 Carrier module 24 Mounting flange 27 Maintenance opening 28 Contact element 30 screw 32 Sealing washer 34 Rivet nut 40 battery frames 50 sealing line 100 installation units

Claims

[1] Installation unit (100) for a high-voltage battery with a battery housing having an interior in which battery cell modules are arranged, in particular for an electric and / or hybrid vehicle, comprising a battery cover (10) and a battery frame (40); wherein the battery cover (10) has an inner side facing the interior of the battery housing and an outer side facing away from the interior of the battery housing, wherein a Battery Management Controller extended (BMCe) (20) is mounted on the inner side, wherein the battery cover (10) is screwed to the battery frame (40) from the inside, thereby ensuring a mechanically stable and corrosion-resistant connection; wherein the BMCe (20) has contact elements (28) for automatic self-contacting between the contact elements (28) on the BMCe (20) and high-voltage battery contacts of the high-voltage battery, thereby enabling an electrical connection to be established without manual intervention;and wherein a sealing line (50) is provided between the battery cover (10) and the battery frame (40) to provide a watertight seal between the battery cover (10) and the battery frame (40) in order to prevent the ingress of moisture and chemical influences when installing the high-voltage battery in a wet area of ​​a vehicle and to allow easy assembly and disassembly of the battery cover (10) for maintenance work without the use of special tools. [2] Installation unit (100) according to claim 1, wherein corrosion-resistant materials such as stainless steel or coated metals are used for the screw connections between battery cover (10) and battery frame (40) to ensure the durability of the connection in humid environments. [3] Installation unit (100) according to claim 1 or 2, wherein the sealing line (50) has a sealing groove into which a sealing compound or a rubber sealing ring (O-ring) is inserted, wherein the sealing compound or the rubber sealing ring (O-ring) is compressed from the inside during screwing to ensure a watertight seal between the battery cover (10) and the battery frame (40) which is resistant to chemicals and temperatures. [4] Installation unit (100) according to one of claims 1 to 3, wherein the contact elements (28) for self-contacting are designed as spring contacts or flexible contact elements to compensate for manufacturing tolerances and to reliably maintain the electrical connection even under vibrations and mechanical loads. [5] Installation unit (100) according to any one of claims 1 to 4, wherein the Battery Management Controller extended (BMCe) (20) is modular and can be easily replaced or updated as needed without having to replace the entire battery cover (10) or the installation unit (100). [6] Installation unit (100) according to any one of claims 1 to 5, wherein the battery cover (10) is provided with reinforcing ribs or structural reinforcements to withstand the mechanical stresses during driving operation and to improve the stability of the overall structure of the high-voltage battery. [7] Installation unit (100) according to any one of claims 1 to 6, wherein the dimensions of the installation unit (100) are flexibly adaptable to different battery sizes and configurations to enable integration into different vehicle models. [8] Method for manufacturing an installation unit (100) for a high-voltage battery with a battery housing having an interior in which battery cell modules are arranged, in particular for an electric and / or hybrid vehicle, comprising the following process steps: - Providing (S10) a battery cover (10) with an inside facing the interior of the battery housing and an outside facing away from the interior of the battery housing, wherein a Battery Management Controller extended (BMCe) (20) is mounted on the inside of the battery cover (10); - Positioning (S20) and aligning self-contacting contact elements (28) on the BMCe (20) for automatic electrical contacting with high-voltage battery contacts during the high-voltage battery assembly process; - Provision (S30) of a battery frame (40); - Applying (S40) a seal along a sealing line (50) on the outside of the battery cover (10) to ensure a watertight seal between the battery cover (10) and the battery frame (40); - Screwing (S50) the battery cover (10) to the battery frame (40), wherein screwing is carried out from the inside of the battery cover (10) to the battery frame (40) to create a stable, corrosion and vibration resistant installation unit (100). [9] Method according to claim 8, wherein the installation unit (100) is designed such that the BMCe (20) can be replaced or upgraded as needed without having to replace the battery cover (10) or the battery frame (40). [10] Method according to claim 8 or 9, wherein the dimensions of the installation unit (100) are flexibly adapted to different battery sizes and configurations to enable integration into different vehicle models.

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