High-voltage battery with a knife-edge EMC bridge

Abstract

The invention relates to 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.The high-voltage battery comprises at least one first battery unit (10) and one second battery unit (20) arranged in or forming part of the battery housing, and at least one EMC bridge (30) for electrical contact between the first battery unit (10) and the second battery unit (20), wherein the EMC bridge (30) is designed as a separate component that can be inserted into a contact space between the first battery unit (10) and the second battery unit (20), wherein the EMC bridge (30) has one or more knife edges (40) arranged in a pattern to penetrate paint or insulating layers of the first battery unit (10) and / or the second battery unit (20) during the assembly of the high-voltage battery and to establish an electrical connection between the first battery unit (10) and the second battery unit (20).

Description

[0001] The invention relates to a high-voltage battery with an EMC bridge with knife edges and a method for mounting a high-voltage battery with an EMC bridge with knife edges.

[0002] The term "EMC" stands for Electromagnetic Compatibility and refers to the smooth functioning of electrical devices and systems in their environment, without mutual interference from electromagnetic fields or radiation. Ensuring the electromagnetic compatibility of individual components is of essential importance, particularly in electrical and electronic systems, such as high-voltage batteries in electric or hybrid vehicles.

[0003] 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.

[0004] 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.

[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 battery casing is typically made of a lightweight yet durable material such as aluminum or special 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 is equipped with seals to prevent the ingress of moisture or other harmful substances.

[0008] An EMC bridge in a high-voltage battery (HV battery) is a component or design element that serves to ensure or improve the electromagnetic compatibility (EMC) of the high-voltage battery. The EMC bridge enables the isolation of specific electrical or electronic areas within the battery to guarantee interference-free operation between different components. Furthermore, the EMC bridge can be used to dissipate certain currents, such as ground currents or leakage currents. This serves to prevent potential interference and to comply with the EMC requirements of the automotive industry.

[0009] The EMC bridge is therefore an essential component in the design of high-voltage batteries in order to avoid potential interference with sensitive electronic control units in the vehicle caused by disruptive electromagnetic fields.

[0010] However, the use of cathodic dip coating (e-coating) or powder coating can impair the electrical conductivity of EMC surfaces, as coatings often have insulating properties. To ensure that these surfaces can make electrical contact, they must either be laser-treated or masked. A laser process allows for the selective removal of coating areas to expose the underlying conductive layer required for EMC contact. Masking involves covering the areas that are to be electrically conductive before coating to prevent the coating from coming into contact with them.

[0011] A potential transition is a point in an electrical system where different electrical potentials or voltages come into contact. With regard to electromagnetic compatibility (EMC), a precise and controlled definition and management of the electrical connection at such a point is crucial to prevent unwanted interference or failures. Such points are necessary, for example, to ensure proper grounding of the battery's electrical system or to guarantee correct signal transmission between different components.

[0012] To achieve effective electromagnetic shielding, the EMC contacts should be arranged around the battery's circumference in a closed grid. All contact points must be interconnected to form a continuous closed circuit that effectively dissipates electromagnetic interference. Such a closed grid effectively protects against external electromagnetic influences and prevents electromagnetic waves from penetrating the battery's sensitive electronic components.

[0013] Overall, it is crucial that EMC measures are carefully planned and implemented to ensure the functional integrity and compliance with safety standards for the high-voltage battery.

[0014] DE 10 2016 225 663 B3 discloses a fastening arrangement for an upper shell (or a cover) and a lower shell of a battery housing. This arrangement uses a U-shaped rail element that is slid over the end face of the overlapping support flanges of the upper and lower shells. By moving the rail element longitudinally along the flanges, it is connected to the flanges by force and / or form locking. The rail element contains cutting elements made of conductive material with cutting edges that, when moved, scrape a protective layer on the flanges, thus exposing an electrically conductive contact surface. This contact establishes an electrical connection between the two components.

[0015] US Patent 2023 / 0282990 A1 describes an electrical connector assembly comprising a flat metallic substrate with a surface having an electrically non-conductive coating and an electrical connector with a contact tab extending from the substrate that is in mechanical and electrical contact with the metallic substrate. The contact tab defines two sharp points formed by two triangular sections of the contact tab that penetrate the electrically non-conductive coating.

[0016] The object of the invention is to provide a high-voltage battery that ensures reliable electromagnetic compatibility (EMC). Effective electrical contact between the battery units should be achieved, even when they are separated by layers of lacquer or insulation. Furthermore, the assembly effort should be reduced and electrical conductivity ensured without complex pretreatment of the contact surfaces.

[0017] This problem is solved according to the invention with respect to a high-voltage battery with the features of claim 1, and with respect to a method for assembling a high-voltage battery with the features of claim 6. The remaining claims relate to preferred embodiments of the invention.

[0018] The present invention enables reliable electrical contact between battery units through the use of knife edges, even when these are separated by lacquer or insulating layers. The assembly of the EMC bridge, which is achieved by inserting it into the contact space between the battery units and subsequently screwing and / or crimping it, is characterized by its simplicity and cost-effectiveness. By establishing a stable electrical connection, electromagnetic compatibility (EMC) is significantly increased, thereby improving protection against electromagnetic interference. The use of corrosion-resistant materials ensures that the electrical connection remains durable and stable. The EMC bridge, designed as a separate component with its integrated knife edges, optimizes EMC properties and enables reliable, efficient, and economical manufacturing of the high-voltage battery.

[0019] According to a first aspect, the invention provides 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 high-voltage battery comprises at least a first battery unit and a second battery unit, which are arranged in or form part of the battery housing, and at least one EMC bridge for electrical contact between the first battery unit and the second battery unit, wherein the EMC bridge is designed as a separate component that can be inserted into a contact space between the first battery unit and the second battery unit, wherein the EMC bridge has one or more knife edges arranged in a pattern, and wherein the shape of the separate EMC bridge is adapted to the shape of grooves and recesses in the battery units.to penetrate the paint or insulating layers of the first battery unit and / or the second battery unit during the assembly of the high-voltage battery and to establish an electrical connection between the first battery unit and the second battery unit.

[0020] Further training stipulates that the knife edges are designed in the form of adjacent points or scraper grids.

[0021] In an advantageous embodiment, the knife edges are made of a corrosion-resistant material.

[0022] In a further embodiment, the knife edges are designed to provide an enlarged contact surface for the electrical connection between the first battery unit and the second battery unit.

[0023] In a further development, it is envisaged that the first battery unit and / or the second battery unit will additionally have molded knife edges on the surface of contact areas between the first battery unit and the second battery unit.

[0024] According to a second aspect, the invention presents a method for assembling a high-voltage battery according to the first aspect. An EMC bridge with knife edges, designed as a separate component, is inserted between a first battery unit and a second battery unit, the shape of the separate EMC bridge being adapted to the shape of grooves and recesses in the battery units. The method comprises the following process steps: - Inserting the EMC bridge into grooves and recesses between the first battery unit and the second battery unit; - Screwing and / or crimping the first battery unit and the second battery unit, wherein the knife edges penetrate the paint or insulating layers of the battery units and establish an electrical connection between the first battery unit and the second battery unit.

[0025] The invention will now be explained in more detail with reference to exemplary embodiments shown in the drawing.

[0026] 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 battery units of a high-voltage battery according to the state of the art; Fig. 3a a schematic representation of a first embodiment of knife edges for an EMC bridge; Fig. 3b a schematic representation of a second embodiment of knife edges for an EMC bridge; Fig. 4 a top view of a battery housing part with an EMC bridge according to the invention with knife edges; Fig. 5 a rear top view of a support module with a mounting flange with contact surfaces; Fig. 6 a flowchart to explain the individual process steps of a process according to the invention.

[0027] Additional features, aspects and advantages of the invention or its embodiments become apparent from the detailed description in conjunction with the claims.

[0028] It is known that high-voltage batteries in modern vehicles are sensitive to electromagnetic interference. This interference can impair the function of electronic control units and lead to malfunctions. To prevent this, effective EMC measures are required to ensure a reliable electrical connection between the battery units.

[0029] One problem in the manufacture of high-voltage batteries is that battery casings and battery units are often coated with layers of lacquer or insulation to protect them from environmental influences. However, these layers prevent a direct electrical connection, which necessitates the use of special processes to expose the conductive surfaces.

[0030] Fig. Figure 1 shows a representation of the inside of a battery cover 2 for a battery box 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) 3, 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.

[0031] The battery cover 2 not only provides protection and sealing for the battery cells, but also serves as a base for mounting the BMCe 3, the battery's central control unit. The battery cover 2 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 3. The battery cover 3 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 entire battery structure, providing high strength at a low weight while simultaneously ensuring external protection against environmental factors such as moisture, dust, and vibrations.

[0032] The battery cover 2 is connected to a battery frame 4. The battery cover 2 is attached using screw connections (in Fig. (1 not shown) attached to battery frame 4. As in Fig. As shown in Figure 2, these screw connections can consist of a screw 5 with a sealing washer and a rivet nut 7, with the screw 5 being screwed into the rivet nut 7. The battery cover 2, with the BMCe 3 mounted on it, is connected to the battery frame 4 and screwed in place. The battery frame 4 serves as a supporting and protective structure that connects the battery cover 2 to the high-voltage battery. The battery frame 4 ensures that the high-voltage battery and the battery cover 2 remain securely and firmly connected to each other, even under vibrations and shocks during driving.

[0033] The battery cover 2 contains electrical and electronic components, such as the BMCe 3 mounted on it. Therefore, it is important that electrical contact is established between the battery cover 2 and the battery frame 4. However, the battery cover 2 and battery frame 4 may have layers of paint or insulation that make electrical contact difficult.

[0034] The present invention solves this problem by using a separate EMC bridge 30 with knife edges 40, which are designed to penetrate the paint or insulating layers and establish a reliable electrical connection during the assembly of a first battery unit 10, such as the battery cover 2, and a second battery unit 20, such as the battery frame 4. The EMC bridge 30 is designed as a separate component, such as a metal bridge, and is positioned in a contact space between the first battery unit 10 and the second battery unit 20.

[0035] The EMC bridge 30 has knife edges 40 which, when the first battery unit 10 is screwed or pressed together with the second battery unit 20, cut the paint or insulating layers and thus establish an electrical contact between the first battery unit 10 and the second battery unit 20.

[0036] In Fig. 3a and Fig. Figure 3b shows possible patterns of the knife edges 40 in the form of adjacent points or scraper grids. It is essential that the knife edges 40 have sharp edges that enable the cutting of paint and insulating layers when screwing or pressing the first battery unit 10 to the second battery unit 20.

[0037] In Fig. Figure 4 shows an EMC bridge 30 designed as an elongated bridge, which is adapted to the shape of grooves and recesses in the battery unit 10, 20. The EMC bridge 30, designed as a separate sheet metal insert, is placed between the battery units 10, 20 to be connected during assembly and pressed into place by the screws. This enables a modular design in which the sharp knife edges 40 function as independent components that can be replaced or modified as needed. Such inserts can be designed to maximize the contact area and thus improve conductivity.

[0038] The knife edges 40 of the EMC bridge 30 are arranged in such a way that optimal penetration of the insulation layers is possible without complex pretreatment such as laser processing or masking. This design of the EMC bridge 30 as a separate component not only enables effective EMC contacting, but also simple and cost-effective mounting of the high-voltage battery.

[0039] The EMC bridge 30 is made of a corrosion-resistant material to ensure a long-term electrical connection.

[0040] As in Fig. As illustrated in Figure 5, contact surfaces 50 of a battery unit 10, such as a mounting flange of a carrier module for a BMCe 3, can themselves be provided with molded knife edges 40 to offer additional contact surfaces for electrical contacting.

[0041] The proposed solution thus makes it possible to overcome the challenge of electrical contacting in high-voltage batteries without resorting to complex processes such as lasers or masking.

[0042] The basic idea is to provide the contact surfaces of a battery unit 10, 20 or a battery component, such as a cast housing or a sheet metal cover with sharp edges, like knife edges or knurling, by using an EMC bridge 30 designed as a separate component with integrated knife edges 40. When the battery units 10, 20 are screwed together, the sharp edges of the EMC bridge 30 can penetrate the paint or coating, thus creating a direct electrical connection between the conductive surfaces. This approach eliminates the need for additional processing steps, such as laser cutting or masking of the contact surfaces.

[0043] The advantage of this concept lies in the fact that it simplifies the assembly process and reduces production costs, as no complex pretreatment steps are required. Furthermore, the EMC bridge 30 according to the invention offers a simple and effective solution to the problem of lacquer or insulating layers, which typically impede electrical contact. The function of the battery components 10, 20 is not affected by the separate EMC bridge 30, while at the same time electromagnetic compatibility (EMC) is improved.

[0044] In Fig. Figure 6 describes the process steps for assembling a high-voltage battery with a battery housing having an interior in which battery cell modules are shown, in which an EMC bridge 30 designed as a separate component with knife edges 40 is inserted between a first battery unit 10 and a second battery unit 20.

[0045] In step S10, the EMC bridge 30 is inserted into a contact space between the first battery unit 10 and the second battery unit 20.

[0046] In step S20, the first battery unit 10 and the second battery unit 20 are screwed or pressed together, with the knife edges 40 penetrating the paint or insulating layers of the battery units 10, 20 and establishing an electrical connection between the first battery unit 10 and the second battery unit 20.

[0047] The present invention enables reliable electrical contact between battery units through the use of knife edges, even when these are separated by lacquer or insulating layers. The assembly of the EMC bridge, which is achieved by inserting it into the contact space between the battery units and subsequently screwing and / or crimping it, is characterized by its simplicity and cost-effectiveness. By establishing a stable electrical connection, electromagnetic compatibility (EMC) is significantly increased, thereby improving protection against electromagnetic interference. The use of corrosion-resistant materials ensures that the electrical connection remains durable and stable. The EMC bridge, designed as a separate component with its integrated knife edges, optimizes EMC properties and enables reliable, efficient, and economical manufacturing of the high-voltage battery.The EMC bridge according to the invention eliminates the need for complex post-processing steps and at the same time ensures that the electrical conductivity remains reliably guaranteed. Reference sign 2 battery covers 3 BMCe 4 battery frames 5 screws 7 rivet nuts 10 first battery unit 20 second battery unit 30 EMC bridge 40 knife edges 50 contact area

Claims

[1] 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 at least a first battery unit (10) and a second battery unit (20) which are arranged in the battery housing or are part of the battery housing, and at least one EMC bridge (30) for electrical contacting between the first battery unit (10) and the second battery unit (20), wherein the EMC bridge (30) is designed as a separate component which can be inserted into a contact space between the first battery unit (10) and the second battery unit (20), wherein the EMC bridge (30) has one or more knife edges (40) which are arranged in a pattern, and wherein the shape of the separate EMC bridge (30) is adapted to the shape of grooves and recesses in the battery units (10, 20),to penetrate the paint or insulating layers of the first battery unit (10) and / or the second battery unit (20) during the assembly of the high-voltage battery and to establish an electrical connection between the first battery unit (10) and the second battery unit (20). [2] High-voltage battery according to claim 1, wherein the knife edges (40) are formed in the form of adjacent points or scraper grids. [3] High-voltage battery according to claim 1 or 2, wherein the knife edges (40) are made of a corrosion-resistant material. [4] High-voltage battery according to one of the preceding claims, wherein the knife edges (40) are designed to provide an enlarged contact area for the electrical connection between the first battery unit (10) and the second battery unit (20). [5] High-voltage battery according to one of the preceding claims, wherein the first battery unit (10) and / or the second battery unit (20) additionally has molded knife edges (40) on the surface of contact surfaces (50) between the first battery unit (10) and the second battery unit (20). [6] Method for assembling a high-voltage battery according to claim 1, in which an EMC bridge (30) designed as a separate component with knife edges (40) is inserted between a first battery unit (10) and a second battery unit (20), wherein the shape of the separate EMC bridge (30) is adapted to the shape of grooves and recesses in the battery units (10, 20), the method comprising the following process steps: - Inserting (S10) the EMC bridge (30) into grooves and recesses between the first battery unit (10) and the second battery unit (20); - Screwing and / or crimping (S20) the first battery unit (10) and the second battery unit (20), wherein the knife edges (40) penetrate the paint or insulating layers of the battery units (10, 20) and establish an electrical connection between the first battery unit (10) and the second battery unit (20).

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