Battery assembly

Abstract

The invention relates to a battery assembly (10) comprising at least one battery cell (1), a main printed circuit board (2) which is electrically connected to the battery cell (1), and a fuse board (3) which is electrically connected to the main printed circuit board (2), wherein the fuse board (3) has an electric fuse (4), preferably at least two electric fuses (4), and the fuse board (3) is designed as a component which is separate from the main printed circuit board (2) and is arranged at a distance (5) to the main printed circuit board (2).

Description

[0001] Description

[0002] title

[0003] Battery arrangement

[0004] State of the art

[0005] The present invention relates to a battery arrangement, a battery pack, and a consumer.

[0006] Battery assemblies are known that have a circuit board that, for example, includes a battery management system. Using the battery management system, battery properties can be monitored and the supply of electrical energy by the battery can be controlled. Battery assemblies often also have electrical fuses that, for example, interrupt the connection between the cells and / or other components above a certain electrical current. Such fuses are known to be integrated into the main current path.

[0007] Disclosure of the invention

[0008] The battery assembly according to the invention with the features of claim 1 is distinguished by a particularly advantageous design that can optimally utilize available installation space. In particular, this can be achieved by means of a particularly simple, robust, and cost-effective design. This is achieved according to the invention by a battery assembly comprising at least one battery cell, a main board, and a fuse board. The main board is electrically connected, in particular directly, to the at least one battery cell. The fuse board is electrically connected to the main board. The fuse board has an electrical fuse. Furthermore, the fuse board is arranged as a separate component from the main board and is arranged at a predetermined distance from the main board.

[0009] In particular, a printed circuit board is considered to be a main board and / or a fuse board, preferably one which can contain electronic components.

[0010] Preferably, an electrical fuse is considered to be a fuse element which prevents current transmission between at least two elements of the battery arrangement as soon as a predefined maximum fuse current is exceeded.

[0011] In other words, a battery arrangement is provided which has at least one battery cell intended to provide electrical energy for a consumer. The battery cell is electrically connected to the main board. In particular, the main board can be configured to monitor operating parameters of the at least one battery cell and / or to control a provision of electrical energy by the battery cell. Particularly preferably, the main board can comprise a battery management system. In addition to the main board, a fuse board is provided, which can, for example, be designed at least partially as a printed circuit board. The fuse board is arranged as a separate component from the main board and at a predetermined distance from the main board. This means that the main board and fuse board can be arranged independently of one another.At least one electrical fuse of the battery arrangement is provided on the fuse board.

[0012] The battery arrangement offers the advantage of being able to provide a particularly flexible geometry for a wide variety of requirements, particularly with regard to the available installation space. By designing the main board and fuse board as separate components, the available installation space can be optimally utilized by arranging the boards independently of one another. This can, for example, avoid enlarging the outer contour of the battery arrangement. Furthermore, simplified production of the battery arrangement is possible, as various connection and fastening options for the fuse board are possible, for example, which do not require additional soldering processes. In particular, very low contact resistance and optimal thermal connection of the fuse board are still possible.For example, it can also be possible for heat-generating power components to be spatially separated from the battery cells by the special separation of the fuse board and the main board in order to avoid unwanted heat input into the battery cells.

[0013] The subclaims contain preferred developments of the invention.

[0014] The battery assembly preferably comprises at least one power contact element that electrically and mechanically connects the main board and the fuse board. In particular, a connecting element configured to enable current transmission within a high-current path of the battery assembly can be considered a power contact element. Because the power contact element simultaneously establishes the electrical and mechanical connection between the main board and the fuse board, a particularly simple, cost-effective, and compact design can be provided.

[0015] Particularly preferably, the power contact element is electrically connected to the electrical fuse. This means that there is an electrical connection between the power contact element and the electrical fuse. For example, this can provide electrical protection via the electrical fuse and the power contact element of the other connected components, such as the battery cells in particular, and in particular against overcurrent. This makes it possible to ensure a particularly high level of effectiveness of the electrical fuse, reliably preventing damage caused by excessive electrical currents.

[0016] The power contact element is preferably at least partially sheet-metal-shaped. The sheet-metal-shaped power contact element preferably has a thickness of at least 0.1 mm, in particular up to a maximum of 1.5 mm, preferably from 0.5 mm to 1 mm. This enables a particularly simple and cost-effective construction that can provide reliable, efficient power transmission. Advantageously, the power contact element can at least partially have a coated surface, for example using tin, silver, nickel, or gold, and / or an increased surface roughness in a contact area with an adjacent component, such as the fuse board. This enables particularly efficient power transmission.

[0017] Particularly preferably, the power contact element is in surface contact with the fuse board. This makes it easy to achieve low contact resistance. Furthermore, the power contact element can, for example, easily provide mechanical support for the fuse board. Furthermore, it can establish good thermal contact.

[0018] Preferably, the contact element is in surface contact with the two opposite sides of the fuse board. This means that the preferably plate-shaped fuse board is contacted by the contact element on both opposite sides. This allows for particularly good electrical, mechanical, and thermal contact.

[0019] Further preferably, the power contact element is connected to the fuse board by means of a force-fit connection, preferably a screw connection. Alternatively or additionally, the contact element is connected to the fuse board by means of a material connection, preferably a welded connection and / or a soldered connection. This enables a reliable electrical and mechanical connection while being simple and cost-effective to manufacture.

[0020] The power contact element is preferably formed from a metal, in particular copper or brass. The power contact element is preferably formed exclusively from the metal. This allows for highly efficient power transmission with a simple and cost-effective design. The power contact element can preferably be formed as a metallic wire. This allows for a particularly flexible geometry to be provided in a particularly simple manner.

[0021] Preferably, the fuse board and the main board are arranged parallel to each other and at least at the predetermined distance along a direction orthogonal to the main board. Preferably, the predetermined distance is not equal to zero. This allows for a particularly advantageous, compact geometry of the battery assembly. In particular, an enlargement of the main board in its plane can be avoided.

[0022] Further preferably, the main board is arranged between the fuse board and the at least one battery cell, in particular along the direction orthogonal to the main board. This means that the fuse board is arranged on the side of the main board facing away from the battery cell. This allows for a large distance between the fuse board, and thus the electrical fuse, and the battery cell. For example, this makes it possible to particularly effectively prevent a thermal influence of the battery cell on the electrical fuse.

[0023] The fuse board preferably has several electrical fuses connected in parallel. This can increase the current-carrying capacity of the overall system.

[0024] More preferably, the electrical fuse comprises a switchable fuse. In particular, a switchable fuse is considered to be an electrical fuse that can be triggered, i.e., interrupts the current transmission, either when a predetermined load current is exceeded or by means of an external control signal. The electrical fuse can preferably be designed as a surface-mounted component of the fuse circuit board. For example, such a surface-mounted component can also be referred to as an SMT component. The fuses are preferably designed such that, when triggered, i.e., when the fuse is triggered by the external control signal, all fuses are triggered together to interrupt the current transmission. This allows the current transmission to be interrupted in a simple and particularly effective manner when the load is present.

[0025] Preferably, the battery assembly further comprises a cell holder for accommodating the at least one battery cell. The fuse board rests on the cell holder and / or is mechanically connected directly to the cell holder. This allows for a particularly simple and robust mechanical design of the battery assembly.

[0026] More preferably, the battery arrangement further comprises a protective element for protecting, in particular, the electrical fuse from moisture and / or dust. In particular, the protective element is embodied as a potting compound on the fuse board, with the electrical fuse preferably being embedded in the potting compound. Preferably, at least partial areas of the contact elements and / or the fuse board are additionally embedded in the potting compound. Advantageously, as large a portion of the contact elements as possible, for example, at least those partial areas that extend directly above the fuse board, are also embedded in the potting compound.

[0027] This makes it possible to provide a particularly robust battery arrangement with reliable protection of the electrical fuse, which enables protection of the electrical fuse against environmental influences.

[0028] Particularly preferably, the battery assembly further comprises at least one electrical control contact element, which is designed for the electrical connection, and in particular for controlling, the fuse board. Preferably, the electrical control contact element is additionally designed to mechanically connect the fuse board and the main board. Particularly preferably, the distance between the fuse board and the main board is additionally defined by the control contact element. This allows for a particularly simple and compact design of the battery assembly, which has few components.

[0029] The battery assembly preferably further comprises a heat sink, wherein the fuse board is directly mechanically connected to the heat sink. This allows for particularly effective heat dissipation from the fuse board to ensure particularly reliable function of the electrical fuse. A cell holder of the battery assembly, for example, or alternatively, preferably another component that enables heat dissipation from the fuse board, can be provided as a heat sink.

[0030] Furthermore, the invention leads to a battery pack, in particular a removable battery pack, comprising the described battery assembly. The battery pack preferably has a housing within which the battery assembly is accommodated, for protecting the battery assembly.

[0031] Furthermore, the invention relates to a consumer, in particular a tool, preferably a hand-held tool, which comprises the described battery pack and / or the described battery arrangement.

[0032] Short description of the drawings

[0033] The invention is described below using exemplary embodiments in conjunction with the figures. In the figures, functionally identical components are identified by the same reference numerals. Here:

[0034] Figure 1 is a perspective view of a battery arrangement according to a first embodiment of the invention,

[0035] Figure 2 is a detailed sectional view of the battery arrangement of Figure 1,

[0036] Figure 3 shows a further detailed view of the battery arrangement of Figure 1,

[0037] Figure 4 is a detailed sectional view of a battery arrangement according to a second embodiment of the invention,

[0038] Figure 5 is a detailed view of a removable battery pack with the battery arrangement of Figure 4,

[0039] Figure 6 is a detailed view of a battery arrangement according to a third embodiment of the invention, and

[0040] Figure 7 is a detailed view of the battery arrangement of Figure 7. Preferred embodiments of the invention

[0041] Figure 1 shows a perspective view of a battery assembly 10 according to a first embodiment of the invention. Figures 2 and 3 show detailed views of the battery assembly 10 of Figure 1.

[0042] The battery assembly 10 serves as an energy storage device for a consumer (not shown), such as a preferably hand-operated power tool. Preferably, at least one electric motor of the consumer can be supplied by the electrical energy stored in the battery assembly 10. The battery assembly 10 is preferably part of a removable battery pack, which can be releasably connected to a tool part of the consumer, in particular by means of a connection mechanism not described in detail. This allows the removable battery pack of the battery assembly 10 to be replaced, for example, with an identically constructed removable battery pack.

[0043] An electrical connection between the battery assembly 10 and the other components, such as the electric motor, of the consumer is established by means of connection elements 25 of the battery assembly 10. The connection elements 25 can preferably be designed in the form of so-called contact tulips. Preferably, a different electrical potential is applied to the two connection elements 25.

[0044] The battery arrangement 10 further comprises a plurality of battery cells 1, which can be electrically connected to one another in parallel and / or electrically in series.

[0045] The battery cells 1 are held in position relative to one another by a cell holder 15. The cell holder 15 can also provide a protective function for the battery cells 1.

[0046] In addition, the battery assembly 10 comprises a main board 2, which is electrically connected to the battery cells 1, for example, by means of cell connectors not shown in detail. The main board 2 can have a battery management system configured to monitor operating parameters of the battery cells 1 and / or to control the output of electrical energy from the battery assembly 10.

[0047] The battery assembly 10 further includes a fuse board 3, which is also designed as a printed circuit board. The fuse board 3 is designed as a separate component from the main board 2. Furthermore, the fuse board 3 is arranged at a predetermined distance 5 from the main board 2.

[0048] In detail, the fuse board 3 is arranged parallel to the main board 2 and along a direction 20 orthogonal to the main board 2 on a side of the main board 2 opposite the battery cells 1.

[0049] The fuse board 3 has two electrical fuses 4. The electrical fuses 4 are each designed as switchable fuses. This means that when a current flow through the electrical fuse 4 reaches or exceeds a predetermined maximum fuse current, the electrical fuse 4 automatically interrupts the current transmission, in particular by melting the electrical fuse 4. Alternatively or additionally, the current transmission through the electrical fuse 4 is interrupted when the electrical fuse 4 is actuated by a switching signal.

[0050] The electrical fuses 4 are protected from moisture and / or dust by a protective element 9 on the fuse board 3. The protective element 9 can be formed as a potting compound on the fuse board 3.

[0051] The two electrical fuses 4 are arranged electrically parallel to each other in order to increase the current carrying capacity.

[0052] Preferably, the fuse board 3 with the electrical fuses 4 is provided exclusively to provide electrical protection for the battery assembly 10. This means that the fuse board 3 preferably serves no other purpose than integrating the electrical fuses 4 into the main current path of the battery assembly 10.

[0053] The battery assembly 10 offers the advantage of providing a particularly flexible geometry and efficient and reliable operation. In particular, the available installation space can be optimally utilized thanks to the possibility of flexibly arranging the fuse board 3 relative to the main board 2. Furthermore, a maximum dimension in the plane of the main board 2 can be kept small, thereby providing a particularly compact battery assembly 10. Furthermore, an optimized thermal connection of the electrical fuses 4 can be enabled in order to ensure optimal function and thus particularly reliable operation of the battery assembly 10.

[0054] The fuse board 3 and the main board 2 are electrically and mechanically connected to each other by means of two power contact elements 6.

[0055] The power contact elements 6 form, in particular, parts of the main current path of the battery assembly 10. In other words, the entire current always flows via the power contact elements 6 during operation of the battery assembly 10. The fuse board 3 with the electrical fuses 4 is integrated between the power contact elements 6 and electrically connected to them in such a way as to electrically protect the power contact elements 6. This means that when the electrical fuse(s) 4 are triggered, the power transmission of the entire battery assembly 10 is completely interrupted.

[0056] In particular, one of the power contact elements 6 can be electrically connected directly to one of the two contact elements 25, while the other power contact element 6 is electrically connected to the battery cells 1. For example, the other contact element 25 can be electrically connected directly to the battery cells 1.

[0057] Preferably, the mainboard 2 is electrically connected to one or both of the power contact elements 6. The power contact elements 6 are formed as thick copper sheets to enable optimal power transmission with low electrical resistance.

[0058] The fuse board 3 is in surface contact with each of the power contact elements 6. In detail, the power contact elements 6 are designed as bent metal sheets such that each power contact element 6 is in surface contact with the two opposite sides 31, 32 of the fuse board 3 (see Figures 2 and 3). At the contact surfaces with the fuse board 3, each power contact element 6 preferably has a gold-plated surface area in order to be able to provide particularly good electrical contact. Alternatively or additionally, each of the power contact elements 6 can have an increased surface roughness at the contact surface with the fuse board 3 in order to further improve the electrical contact.

[0059] The power contact element 6 and the fuse board 3 can be connected by means of a screw connection 8, whereby, for example, two screws can be provided for each power contact element 6 (see Figure 3). A push-through screw connection is particularly advantageous, as the power contact element 6 can be pressed onto the fuse board 3 on both sides by means of the screw connection 8, further improving the electrical contact.

[0060] Figure 4 shows a detailed sectional view of a battery assembly 10 according to a second exemplary embodiment of the invention. The second exemplary embodiment essentially corresponds to the first exemplary embodiment of Figures 1 to 3, with the difference of an alternative arrangement and fastening of the fuse board 3. In the second exemplary embodiment of Figures 4 and 5, the fuse board 3 is arranged such that it is in direct contact with a heat sink 7. In particular, the fuse board 3 is mechanically connected to the heat sink 7. Thus, the heat sink also serves to mechanically hold the fuse board 3.

[0061] The heat sink 7 is, in particular, a part of the cell holder 15. Arranging the fuse board 3 in mechanical contact with the heat sink 7 enables particularly effective heat dissipation from the fuse board 3 and thus from the electrical fuses 4. This ensures particularly reliable operation of the electrical fuses 4.

[0062] Figure 5 also shows a housing cover 16 of the battery assembly 10, which can be provided to at least partially cover the battery assembly 10, particularly in the area of ​​the circuit boards 2, 3. This can provide mechanical protection and protection against environmental influences, such as dust and / or moisture, for the battery assembly 10. Such a housing cover 16 can preferably be provided in every exemplary embodiment.

[0063] Figure 6 shows a detailed view of a battery arrangement 10 according to a third exemplary embodiment of the invention. The third exemplary embodiment essentially corresponds to the first exemplary embodiment of Figures 1 to 3, with the difference of an alternative design and connection of the power contact elements 6. In the third exemplary embodiment of Figures 6 and 7, the power contact elements are also designed as thick copper sheets. Other shapes of power contact elements 6 are also conceivable. In the third exemplary embodiment, however, the power contact elements 6 are in contact with only one side of the fuse board 3, namely the underside facing the main board 2. This makes it possible to provide a particularly simple and cost-effective design of the battery arrangement 10.

[0064] In addition, the second exemplary embodiment of Figures 6 and 7 provides an alternative connection between power contact elements 6 and fuse board 3. Each of the power contact elements 6 is connected to the fuse board 3 by means of two integrally bonded connections 8a. The integrally bonded connections 8a can preferably be designed as a welded connection and / or soldered connection. This allows a reliable electrical connection with low electrical resistance to be provided while providing a reliable, simple, and cost-effective mechanical connection between power contact elements 6 and fuse board 3. In particular, the fuse board 3 has at least one recess 100 for each power contact element 6, for example two recesses 100, into which the power contact elements 6 engage.The power contact elements 6 are designed in such a way that they pass through the recesses 100 and exit on the other side of the fuse board 3, as can be seen in Figure 7. The material connection is then made by soldering.

[0065] Figure 7 shows the rear side of the fuse board 3, which faces the main board 2, wherein, for example, a single switchable electrical fuse 4 is arranged on the rear side. Alternatively, it is also conceivable to arrange no electrical fuses or at least two electrical fuses on the rear side. The front side of the fuse board 3 can have the same number of electrical fuses 4, a different number of electrical fuses 4, or no electrical fuse at all. For example, the front side of the fuse board 3 has two further electrical fuses 4. The electrical fuses 4 are, for example, of identical design, but it would also be conceivable to use different electrical fuses 4. For example, it would be conceivable to use both switchable and non-switchable or passive electrical fuses.

[0066] The electrical fuses 4 of the fuse board 3 are designed, for example, as switchable electrical fuses. The electrical fuses 4 are designed to be switchable via a control element 102 in the form of a contact pin 104. The fuse board 3 is connected to at least one control element 102. Preferably, the fuse board 4 is connected to at least two control elements 102, for example, to four control elements 102. This advantageously retains the switching function even if one of the control elements 102 is damaged or broken off. The four control elements 102 are connected, for example, to the fuse board 3 via circular recesses 106 in the fuse board 3 and to the switchable electrical fuses 4 via the fuse board 3.It is also conceivable for the fuse board 3 to be connected to at least one control element 102 for each electrical fuse 4, whereby the electrical fuses 4 can also be switched independently of one another. The switchable electrical fuses 4 are designed, for example, such that if the current flowing through the power contact elements 6 is too high, the electrical fuses 4 are passively triggered. This can advantageously provide overcurrent protection.

[0067] In addition, the switchable electrical fuses 4 are designed such that if the temperature of a battery cell 1, multiple battery cells 1, or the battery pack becomes too high, the electrical fuses 4 are actively triggered by the control element 102. This can advantageously provide cell overtemperature protection.

[0068] Furthermore, the switchable electrical fuses 4 are designed such that, if the voltage of a battery cell 1, multiple battery cells 1, or the battery pack is too high, the electrical fuses 4 are actively triggered by the control element 102. This can advantageously provide cell overvoltage protection.

[0069] In addition, the fuse board 3 has a protective element 108 designed to protect the contact areas of the electrical contact elements 6 and the control elements 102 with the fuse board 3. The protective element 108 is designed, for example, as a potting compound.

Claims

Claims 1 . Battery assembly comprising: - at least one battery cell (1), - a main board (2) which is electrically connected to the battery cell (1), and - a fuse board (3) which is electrically connected to the main board (2), - wherein the fuse board (3) has an electrical fuse (4), preferably at least two electrical fuses (4), and - wherein the fuse board (3) is designed as a component separate from the main board (2) and is arranged at a distance (5) from the main board (2), characterized in that the at least two electrical fuses (4) are designed as switchable electrical fuses (4).

2. Battery arrangement according to claim 1, further comprising at least one power contact element (6) which electrically and mechanically connects the main board (2) and the fuse board (3) to one another.

3. Battery arrangement according to claim 2, wherein the power contact element (6) is electrically connected to the electrical fuse (4).

4. Battery arrangement according to claim 2 or 3, wherein the power contact element (6) is at least partially sheet-shaped.

5. Battery arrangement according to one of claims 2 to 4, wherein the power contact element (6) is connected to the fuse board (3) by means of a force-fitting connection and / or by means of a material-fitting connection.

6. Battery arrangement according to one of claims 2 to 5, wherein the power contact element (6) is formed from a metal, in particular copper or brass.

7. Battery arrangement according to one of the preceding claims, wherein the main board (2) and the fuse board (3) are arranged parallel to one another and at least at the predetermined distance (5) along a direction (20) orthogonal to the main board (2).

8. Battery arrangement according to one of the preceding claims, wherein the battery arrangement has at least two control elements (102) which are designed to switch the electrical fuses (4).

9. Battery arrangement according to one of the preceding claims, wherein the fuse board (3) has a plurality of electrical fuses (4) connected in parallel to one another.

10. Battery arrangement according to one of the preceding claims, wherein the electrical fuse (4) comprises a switchable fuse.

11. Battery arrangement according to one of the preceding claims, further comprising a protective element (9) for protection against moisture and / or dust, in particular wherein the protective element (9) is designed as a potting compound on the fuse board (2).

12. Battery arrangement according to one of the preceding claims, further comprising at least one electrical control contact element which is designed for the electrical connection and in particular control of the fuse board (3).

13. Battery assembly according to one of the preceding claims, further comprising a heat sink (7), wherein the fuse board (3) is directly mechanically connected to the heat sink (7).

14. Battery pack, in particular a replaceable battery pack, comprising a battery arrangement (10) according to one of the preceding claims 15. Consumer, in particular tool, in particular hand-operated tool, comprising a battery arrangement (10) according to one of claims 1 to 13 and / or a battery pack according to claim 14.

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