Cell contact-making unit

Abstract

The invention provides a cell contact-making unit (6) for a battery having a plurality of cells, wherein, in the assembled state, adjacent cells are electrically connected to one another via cell connectors (8) and a sensor cable set (12) is provided and has at least one sensor line (14) which, in order to measure the cell voltage, is electrically connected to the cell in a manner protected against overcurrent, wherein the sensor line (14) is electrically connected to a voltage tapping point via a bonding wire (64) and by means of bonding.

Description

[0001] Description

[0002] Cell contact unit

[0003] The invention relates to a cell contact unit for a battery with several cells.

[0004] A cell contact unit is used to electrically connect several cells in a battery. The cells are connected in series and / or parallel as required so that the battery provides a specific voltage and current. Several cells are arranged in a row to form a cell stack. The cells of the cell stack each form a module of the battery, for example. For sufficiently large batteries, e.g. for an electric vehicle (electric vehicle), a correspondingly large number of cells are required and the battery is correspondingly large. For example, the battery has a width and a length in the range of 0.5 m to 2 m, so that contact between the cells over a longer distance is necessary.

[0005] Such a cell contacting unit typically has a support frame in which individual cell connectors are each accommodated and held in a holding receptacle. Each cell connector provides an electrical connection between the cell poles of neighboring cells. During assembly, the support frame is attached to a stack of cells lined up next to one another, and the individual cell connectors are electrically contacted with a cell pole of each cell. This is usually done by laser welding. Each support frame is often as large as the cell stack. Due to the size, tolerance problems can arise for widely spaced holding receptacles. In addition, different support frames are required for different stack sizes, which leads to significant manufacturing and logistical costs.Due to the sometimes very high voltages of typically several 100 V, especially in traction batteries for electrically powered vehicles, additional precautions must be taken to protect against contact.

[0006] Especially with such high-voltage batteries, a so-called battery management system is usually provided, which, among other things, is also designed to monitor the condition of the battery and its individual cells. This usually requires that sensor lines, for example for temperature, pressure, or voltage measurements, be routed to the individual cells or at least to parts of the battery. A sensor cable set is often provided for this purpose.

[0007] Overall, the provision of such a cell contact unit is complex and involves a high level of effort.

[0008] Based on this, the invention is based on the object of specifying a cell contacting unit in which the production and preferably also the handling is simplified and / or reliable operation is ensured.

[0009] The object is achieved according to the invention by a cell contact unit for a battery with multiple cells, wherein adjacent cells are electrically connected to one another via cell connectors. The cell contact unit comprises a sensor cable set with at least one sensor line that is electrically connected to the cell for measuring the cell voltage and protected against overcurrent. The sensor line is electrically connected to a tapping point for the cell voltage (potential tap) by means of a bonding wire and bonding.

[0010] The bonding wire is, in particular, a bare metal wire that is directly electrically connected to the tapping point using the conventional bonding technique. Direct bonding eliminates the need for a separate connection element to connect the sensor line to the tapping point for voltage measurement. Such a voltage measurement is typically required for each cell of a battery, particularly in the context of battery monitoring and the battery management system. The cell voltage is generally recorded through the voltage tap.

[0011] The various cell connectors are generally held within at least one holder. According to one embodiment, several cell connectors, and in particular all cell connectors arranged in a row, are held together within a holder. For this purpose, the holder has a plurality of receptacles for the individual cell connectors. Alternatively, a modular design of the cell contact unit is provided, in which several individual holders, each preferably accommodating exactly one cell connector, are arranged in a row. The holder(s) are each made of insulating material and are designed, in particular, as plastic injection-molded parts.

[0012] In a preferred embodiment, the bonding wire itself forms an overcurrent fuse with a predetermined nominal fuse value. The bonding wire is therefore designed as a fuse element, in particular as a fusible fuse wire. Therefore, no separate fuse is required, and one is omitted.

[0013] The fuse rating is defined by the properties of the bonding wire. Specifically, the geometric properties, i.e., the length and / or cross-sectional area, are adjusted accordingly.

[0014] Preferably, the bonding wire has a fuse rating in the range of 250 mA to 5 A and in particular in the range of 750 mA to 1.5 A.

[0015] The bonding wire is typically made of aluminum or an aluminum alloy. In particular, it is made of a silicon-aluminum alloy with a silicon content of, for example, 1%. Its diameter is, for example, in the range between 25 pm and 150 pm, and in particular in the range between 50 pm and 100 pm.

[0016] Its length is preferably in the range of 10 mm to 30 mm and in particular 15 mm.

[0017] One end of the bonding wire is directly connected to a cell connector. Since the cell connector makes direct electrical contact with the cell terminal, the cell connector defines a voltage tap point.

[0018] The bonding wire is preferably connected at its other end to a contact element, in particular a crimp contact. It is preferably also connected to the contact element by bonding. The sensor line is, in turn, connected to the contact element itself, in particular by crimping. The bonding wire is therefore preferably electrically contacted at both ends by bonding.

[0019] Overall, this allows for simple installation and connection of the sensor cable with an integrated fuse formed by the bonding wire. The advantage of this design is that no separate fuse elements, no circuit boards with fuse elements, etc. are required or provided. Overall, the voltage measurement is therefore very simple, compact, and cost-effective. Conventional components, particularly conventional crimp contacts, are used. In particular, only so-called SMD components can be used, as they are familiar from circuit board assembly and can be easily and automatically assembled.

[0020] According to a further, independently inventive aspect, which can, however, also be combined with the previously described aspect and one or more of the previously described features, a cell contacting unit with the features of claim 6 is provided. In this case, according to a first alternative, it is provided that several cell connectors form a group and several groups are arranged in series. The sensor cable harness has a modular design and is divided into sections at separation points. Each group has a section of the sensor cable harness, and the sections of adjacent groups are electrically connected to one another at the separation points. The connection of the sections takes place, in particular, only during assembly of the respective cell contacting unit and not as part of prefabrication.

[0021] For this purpose, connecting elements, hereinafter referred to as connectors, are arranged, via which a sensor line interrupted by a respective separation point is electrically reconnected, preferably individually. Within a group, the sensor lines are uninterrupted. A group preferably consists of 2 to 8, and preferably 2 to 6, cell connectors.

[0022] This measure achieves a modular design and, in particular, a modular concept described in more detail below is further developed and transferred to the sensor cable harness. The cable harness is therefore formed from a large number of group sections connected by connectors. This enables particularly simple scalability for different applications and cell contact unit designs. Previous sensor cable harnesses required specific preconfiguration for each cell contact unit type. The modular design of the sensor cable harness allows virtually any cell contact unit with a different design to be constructed modularly. This simplifies assembly, increases flexibility, and reduces costs.

[0023] According to a second alternative, it is provided that the sensor cable set has at least one flat cable with individual conductor strands, wherein the flat cable runs along the cell connectors and a respective conductor strand forms at least one section of a respective sensor cable.

[0024] By using a flat cable instead of a conventional sensor cable harness consisting of a multitude of individual round cables / sheathed cables, a particularly flat structure is achieved as well as an overall compact design. Such a flat cable is also particularly suitable in conjunction with the previously described first alternative with the modular design. The individual modular sections of the cable harness are therefore preferably each formed by sections of the flat cable. This is therefore divided into several sections in the longitudinal direction, with each group being assigned a section of the flat cable.

[0025] It is worth emphasizing that at least some of the sensor cables, and thus also the conductor strands, are looped through one or more of the separation points. For example, the sensor cables required to connect a group, which forms the last connection group in the longitudinal direction, are looped through all preceding separation points and groups. At the beginning of this modular cable harness, all sensor cables / conductor strands are preferably connected via a common cable harness connector and connected, for example, to a battery management system.

[0026] According to a preferred embodiment, several separate flat cables or sections of flat cables are arranged next to one another. Each of the flat cables has several conductor strands. Initially, the cable set preferably has enough flat cables that the total number of conductor strands is sufficient to suitably electrically contact all groups.

[0027] The number of flat cables arranged side by side is preferably reduced successively in the longitudinal direction. The individual conductor strands are preferably looped through only to the respective group to which they are connected. This design therefore also provides a stepped configuration for the entire cable harness, reducing the number of flat cables in the longitudinal direction. "Arranged side by side" is understood here to mean that the flat cables are arranged with their flat sides next to each other or with their flat sides one above the other.

[0028] For example, a respective flat cable has a number of 2-6 and preferably 4 conductor strands.

[0029] In a preferred embodiment, the flat cable is designed as a (flexible) flexible ribbon cable. In this case, the individual conductor strands, for example, as bare wires (solid or stranded wire), are arranged parallel to one another (within a single layer) in a common insulating sheath, and are insulated from one another by this sheath. The ribbon cable can be an extruded or laminated cable.

[0030] Alternatively, a printed foil cable (e.g., FPC: flexible printed circuit) can be used. However, the flexible ribbon cable offers advantages, particularly with regard to its modular design and assembly.

[0031] With regard to the electrical connection of the individual conductor strands, for example, between each other across the separation points or to other components, the aforementioned connectors are used. These preferably have different functions and / or different designs. In particular, connectors are used for one or more, and in particular all, of the following electrical connections:

[0032] To connect the conductor strands between two sections, connectors are used which preferably individually connect opposite conductor strands of the two sections to one another and thereby bridge the separation point. Connectors known as butt connectors are preferably used for this purpose. These are particularly elongated and have a connection terminal at their opposite end regions, particularly in the form of a crimp terminal. Furthermore, connectors are provided for connecting the flat cable to a plug connected to it. This plug is used in particular for the connection to a multi-core connecting cable which leads, for example, to the battery management system. These connectors are preferably located directly in a plug housing and are thus designed for a direct connection of the plug to the flat cable.Exactly one connector is designed for each wire harness. This connector is equipped, for example, with a crimp terminal at one end for connecting to the wire harness and a plug-in terminal (socket or pin) at the other end, which forms a plug-in contact for the plug.

[0033] As an alternative to such direct contact, such a connector is connected indirectly via individual connecting lines, which are preferably designed as round conductors. For this purpose, the connectors are preferably designed as double-sided connectors, with one end contacting a respective conductor strand and the other end contacting a respective connecting line. The two ends are preferably each designed as suitable crimp terminals of different types.

[0034] Another connector type is provided for a connection between a respective conductor strand and one of the cell connectors and / or with a sensor. Such a connector type preferably has a welding tab for electrically contacting the cell connector and / or the sensor, so that one end of the connector is electrically contacted to the sensor or cell connector by welding (in particular ultrasonic welding). The other end is preferably designed as a crimp terminal, with which a respective conductor strand is electrically contacted.

[0035] In general, in a preferred embodiment, for contacting a respective conductor strand, each connector is provided with a crimp terminal. When connecting the conductor strands across a separation point, the connector accordingly has two crimp terminals. To simplify the connection of the connectors during assembly, a recess is formed below each connector, specifically at least in the area of ​​a crimp terminal, in a practical embodiment, so that the connector / crimp terminal is accessible to an assembly tool, in particular a crimping tool, which is designed for fastening and electrically connecting the connector.

[0036] In a preferred embodiment, the cell connectors of a group are held by a common holding frame. The multiple holding frames are arranged in series with the assembled cell contact unit. Preferably, the aforementioned recess is formed directly on the holding frame, ensuring accessibility for the crimping tool. Since the holding frames also form the separation points for the different sections of the modular cable harness, these recesses are formed particularly on the edges where the holding frames abut one another.

[0037] Generally, a holding frame typically has several recesses located at the positions where a respective crimp terminal is required and intended. The recesses are generally located on the underside of the holding frame, i.e., on the side opposite the flat cable. The flat cable generally rests on the top side.

[0038] To ensure the simplest possible contacting, the connector, in particular the crimp terminal, is electrically connected to the respective conductor strand without stripping the insulation. The crimp terminal and, in particular, the (sharp-edged) crimp flanks are therefore pressed through the insulation and contact and clamp (crimp) the respective conductor strand.

[0039] The object is further achieved according to the invention by a modular cell contacting unit with the features of claim 15. This modular aspect is an independent inventive aspect, but can also be combined with one or more of the previously described aspects and features. The modular cell contacting unit is designed for a battery with multiple cells and has a plurality of individual holders that are arranged in a modular row. Each holder has at least one and preferably exactly one cell connector for electrically connecting adjacent cells. For this purpose, the respective holder has a holding receptacle, in particular a stretching receptacle, into which a respective cell connector is inserted, in particular plugged in, and in which the cell connector is preferably held in a form-fitting manner.The individual holders are typically made of an insulating material, especially plastic, whereas the cell connectors are conductive and are usually made of metal. These holders thus form a support frame for the cell connectors.

[0040] In this case, modular arrangement means that the number of holders of the cell contact unit can be selected by simply adding or removing individual holders. This means that the length of the support frame formed by the holders can be easily adapted to the required length of a cell stack. The individual holders are therefore individual and, in particular, monolithic pieces that are manufactured, for example, using an injection molding process. This modular design means that different variants of cell contact units can be easily assembled and constructed using the same module components. Because the holders are designed as identical parts, the entire support frame can be easily scaled. Overall, production and production logistics are significantly simplified.

[0041] Furthermore, this modular design enables better positioning of the individual holders and cell connectors in relation to the respective cell, even with large batteries. Because the holders are designed as individual components, they can preferably be offset at least slightly relative to one another. Alternatively or additionally, each cell connector can be arranged in the respective holder so that it can be moved at least slightly to compensate for tolerances. Overall, this allows tolerances to be compensated even with large cell stacks, so that each cell connector can be positioned at the desired location relative to the respective cell pole during assembly.

[0042] In a preferred embodiment, the holders are lined up along an assembly line and held thereto. The assembly line is designed in particular in the manner of a rail, specifically as a metal rail. It is therefore particularly resistant to tension and compression and also has a high degree of rigidity, particularly high flexural rigidity. For this purpose, the assembly line is preferably designed as a profile rail and thus not merely as a simple flat rail. Viewed in cross-section, it is designed in particular as a C-profile rail.

[0043] Preferably, the individual holders are not directly connected to one another, but rather simply rest loosely against one another. The individual holders are therefore only indirectly held to one another via the assembly line. This measure enables a simple design of the individual holders, and they do not, for example, have any connecting elements, in particular no molded connecting elements for directly connecting the individual holders to one another.

[0044] Preferably, each holder has at least one guide for the assembly line, wherein each holder with the guide is applied to the assembly line, for example pushed onto it or clipped (in). The guide therefore extends in the longitudinal direction of the assembly line and is designed in particular in the manner of a guide channel so that the assembly line can be pushed through the guide. At the same time, the assembly line is held in a form-fitting manner by the guide such that it is only movable in the longitudinal direction and is held stationary perpendicular to the longitudinal direction. For this purpose, the guide is designed, for example, to be C-shaped when viewed in cross-section. The individual holders are essentially threaded onto this assembly line. When configuring the support frame, they are arranged in series simply by pushing or clipping them onto the assembly line. This enables simple scalability and production.In a preferred embodiment, each holder has two opposing guides, particularly at the edges, for two assembly lines. The guides are, for example, identically designed. However, they preferably differ, for example, in terms of their size. Accordingly, the two assembly lines are either identical or, preferably, differently designed. The assembly lines, particularly arranged opposite one another, ensure reliable and precise guidance and alignment of the individual holders.

[0045] Preferably, the respective holding receptacle for the respective cell connector is arranged between the two guides.

[0046] In a preferred embodiment, the at least one assembly band is designed as a tensioning band, by means of which the individual cells of the battery are clamped together in the assembled state. In the assembled state, a tensioning force is exerted on two cells, in particular on the edges, with the help of the assembly band, so that these two cells and further cells arranged between these cells are permanently and compactly clamped against one another. The cell stack usually has pressure plates, in particular made of metal (steel), which are attached at least to the opposite ends of the cell stack. The assembly bands, which are usually designed as steel bands, are welded to these pressure plates. The compressibility of at least two adjacent cells is preferably achieved by placing a compression pad between these cells, which is easily compressible and has a high strength for longer-lasting loads.During assembly, for example, the individual cells are clamped against each other in an auxiliary clamping device, and the clamping band is then secured before the auxiliary clamping device is released. The clamping band therefore fixes and holds the cell stack in its clamped state.

[0047] According to a preferred embodiment, the holders arranged next to one another form a longitudinal channel for receiving a cable set referred to as a sensor cable set. Each holder defines a channel section, which is formed in particular between the at least one guide and the holding receptacle. As a result, a cable guide for the cable set is easily formed as an integral component of the respective holder. The cable set typically has a plurality of sensor lines, each of which leads to a sensor, for example a temperature sensor, voltage sensor (at least one voltage tap), etc. In the finally assembled state, the sensors are connected via the cable set in particular to a battery management system, via which the battery and the individual cells are monitored.

[0048] Generally, edge regions of the holder adjoin the holding receptacle on both sides, forming base surfaces on a rear side, which are preferably intended to rest on at least one cell. In the assembled state, the holders preferably rest with their base surfaces on at least one cell, in particular on a cell housing, specifically in the area adjacent to a respective cell pole. At least the base surface runs parallel to the cell housing with a tolerance distance. Typically, each holder partially covers two adjacent cells. The base surfaces are, in particular, flat.

[0049] The edge areas alternatively and particularly complementarily form the guides on a front side.

[0050] The holding receptacle is preferably designed like a recess that is open toward the rear and thus toward the cell connector, allowing the connector to be inserted from the rear. The recess is preferably dimensioned to accommodate a respective cell terminal, so that the base surfaces preferably rest on an outer side of the cell next to the cell terminal.

[0051] The base of the recess is preferably generally designed to provide a cover for the cell connector and thus a contact protection. The cell contact unit usually has connection terminals, thus defining a connection for the positive or negative pole of the respective cell stack (module). Connecting cables (battery cables) are connected to these connection terminals in the final assembly state.

[0052] Preferably, the cell contact unit generally comprises—also independent of the modular design—a plurality of temperature sensors, which are arranged in particular distributed along the length of the cell contact unit. Each temperature sensor is connected to a sensor line via a contact plug. This simplifies the assembly and electrical connection of the temperature sensors. During assembly, the temperature sensors are first attached to a desired position, for example, by gluing, before being subsequently connected to the sensor line.

[0053] Preferably, the temperature sensor itself has contact pins for plugging into the contact plug. The temperature sensor typically has an electronic component as its sensor element, for example, a so-called NTC thermistor.

[0054] A respective contact plug is preferably received in a plug receptacle of a respective holder and secured there. Generally, at least some of the holders, and preferably all holders, have such a plug receptacle according to the common parts principle. The contact plug can be inserted into the plug receptacle in one plugging direction and is secured and held there.

[0055] In the area of ​​the plug receptacle, and especially adjacent to the plug receptacle, the holder preferably has an opening to a rear side. In contrast, the contact plug is attached to an opposite front side of the holder and inserted from there into the plug receptacle.

[0056] Generally, the holder has one or more such connector receptacles and also openings for sensor elements. Preferably, the holder has at least one connector receptacle on each side of the holding receptacle. The temperature sensors are preferably in thermally conductive contact with the cell, in particular with the cell housing. Each temperature sensor therefore rests on the cell housing. This occurs either directly or indirectly, for example, via a thermally conductive element, such as a thermal pad.

[0057] At least some of the temperature sensors perform what's known as a hot spot temperature measurement during operation. The corresponding temperature sensors are preferably positioned adjacent to a cell terminal or cell connector, since high temperatures occur in the area of ​​the cell terminals during operation due to the current flow.

[0058] Preferably, at least one additional temperature sensor is mounted for a so-called cold spot temperature measurement, which is mounted at a distance from the cell connector. This additional temperature sensor therefore performs a temperature measurement during operation at a distance from a cell terminal of a respective cell. In the mounted state, the temperature sensor is in thermal contact with the cell, specifically with the cell housing.

[0059] The additional temperature sensors are arranged in particular in the area of ​​the assembly line. In a preferred embodiment, this has sensor openings through which the respective additional temperature sensor is / will be electrically connected to the respective sensor line. In particular, the temperature sensor is inserted into such a sensor opening and preferably extends through it. Contact is again established via a contact plug as described above.

[0060] The various temperature sensors are designed as identical parts.

[0061] In a preferred embodiment, at least some of the holders, and in particular an edge-side holder, have an opening with a positioning element, wherein the positioning element engages in the sensor opening to fix the mounting strip in place. The positioning element is designed in particular as a web, in particular a web running around the opening. This running web preferably engages precisely in the sensor opening. The additional temperature sensor is therefore located in this opening, particularly in a protected manner, which thus forms a type of sensor receptacle.

[0062] An edge-mounted holder forms the end of the cell contact unit and, preferably instead of a standard cell connector, accommodates only a cell connection, which is connected to the connection terminal or is a part of it. The cell connection serves—similar to a cell connector—to electrically contact the cell pole of an edge-mounted cell. The connection terminal then enables connection to a connecting cable.

[0063] The object is further achieved according to the invention by a cell contact unit for a battery with a plurality of cells, wherein, in the assembled state of the cell contact unit, adjacent cells are electrically connected to one another via the cell connectors and the cell connectors are held in at least one holder. Furthermore, a measuring sensor, in particular a temperature sensor, is attached to the holder in a mount connected to the holder. The measuring sensor is held elastically in the mount. The mount is therefore designed to be suitable and flexible in order to enable the desired elastic fastening. Preferably, the measuring sensor is held elastically at least in the longitudinal direction of the cell contact unit.

[0064] The features previously described with regard to the temperature sensor can be combined with this elastic holding principle (unless technically excluded), and are therefore preferred developments of this elastic holding principle.

[0065] Instead of a temperature sensor, another measuring sensor, such as a voltage sensor, can be used and held elastically. The measuring sensor generally records a state variable of the battery or a cell within the battery.

[0066] The temperature sensor measures the temperature of the battery or at least one cell during operation. The temperature sensor is in heat-conducting contact with the cell either directly or indirectly, for example via a contact pad. This contact pad, or more generally a thermal contact element to a temperature measuring location, is usually permanently connected to this temperature measuring location. In general, the measuring sensor is (permanently) connected to the measuring location by a measuring element. The measuring location is, for example, a typically metallic housing of the cell or, for example, a cell terminal in the case of a voltage measurement. The contact element is preferably attached to this measuring location. This can be achieved, for example, by a material-to-material connection such as gluing or the previously described bonding using a bonding wire, or by some other type of connection.

[0067] During operation, the problem arises that, for example, temperature changes can cause different length expansions between the cell contact unit and the battery / cells, so that the cell contact unit and thus the measuring sensor may shift relative to the (fixed) measuring location. The elastic mounting of the measuring sensor on the cell contact unit therefore enables length compensation, so that the contact between the measuring sensor and the measuring location is as free as possible from mechanical stress. This at least reduces the risk of the (thermal) contact between the temperature sensor (measuring sensor) and the measuring location being impaired, which could lead to incorrect (temperature) measurements.

[0068] In a preferred embodiment, the holder, together with the at least one holder, forms a monolithic component. In particular, a monolithic injection-molded component. The holder is generally made of plastic.

[0069] To exert the elastic holding force on the measuring sensor, the holder, in a preferred embodiment, has at least one curved retaining tab against which the measuring sensor rests. This curved retaining tab holds the measuring sensor elastically and thus flexibly. The retaining tab thus forms a spring tab and thus a resilient holder. The retaining tab is part of the monolithic injection-molded component.

[0070] Preferably, viewed in the longitudinal direction, a retaining tab is arranged on both sides of the measuring sensor.

[0071] The measuring sensor generally has a (thermal or electrical) contact element for (thermal or electrical) contact with the (temperature) measuring location. This contact element is designed as an electrical sensor component or connected to one. Furthermore, the measuring sensor typically includes sensor electronics to generate a sensor signal. This signal is transmitted via a corresponding sensor cable to an evaluation unit, which may be part of the battery management system, for example.

[0072] This sensor cable is usually connected to the measuring sensor via a contact plug.

[0073] In particular, the measuring sensor has a circuit board with sensor electronics mounted thereon as well as connections, in particular plug connections for connecting the sensor cable.

[0074] Exemplary embodiments of the inventions are explained in more detail below with reference to the figures. These show

[0075] FIG 1 is a perspective view of a cell contacting unit,

[0076] FIG 2A shows a partially enlarged view of the cell contact unit according to FIG 1 with a view of the rear side

[0077] FIG 2B shows a partially enlarged view of the cell contact unit according to FIG 1 with a view of the front

[0078] FIG 3 is a perspective view of a holder looking towards a front side, FIG 4 is a perspective view of the holder according to FIG 3 looking towards a rear side,

[0079] FIG 5 is a partial perspective view of the cell contact unit according to FIG 1,

[0080] FIG 6 shows the view according to FIG 5, but with one of the holders hidden so that the view of the cell connector and other components in the holder is clear,

[0081] FIG 7 is an enlarged partial perspective view of the cell contact unit in the area of ​​two adjacent cell poles, with several components hidden, to explain the arrangement of a temperature sensor,

[0082] FIG 8 is an enlarged partial perspective view of an end region of the cell contact unit according to FIG 1,

[0083] FIG 9 a highly simplified, partial plan view of a cell contact unit with a modular sensor cable set,

[0084] FIG 10 is a perspective, partial view from above of a cell contact unit with a temperature sensor held elastically in a holder,

[0085] FIG 11 the view according to Figure 10, with the contact plug hidden and a transparent printed circuit board as well as

[0086] FIG 12 a perspective view from above of a holder for the cell connectors with the monolithically formed holder for the temperature sensor.

[0087] FIG 1 shows a cell contact unit 6 for a battery (not shown in detail here), which is preferably intended for an electric motor-driven motor vehicle and is also used there as a traction battery. The battery is usually composed of several modules that are interconnected. Each module, in turn, has a large number of individual (battery) cells that are arranged next to one another in a longitudinal direction L and form a cell stack. The individual cells are often cuboid-shaped / prismatic. The cell contact unit 6 extends accordingly along the longitudinal direction L and in a vertical direction V. The cells are connected in a transverse direction Q. The longitudinal direction L, transverse direction Q and vertical direction V form a Cartesian coordinate system.

[0088] The individual cells of a module are electrically connected in series via the cell contact system. For this purpose, each cell pair is electrically connected via a respective cell connector 8 (FIG. 2).

[0089] The voltage tap for the total voltage of the module is made via connection terminals 10 on the edge and opposite each other in the longitudinal direction L, to each of which a connection cable is connected when installed.

[0090] The entire battery typically includes a battery management system, which, among other things, is designed to monitor the current state of the battery and, in particular, the individual cells. The module, and, in particular, the cells, are generally equipped with sensors connected via a cable set 12 and linked to the battery management system when installed. The cable set 12 includes a plurality of individual sensor lines 14. In the exemplary embodiment, the cable set 12 includes a multi-pin connector 16 at one end, via which the cable set 12 can be connected, for example, to the battery management system.

[0091] The structure and function of the cell contact unit 6 is explained below in connection with some essential aspects:

[0092] 1. Modular design

[0093] A key aspect of the cell contacting unit 6 is its modular design, as can be seen in particular from FIGS. 2A and 2B: A plurality of individual holders 18 made of insulating material are arranged in a row in the longitudinal direction L. Each of the holders 18 accommodates a cell connector 8. The individual holders 18 are designed in particular as (plastic) injection-molded parts and specifically as identical parts. The individual holders 18 are arranged in a row along at least one assembly line 20, in the exemplary embodiment two assembly lines 20, namely a lower assembly line 20A and a preferably different, in particular narrower, upper assembly line 20B. In particular, the holders 18 are pushed and / or clipped onto a respective assembly line 20 and held therein in a form-fitting manner. In the exemplary embodiment, the assembly lines 20 are designed as profile rails, in particular made of metal.

[0094] The holders 18 and also the respective cell contacting unit 6 each have a rear side 22 oriented towards the cells (see FIG 2A) and an opposite front side 24 (see FIG 2B).

[0095] The individual holders 18 are rectangular in shape when viewed in the transverse direction Q and have opposite side edges in the longitudinal direction L, which preferably run straight. The individual holders 18 rest flatly and preferably loosely against one another with these side edges. They are connected and held together only by the mounting straps 20.

[0096] The assembly belts 20 are preferably designed as tensioning belts and ensure that, in the final assembled state, the individual cells are held against each other in the longitudinal direction L. For this purpose, the assembly belts 20 are mechanically fastened to the cell stack at least in a suitable manner.

[0097] In the exemplary embodiment, a respective holder 18 - as can be seen in particular from FIGS. 3 and 4 - has a central holding receptacle 26 which is designed in the manner of a trough and is open towards the rear side 22. The cell connector 8 is arranged in the holding receptacle 26. Edge regions 28 adjoin both sides in the vertical direction V. These edge regions form flat base surfaces 30 on the rear side 22, with which the holder 18 rests on a respective cell in the assembled state or is at least positioned parallel to an outer side of the cell with a short distance. On the front side 24, the holder 18 forms a central cover 32 which delimits the holding receptacle 26 towards the front side 24 and forms a contact guard.

[0098] On the front side 24, the edge regions 28 each form a guide 34 at opposite end regions in the vertical direction V, namely a lower guide 34A for receiving the lower assembly belt 20A and an upper guide 34B for receiving the upper assembly belt 20B. The guides 34 each have, in particular, hook-shaped holding elements which engage around the respective assembly belt 20 so that they are held in a form-fitting manner in the transverse direction Q. In this respect, the guides 34 each form a type of guide channel into which the assembly belts 20 can be pushed or inserted / clipped or with which the respective holders 18 can be pushed or clipped onto the assembly belts 20. The holding elements are designed, for example, as continuous strips (lower guide 34A) or as individual shaped elements (upper guide 34B) which only extend over a portion of the length of the holder 18.

[0099] The two edge regions 28 preferably each have the same width in the vertical direction V. On the front side 24, the upper edge region 28 has, in addition to the upper guide 34B, a channel section 36. The adjacent channel sections 36 form a cable channel 38 in which the cable set 12 is inserted. The sensor lines 14 of the cable set 12 are held by individual retaining elements designed as clips 40.

[0100] The holder 18 is further configured to accommodate sensor elements, such as temperature sensors, pressure sensors, voltage taps, etc., which are each connected via the individual sensor lines 14. In particular, connector receptacles 42 are configured on the holder 42, in which connector elements for connecting the sensor lines 14 are arranged.

[0101] According to FIG. 2B, each cell connector 8 has two contact tabs 44, which are opposite one another in the longitudinal direction L and are in particular approximately strip-shaped, and which are connected to one another via an intermediate part 46. This is preferably designed for length compensation and, in the exemplary embodiment, is in particular wave-shaped. Furthermore, the cell connector 8 has a connection area, in particular formed by a connection tab 48, which is used for a voltage tap. The cell connector 8 also has two pole openings 50, in particular circular. These are in particular formed centrally in each contact tab 42.

[0102] During assembly with a respective cell, the contact tabs 44 are placed flat on a respective cell pole of the cell. For this purpose, the cell pole is preferably approximately cuboid-shaped. It also preferably has an upwardly projecting contact pin with a typically circular cross-section. The pole openings 50 are each slipped over this contact pin and accommodate it preferably with a precise fit (with insertion play). This ensures and enables correct positioning and also verification of the positioning. Alternatively - particularly in a variant without contact pins - the positioning is preferably checked using the edges of the, for example, cuboid-shaped cell pole.

[0103] The assembly of the respective cell contact unit 6 is carried out as follows: First, the individual holders 18 are equipped with the required components, specifically with the cell connector 8 and preferably with at least some of the sensor elements, such as the aforementioned connection elements, in particular contact plugs. The holders 18 are then successively pushed or clipped onto the two assembly lines 20. Subsequently, the cable set 12 is mounted, and the individual sensor lines 12 are connected to the sensor elements. A functional test is preferably performed afterward. The thus completed cell contact units 6 are then typically packaged and delivered to an assembly site where the battery is assembled.

[0104] There, the cell contact units 6 are attached to the cell stack to form the module. For this purpose, the individual cell connectors 8 are electrically and mechanically connected to the cell poles of the cells, in particular by welding. The individual cells of the module are preferably additionally held mechanically to one another via the assembly belts 20, in particular in a clamped state in which the cells are pressed against one another in the longitudinal direction with a clamping force. For this purpose, the assembly belts 20 are mechanically connected to the cell stack in a suitable manner, in particular by welding. The cell stack usually has pressure plates, in particular made of metal, which are attached at least to the opposite ends of the cell stack, and if necessary, further pressure plates are attached distributed along the length. These pressure plates are attached in particular in an electrically insulated manner from the cells.The assembly lines 20 are welded to these pressure plates.

[0105] The assembly lines 20 are electrically insulated from the cell housings, which are also typically made of metal. This is achieved in particular by the plastic holders 18.

[0106] In a preferred embodiment, a (double-sided) adhesive tape is also applied, with which the cell contact unit 6 is additionally held to the cells and thereby also mechanically couples the individual cells to one another. The adhesive tape is thus applied between the cell housing and the cell contact unit 6, in particular between the cell housing and the holders 18. Specifically, the rear base surfaces 30 of the holders rest on the adhesive tape.

[0107] Compression elements, also called compression cushions, are typically placed between two adjacent cells.

[0108] The particular advantage of the described modular design is its easy scalability to cell stacks of different sizes. Due to the use of identical parts, simple storage and overall simple assembly are achieved. The principle of the holders 18 that can be pushed onto the assembly lines 20 achieves very simple assembly, particularly since the individual holders 18 do not need to be connected to one another. In the exemplary embodiment, each holder 18 has exactly one cell connector 8. Alternatively, a respective holder can, for example, also have several holding receptacles 26, wherein the holders are still arranged in a modular row. In particular, such (pair) holders have exactly two holding receptacles 26 or, alternatively, exactly three or exactly four holding receptacles 26.Such (multiple) holders 18 with a plurality of holding receptacles 26 are formed, for example, by a series of the (individual) holders 18 described in the exemplary embodiment, wherein a respective (multiple) holder 18 is designed as a monolithic, one-piece component, in particular as an injection-molded component.

[0109] The further aspects described below are combined, for example, with a modular holder 18, as previously described. Alternatively, they are combined with a common holder for several, and in particular all, cell connectors in a row. Such a common holder, preferably designed as a plastic injection-molded part, is shown, for example, in Figures 10 to 12.

[0110] 2. Contact protection

[0111] As already mentioned, the cover 32 forms a contact protection, in particular in accordance with protection class IPXXB according to ISO 20653. The contact protection is explained in more detail below with reference to FIGS. 3 and 4. The contact protection ensures that the cell connector 8 cannot be touched from the front side 24 with a finger, more precisely with a test finger according to IEC 61032 (Figure 2, test sample B). In order to simultaneously enable assembly of the cell contact unit 6 on the cells, which requires an electrical and mechanical connection of the cell connector 8 to a cell pole of the respective cell, the cover 32 is suitably designed: It firstly has assembly openings 52, which are L-shaped in the exemplary embodiment. An assembly tool can reach through these during assembly. In particular, a welding tool for welding the cell connector 8 to the cell.Alternatively, other geometries, such as elongated and / or curved ones, are also possible. Additionally, pole windows 54 are formed, each of which is preferably arranged between two opposing mounting openings 52. When the cell connector 8 is inserted, the pole windows 54 are aligned with its pole openings 50 (see FIG. 2). The pole windows 54 therefore enable visual inspection of the correct positioning relative to the cell poles.

[0112] As can also be seen from FIG 4, fixing webs 56 are formed in the interior of the holding receptacle 26. In the exemplary embodiment, these each surround a mounting opening 52. They protrude counter to the transverse direction Q from a base formed by the cover 32 into the interior of the holding receptacle 26 and form a counter-bearing for the cell connector 8. The cell connector 8 rests on these fixing webs 56 at least during assembly and preferably also in the assembled state or, alternatively, has a tolerance distance in the assembled state. With these fixing webs 56, the cell connector 8 is pressed against the cell poles during assembly so that a welded connection can be reliably formed. The pressing force is typically exerted by a hold-down device which is supported on the front side 24 on the cover 32.Typically, a welding electrode is passed through the hold-down device and is guided through the mounting opening 52 for welding.

[0113] To ensure the desired contact protection, the openings 52, 54 have a limited maximum opening width so that the relevant standards for contact protection are met. The contact protection is designed in particular in accordance with ISO 20653. This standard defines a test probe, also referred to as a test finger. The contact protection is now designed in such a way that contact with the cell connector is reliably avoided with such a test probe. According to the standard, the test probe has a diameter of 12 mm, 8 mm, or 4 mm, depending on the penetration depth. Therefore, the maximum opening width is specifically less than 12 mm and preferably less than 8 mm. Maximum opening width is understood in particular to mean that the respective opening 52, 54 must have a maximum circular area of ​​less than 12 mm, preferably less than 8 mm, at any point (if necessary, subject to further boundary conditions as specified in the standards).

[0114] 3. Sensor technology

[0115] A sensor system is generally provided for monitoring the battery. The respective cell contact unit 6 is designed specifically for temperature and voltage measurement. This means that the corresponding sensor system is directly integrated into the cell contact unit 6. The specific measures for the sensor system are explained in more detail in connection with FIGS. 5-8 and also in connection with FIGS. 3 and 4.

[0116] It should be emphasized that a respective holder 18 is designed by the plug receptacles 42 to accommodate parts of the sensor system, in particular contact plugs 58.

[0117] As can be seen in particular from FIG. 3, in the exemplary embodiment, the plug receptacles 42 are formed in the longitudinal direction L on opposite sides of the holder 18 and are thus each adjacent to the holding receptacle 26. The plug receptacles 42 are designed in particular in the manner of receiving channels, in particular continuous receiving channels. A respective contact plug 58 can be inserted, for example, on the front side 24 into these plug receptacles 42 in a plugging direction that, in the exemplary embodiment, is oriented opposite to the vertical direction V, as shown by arrows in FIG. 3.

[0118] Since the sensor system is arranged on the side facing the cell and is typically connected to the cell, suitable openings 60 are formed in which parts of the sensor system, for example, a sensor, are located. The openings 60 thus create a connection from the rear side 22 to the front side 24. In the exemplary embodiment, the openings 60 are arranged adjacent to a respective connector receptacle 42.

[0119] As can be seen specifically from FIGS 6 and 7, at least some of the holders 18 have contact plugs 58 inserted into the opposite plug receptacles 42, which can be seen in particular in FIG 7, where the holder 18 is hidden. The contact plug 58A shown on the left is used to connect a temperature sensor 62. The contact plug 58B shown on the right is used for voltage measurement and, in the exemplary embodiment, is connected to a bonding wire 64, which is preferably designed as a continuous bare conductor and which directly contacts the cell connector 8, in particular its connection tab 48.

[0120] Each contact plug 58 has an internal contact element (not shown in detail here), which is designed in particular as a crimp contact. This typically has a crimping area to which a stripped conductor of the respective sensor line 14 is connected. At the opposite front end, the contact element has a front plug-in part, typically a contact pin or a contact socket.

[0121] In general, a very small contact element is preferred, with a length of preferably less than 20 mm and, for example, less than 15 mm, and a width and height of preferably less than 4 mm and, in particular, less than 2 mm. The crimp contact, for example, is a contact element known under the brand name "NanoMQS."

[0122] The contact element is surrounded by an insulating connector housing. Preferably, the front end of the contact element is freely accessible and not protected by the connector housing, particularly in the case of contact plug 58B. Unlike conventional contact plugs, a portion of the contact element, specifically the front plug-in part, is therefore virtually exposed and no longer surrounded by the connector housing.

[0123] 3.1. Direct bonding with overcurrent protection for voltage measurement

[0124] For voltage measurement, the voltage—preferably of each cell—is tapped via bonding wire 64. This bonding wire 64 is connected at both ends by direct bonding, on the one hand to the cell connector 8 and, on the other hand, to the described contact element, specifically to its front plug-in part. The bonding wire 64 is thus directly connected to the respective element, i.e., without any additional intermediate elements.

[0125] Such voltage measurements of a particular cell often require protection against overcurrents. Traditionally, separate fuse elements are used for this purpose. These must be connected separately and typically require a fuse carrier, for example, and are arranged on a circuit board.

[0126] In the present embodiment, the bonding wire 64 itself serves as a fuse element and, in particular, as a fuse. The fuse properties of the bonding wire 64 are suitably adjusted by its geometry and material properties. For example, the bonding wire 64 has a total length of only 10-30 mm and a diameter of, for example, 50 μm to 100 μm. It consists, in particular, of aluminum or an aluminum alloy, for example, an aluminum-silicon alloy with a 1% silicon content. This results in a total fuse rating of, for example, 750 mA to 1.5 A.

[0127] The advantage of securing via bond wire 64 is that it requires extremely little space and eliminates the need for a separate fuse element, which usually requires a fuse carrier, such as a circuit board.

[0128] 3.2. Temperature measurement

[0129] A plurality of temperature sensors 62 are provided for temperature monitoring. These temperature sensors 62 are each in thermally conductive contact with the cell, in particular with the cell housing, for example on the front side. In the exemplary embodiment, some of the temperature sensors 62A are provided for hot spot measurement and are preferably positioned directly adjacent to a respective cell pole 66 (see in particular FIG. 7). In addition, further temperature sensors 62B are provided for so-called cold spot temperature measurement, each of which is arranged further away from the cell pole 66. Specifically, such a further temperature sensor 62B is positioned in an edge region 28 of the holder 18, as will be explained in more detail below in connection with FIG. 8.

[0130] The structure of each temperature sensor 62 can be seen in FIG. 7, using a hot spot temperature sensor 62A. The temperature sensor 62 has a suitable electronic component, in particular an NTC thermistor, as its sensor element. This component is connected to a circuit board, which is attached to the cell housing either directly or, in the exemplary embodiment, via a heat-conducting intermediate element (heat pad), for example, by gluing.

[0131] Contact pins 68 are connected to the circuit board and the sensor element, onto which the contact plug 58A is directly plugged in the assembled state. The contact plug 58A is preferably identical to the previously described contact plug 58B (possibly without a partially exposed contact element).

[0132] The contact element embedded in the connector housing is again preferably a crimp contact. The front plug-in area has contact sockets that are plugged onto the contact pins 68.

[0133] The contact pins 68 are bent out from the plane of the circuit board. They run, in particular, parallel to the plane of the circuit board and are accordingly bent at least in an L shape and, in the exemplary embodiment, in a U shape. A vertically projecting stabilizing element 70 is arranged on the circuit board, which serves to mechanically stabilize the contact pins 68. The upper region of the contact pins 68, which is plugged into the contact plug 58A, protrudes from this stabilizing element 70 in the exemplary embodiment. The stabilizing element 70 also serves, in particular, to absorb the insertion forces when plugging in the contact plug 58A.

[0134] FIG. 7 shows the typical design of the cell pole 66, which has an approximately cuboid base with a contact pin 72 projecting upwards in the center, which, when mounted, lies in the pole opening 50 of the cell connector 8. The further temperature sensor 62B is - as can be seen from FIG. 8 - arranged in the region of one of the two assembly lines 20 and in particular in the region of the upper assembly line 20B. For this purpose, the upper assembly line has a sensor opening 74 through which the temperature sensor 62B can pass from the rear side 28 to the front side. Accordingly, the holder 18 also has an opening, particularly in the region of the guide 34, 34B, through which the temperature sensor 62B is inserted. In a preferred embodiment, a positioning element 76 is formed, which is designed in particular as an upwardly projecting edge web running around the opening.The holder 18 engages with this positioning element 76 into the sensor opening 74 so that the mounting band 20B is fixed in place and the temperature sensor 62B is protected.

[0135] FIG. 8 also shows an edge-side holder 18'. Instead of a cell connector 8, this holder accommodates a cell terminal (not shown in detail here). Similar to the cell connector 8, this terminal is designed for electrically contacting a cell terminal 66, but only for electrically contacting the outermost, edge-side cell terminal 66 of the first or last cell in the module. The edge-side holder 18' is designed approximately as half a normal holder 18.

[0136] Similar to the cell connector 8, the cell terminal has a contact tab 44 with a terminal opening 50 formed therein. The cell terminal, at least its portion located in the edge-side holder 18', is designed in particular as a flat sheet metal part. The cell terminal as a whole is preferably designed in particular as a bent sheet metal part, which extends laterally from the edge-side holder 18' and is connected to the connection terminal 10 or is part of the same. The cell terminal is electrically and mechanically connected to the cell terminal 66.

[0137] The edge-side holder 18', like the normal holders 18, also has mounting openings 52 and a terminal window 54. Furthermore, it has at least one connector receptacle 42, in which, in particular, a contact plug 58B is arranged for tapping the cell voltage by means of the bonding wire 64. An identically constructed edge-side holder 18' is arranged at the opposite end of the cell contact unit.

[0138] 4. Modular sensor cable set

[0139] In connection with Figure 9, a cell contact unit 6 with a modular sensor cable set 12 is shown. This is combined in particular with one or more of the previously described aspects, in particular with the entire modular structure of the cell contact unit 6. In principle, however, this is also designed as an independent inventive concept that can be used independently of the previously described aspects, especially in the case of generally modular cell contact units.

[0140] In the exemplary embodiment, several cell connectors 8 are initially combined into a group 80. The cell connectors 8 of a respective group 80 are held by a common holding frame 82. They therefore form a prefabricated modular unit with the holding frame 82.

[0141] The sensor cable set 12 has in particular a plurality of flat cables 84 arranged next to one another, each of which has a plurality of conductor strands 86.

[0142] A respective flat cable 84 is divided into sections 88, viewed in the longitudinal direction, with each group 80 comprising a section 88 of a respective flat cable 84. This means that several sections adjoining one another in the longitudinal direction form a respective flat cable 84. The flat cable 84 is, in particular, a flexible ribbon cable in which the individual conductor strands 86 are embedded in a common insulating sheath.

[0143] As can be seen from Figure 9, a plurality of flat cables 84 and thus also a plurality of sections 88 of the plurality of flat cables 84 are arranged next to one another. The flat cables 84 and thus the cable set 12 extend from a connection side (starting side) on the right half of the figure to an end side in the direction of the left half of the figure. The first group 80 preferably has at least as many flat cables 82 and thus as many conductor strands 86 as are required for the electrical contacting of all components of the cell contacting unit 6 to be contacted. Towards the end, the number of flat cables 84 arranged next to one another is successively reduced, so that the cable set 12 has a stepped design in the area of ​​the cell connectors 8.

[0144] The conductor strands 86 are generally initially interrupted at the boundaries between the groups formed by the holding frames 82. The holding frames 82 therefore simultaneously define separation points for each conductor strand 86 and thus also for the flat cable 82. The conductor strands 86 are only subsequently electrically connected to one another across the separation point during assembly via connectors 90.

[0145] A first type of connector 90A is designed to connect two conductor strands 86. For this purpose, it has, in particular, two opposing crimp terminals, via which a respective conductor strand 86, or more precisely, two sections of the conductor strand 86 of the flat cable 82, are connected to one another. The electrical contact is preferably made without removing the insulation.

[0146] A second type of connector 90B is designed to connect a respective conductor strand 86 to a respective cell connector 8 or also to a sensor, in particular temperature sensor 62. This connector 90B has, in particular, a welding tab at one end, with which it is electrically connected, for example, by ultrasonic welding, to the cell connector 8 or to the sensor 62. The other end is preferably designed as a crimp terminal for contacting a respective conductor strand 86. This second type of connector 90B is preferably designed as an angled (in particular L-shaped) connector, so that one end, specifically the crimp terminal, extends in the longitudinal direction of the cable harness 12 and the other end, specifically the welding tab, is oriented perpendicular thereto.In the exemplary embodiment, the individual flat cables 84 at the beginning of the cable set 12 are connected via round cables 92 to a multi-pin connector 16, via which the entire sensor cable set 12 is connected, for example, to a battery management system. The round cables 92 form connecting lines between the flat cables 84 and the connector 16. Finally, to contact these round cables 92 to a respective conductor strand 86, a third type of connector 90C is provided, which is designed at one end to contact a respective conductor strand 86 and at its other end to contact a respective round cable 92. Both ends are preferably formed by suitably designed, different crimp terminals.

[0147] During assembly, the individual groups 80 of the cell contact unit 6 are prefabricated and preferably simultaneously provided with the sections 88 of the flat cables 84. The support frame 82, the cell connectors 8, any sensors 62, and any multiple sections 88 of the flat cables 84 arranged side by side therefore preferably form a prefabricated modular unit. The individual conductor strands 86 are, for example, already electrically connected to the cell connectors 8 and / or sensors 62 that each group 80 has.

[0148] To form the cell contact unit 6, these modular units and thus several groups 80 are arranged in series, in particular. The conductor strands 86 of sections 88 of adjacent groups 80 are then electrically connected via connectors 90A, so that each conductor strand 86 is looped through several holding frames 82 and thus across the separation points. If necessary, the cell connectors 8 and / or sensors 62 can also be electrically connected via connectors 90B, provided this has not already been done during the preconfiguration of the modular units.

[0149] To enable reliable crimping, recesses 94 are provided, in particular, on the holding frames 82, which are represented only by dashed lines in Figure 9. These recesses are formed, in particular, at the edge regions of the holding frames 82, and there, in particular, on the underside. These recesses 94 are designed such that, in the area of ​​the connectors 90A and especially in the area of ​​their crimp terminals, they can be encompassed by a crimping tool.

[0150] 5. Elastic and flexible attachment of the temperature sensor to the holder

[0151] In connection with Figures 10-12, a variant embodiment with an elastically mounted temperature sensor 62 is described in more detail. This elastic mounting of the temperature sensor 62 is considered an independent inventive concept.

[0152] As can be seen from Figures 10-12, the temperature sensor 62 is held in a special holder 100. This is a monolithic part of a holder 18, which, in contrast to the previous exemplary embodiments, forms a common holder 18 for a plurality of cell connectors 8. In particular, it forms a common holder 18 for all cell connectors 8 arranged next to one another in a row in the longitudinal direction L. The holder 18 is, in particular, a plastic injection-molded part.

[0153] The holder 100 has two holding parts 102 located opposite one another in the longitudinal direction L, each of which is connected to the remaining holder 18 via a base part. Adjoining this base part is a virtually freely cut and bent holding tab 104. In the exemplary embodiment, this has two parallel, adjacent arches, particularly U-shaped arches. These are also made of the same plastic material and are part of the monolithic holder 18 of the holder 100.

[0154] In principle, alternative curved designs are also possible, for example, S-shaped. In the exemplary embodiment, the arches are bent in the transverse direction (according to the present directional nomenclature), i.e., they are bent upwards out of the plane of the cell connectors 8 (plane spanned by the longitudinal direction L and the vertical direction V). Alternatively, it is also possible for them to run in an arc within the plane of the cell connectors 8.

[0155] In general, this curved shape of the retaining tabs 104 creates elasticity in the longitudinal direction L. The retaining tabs 104 are therefore designed as spring tabs.

[0156] The temperature sensor 62 is accommodated in the holder 100. In particular, the temperature sensor comprises a circuit board 106 with integrated sensor electronics. This circuit board is connected to a sensor line 14 via a contact plug 108 and, for example, to a battery management system via the cable set 12, as previously described.

[0157] The circuit board 106 is clamped between the two opposite holding parts 102 against the elastic holding force of the respective holding part 102 or the respective holding tab 104.

[0158] As can be seen in particular from Figures 11 and 12, each retaining tab 104 has retaining elements at its end, in particular for the positive-locking fixation of the circuit board 106. Specifically, each retaining tab 104 forms a lower support, in particular in the form of a strip-shaped element, which in the exemplary embodiment is approximately L-shaped, and which in particular also has a stop against which the temperature sensor 62 and in particular the circuit board 106 preferably rest with their long sides. Furthermore, each retaining tab 104 forms a retaining element effective in the longitudinal direction L, which is designed in particular to engage over the circuit board 106.

[0159] In FIG 11, the contact plug 108 has been omitted and the circuit board 106 is shown transparently so that electronic components such as the conductor tracks can be seen. In particular, the transparent representation shows that a thermal contact element 110 is arranged which is in thermal contact with the cell of the battery (not shown here) and is thermally conductively connected. In particular, this contact element 110 lies flat on the cell housing and is firmly connected to it, for example, in a materially bonded manner, for example by gluing. This contact element 110 is, for example, a metal plate whose temperature is detected, for example, by corresponding measuring electrodes of the temperature sensor 62.

[0160] List of reference symbols

[0161] Cell contact unit

[0162] 8 cell connectors

[0163] 10 Connection terminal

[0164] 12 cable set

[0165] 14 Sensor cable

[0166] 16 multi-pin connectors

[0167] 18 holders

[0168] 20 assembly line

[0169] 20A lower assembly line

[0170] 20B upper assembly line

[0171] 22 Back

[0172] 24 Front

[0173] 26 Holding bracket

[0174] 28 Marginal area

[0175] 30 base area

[0176] 32 Coverage

[0177] 34 Guide

[0178] 34A lower guide

[0179] 34B upper guide

[0180] 36 canal section

[0181] 38 cable duct

[0182] 40 clips

[0183] 42 plug receptacle

[0184] 44 Contact tab

[0185] 46 Intermediate part

[0186] 48 connection tab

[0187] 50 pole openings

[0188] 52 Mounting opening

[0189] 54 pole windows

[0190] 56 Fixing bar

[0191] 58, 58A, 58B contact plug

[0192] 60 Breakthrough

[0193] 62, 62A, 62B temperature sensor

[0194] 64 Bonding wire 66 Cell pole

[0195] 68 contact pin

[0196] 70 Stabilizing element

[0197] 72 contact pins

[0198] 74 Sensor opening

[0199] 76 Positioning element

[0200] 80 Group

[0201] 82 holding frames

[0202] 84 flat cable

[0203] 86 conductor strands

[0204] 88 section

[0205] 90 AC connector

[0206] 92 round line

[0207] 94 recess

[0208] 100 bracket

[0209] 102 Holding part

[0210] 104 retaining tab

[0211] 106 circuit board

[0212] 108 contact plugs

[0213] 110 Contact element

[0214] L longitudinal direction

[0215] Q transverse direction

[0216] V Vertical direction

Claims

Claims 1 . Cell contact unit (6) for a battery with a plurality of cells, wherein adjacent cells in the assembled state are electrically connected to one another via cell connectors (8) and a sensor cable set (12) is provided which has at least one sensor line (14) which is electrically connected to the cell for measuring the cell voltage and is protected against overcurrent, characterized in that the sensor line (14) is electrically connected to a voltage tapping point via a bonding wire (64) and by bonding.

2. Cell contacting unit (6) according to the preceding claim, wherein the bonding wire (64) forms an overcurrent fuse with a predetermined fuse rating.

3. Cell contact unit (6) according to the preceding claim, wherein the bonding wire (64) has a fuse rating in the range from 250 mA to 5 A, in particular in the range from 750 mA to 1.5 A.

4. Cell contact unit (6) according to one of the two preceding claims, wherein the bonding wire (64) is contacted with its one end directly to the cell connector (8) via bonding.

5. Cell contacting unit (6) according to one of the preceding claims, wherein the bonding wire (64) is connected with its other end to a contact element, in particular by bonding, and the sensor line (14) is connected to the contact element.

6. Cell contact unit (6) for a battery, in particular according to one of the preceding claims, wherein the cell contact unit (6) has cell connectors (8) for electrically connecting adjacent cells of the battery and a sensor cable set (12) with a plurality of sensor lines (14), characterized in that a) a plurality of cell connectors (8) form a group (80) and a plurality of groups (80) are arranged in a row, and in that the sensor cable set (12) is of modular construction and is divided into a plurality of sections (88), wherein each group (80) has a section (88) and the sections (88) of adjacent groups (80) are electrically connected to one another, and / or in that b) the sensor cable set (12) has at least one flat cable (84) with individual conductor strands (86) which runs along the cell connectors (8), and a respective conductor strand (86) forms at least one section of a respective sensor line (14).

7. Cell contact unit (6) according to the preceding claim, in which several separate flat cables (84) are arranged next to one another.

8. Cell contacting unit (6) according to one of claims 6 to 7, wherein the at least one flat cable (84) is designed as a flexible ribbon cable.

9. Cell contact unit (6) according to one of claims 6 to 8, in which connectors (90A-C) are arranged which are used for one or more of the following electrical connections: - connection of the conductor strands (86) to each other, - Connection between flat cable (84) and a plug (16) connected to it, - connection between a respective conductor strand (86) and a round conductor, - connecting one of the conductor strands (86) to one of the cell connectors (8), - Connection of one of the conductor strands (86) to a sensor.

10. Cell contact unit (6) according to the preceding claim, wherein the connector (90A-C) has a crimp terminal for connection to each of the conductor strands (86).

11. Cell contact unit (6) according to the preceding claim, wherein a recess is formed below the connector (90A-C) so that it is accessible for an assembly tool, in particular for a crimping tool.

12. Cell contact unit (6) according to one of claims 9 to 11, wherein the connector (90B) for the connection between the conductor strand (86) and the cell connector (8) and / or the sensor has a welding tab and is connected to the cell connector (8) or the sensor via a welded connection.

13. Cell contact unit (6) according to one of claims 9 to 12, wherein the connector (90A-C) is contacted with the respective conductor strand (86) without stripping the insulation thereof.

14. Cell contacting unit (6) according to one of claims 9 to 13, in which the cell connectors (8) of a group (80) are held by a common holding frame (82) and the holding frames (82) are arranged in a row, wherein at least one recess (94) for a crimping tool is preferably formed on the holding frame (82).

15. Modular cell contact unit (6), in particular with the features according to one of the preceding claims, for a battery with several cells, which has a plurality of holders (18) which are arranged in a modular row, wherein the holders (18) each have a holding receptacle (26) in which a cell connector (8) for the electrical connection of adjacent cells is arranged.

16. Modular cell contacting unit (6) according to the preceding claim, wherein the holders (18) are arranged in a row along an assembly line (20) which is designed in particular as a rail and are held on the latter.

17. Modular cell contacting unit (6) according to the preceding claim, wherein a respective holder (18) has a guide (34) for the assembly line (20) and is applied to the assembly line (20) with the guide (34).

18. Modular cell contacting unit (6) according to the preceding claim, wherein a respective holder (18) has two guides (34) for a respective assembly line (20), wherein the holding receptacle (26) is preferably arranged between the guides (34).

19. Modular cell contacting unit (6) according to one of claims 16 to 18, wherein the mounting band (20) is designed as a tensioning band, by means of which a plurality of cells are clamped together in the mounted state.

20. Modular cell contacting unit (6) according to one of claims 15 to 19, wherein the holders (18) arranged next to one another form a cable channel (38) for receiving a sensor cable set (12), wherein each holder (18) defines a channel section (36) which is arranged in particular between the guide (34) and the holding receptacle (26).

21. Modular cell contacting unit (6) according to one of claims 15 to 20, wherein edge regions (28) adjoin the holding receptacle (26) on both sides, which edge regions form base surfaces (30) on a rear side (22), which base surfaces are preferably provided for resting on a respective cell and which preferably have the guides (34) on a front side (24).

22. Cell contacting unit (6) according to one of the preceding claims, which has a plurality of temperature sensors (62), each of which is connected to a sensor line (14) via a contact plug (58).

23. Cell contact unit (6) according to the preceding claim, wherein the respective temperature sensor (62) has contact pins (68) for plugging in contact with the contact plug (58).

24. Cell contacting unit (6) according to the preceding claim, wherein a respective contact plug (58) is received in a plug receptacle (42) of a respective holder (18).

25. Cell contacting unit (6) according to one of claims 22 to 24, wherein for a hot spot temperature measurement at least one of the temperature sensors (62, 62A) is positioned adjacent to a cell connector (8).

26. Cell contacting unit (6) according to one of claims 22 to 25, wherein for a cold spot temperature measurement at least one further temperature sensor (62, 62B) is positioned at a distance from the cell connector (8).

27. Cell contacting unit (6) according to the preceding claim and according to one of claims 16 to 19, wherein the mounting band (20) has at least one sensor opening (74) through which contact is made with the further temperature sensor (62, 62B) by means of a further contact plug (58).

28. Cell contacting unit (6) according to the preceding claim, wherein at least one of the holders (18), in particular an edge-side holder (18'), has an opening with a positioning element (76), wherein the positioning element (76) engages in the sensor opening (74) for fixing the mounting band (20) in place.

29. Cell contacting unit (6) according to one of claims 15 to 28, which has an edge-side holder (18') which has a cell connection for electrically contacting a cell pole (66) of an edge-side cell, wherein the cell connection is connected to a connection terminal (10) to which a connection line can be connected.

30. Cell contact unit (6) for a battery with several cells, in particular according to one of the preceding claims, wherein in the assembled state, adjacent cells are electrically connected to one another via cell connectors (8) and the cell connectors (8) are held in at least one holder (18) and wherein a measuring sensor, in particular a temperature sensor (62) is held elastically in a holder (100).

31. Cell contacting unit (6) according to the preceding claim, characterized in that the holder (100) forms a monolithic component with the holder (18).

32. Cell contacting unit (6) according to one of the two preceding claims, characterized in that the holder (100) has at least one curved retaining tab against which the measuring sensor rests, wherein the measuring sensor is held elastically by the curved retaining tab.

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