Device for arranging battery cells, battery cell assembly with such a device and method for establishing electrical contact between battery cells

Abstract

Device for arranging battery cells, battery cell assembly with such a device and method for establishing electrical contact between battery cells. The invention relates to a device for arranging battery cells (2) with a battery cell longitudinal axis, for which the electrical contacts (2a, 2b) are arranged on different sides along the battery cell longitudinal axis, preferably of hollow cylindrical rod cells, which device has: - an electrically insulating outer sheath (5) for the battery cells (2); - at least one electrical connection (7, 10) which is guided out, preferably on the front side of the sheath (5); - at least one module carrier (3) housed in the sheath (5) and made of an electrically insulating material;which module holder (3) has at least one receptacle (4) for a battery cell (2), into which receptacle (4) the battery cell (2) can be inserted along its longitudinal axis, into which the extension of a longitudinal axis (L) of the receptacle (4) pierces the connection (7, 10), which receptacle (4) preferably opens in the direction of the connection and on a side facing the connection and is held at a distance from the sheath (5) and has at least one first elastic holding element (3a, 3b), which first elastic holding element (3a, 3b) is designed and is intended to bring a battery cell (2) housed or to be housed in the receptacle (4) into contact at least in places transversely to the longitudinal axis (L) of the receptacle (4) with an inner wall (4a) of the receptacle (4). Figure for abstract: Fig. 1;

Description

Title of the invention: Device for arranging battery cells, set of battery cells with a device of this type and method for establishing electrical contact between battery cells

[0001] The present invention relates to a device for arranging battery cells. The battery cells, for which the device is intended, have a battery cell longitudinal axis, and the electrical contacts of the battery cells are arranged on different (front) sides along the battery cell longitudinal axis. The battery cells are preferably hollow cylindrical bar cells.

[0002] The present invention further relates to a battery cell assembly with an above device and with a number of battery cells with a battery cell longitudinal axis, in which the electrical contacts are arranged on different sides along the battery cell longitudinal axis, preferably hollow cylindrical bar elements, in which preferably one battery cell is arranged in each housing, in which the battery cell housed in a respective housing is brought into contact by the first holding element at least in places transversely to the housing longitudinal axis with an inner wall of the housing, which battery cell assembly comprises a device according to the invention and a number of battery cells, which battery cells are designed as described above.

[0003] Furthermore, the present invention also relates to a method for establishing electrical contact between a multitude of battery elements, it being understood that a device according to the invention is also used, which device cooperates with the battery elements defined in the introduction.

[0004] The currently desired or targeted transition to widespread electromobility goes hand in hand and coincides with the provision of suitable battery cells or battery cell assemblies. In the context of this description, a "battery cell assembly" means an electrical interconnection of several battery cells, which usually occurs in the manner of an electrical series connection so that the voltages supplied by the individual battery cells add up to an overall voltage. A battery cell assembly of this type can then be used, for example, to operate a traction motor (drive motor) for a motor vehicle.

[0005] A battery module is known from the state of the art, in which round elements arranged in a plastic holder (rod elements of circular cylindrical shape) are arranged in the form of an electrical connection in parallel. A battery module of this type can then be connected in series with other battery modules of the same type, resulting in the series connection of battery cells mentioned above. A contact plate is provided or welded for the parallel connection of the battery cells within a battery module, which connects all the battery cells of a battery module on the front side to each other and thus ensures potential equalization. In addition, the cells of the battery module that is connected in series next to it are brought into contact via the aforementioned contact plate.

[0006] In this context, the applicant has found that the welding of one side of the contact sheet can be carried out technically without any major problems, it being understood, however, that the manufacture and assembly of the contact sheet already lead to an increase in production costs. Carrying out the contacting of the second side respectively of the battery cells (round cells) which regularly have a certain production tolerance, in particular with respect to their length, is more complex and more expensive. According to the state of the art, a contact sheet of the type mentioned is also welded to the other contact side of the battery module, which is, in accordance with the above, expensive, production-intensive and, correspondingly, heavy in terms of costs.

[0007] It is necessary to provide a battery cell assembly or a battery cell arrangement device for the purpose of creating a battery cell assembly that does not require contact sheets to be welded on either side, thereby reducing production resources and costs. Furthermore, overall potential balancing with respect to the battery cells must be possible. The present object is achieved according to the invention by a device for arranging battery cells with a battery cell longitudinal axis, in which the electrical contacts are arranged on different sides along the battery cell longitudinal axis, preferably hollow cylindrical bar cells, which device has: - an electrically insulating outer sheath for the battery elements; - at least one electrical connection exited in a guided manner, preferably on the front side of the sheath; - at least one module support housed in the sheath, made of an electrically insulating material; which module holder has at least one housing for a battery element, in which housing the battery element can be introduced along its longitudinal axis, in which the extension of a longitudinal axis of the housing pierces the connection, which housing is held at a distance from the sheath and has at least one first elastic holding element, which first holding element is designed and is intended to bring a battery cell housed or to be housed in the housing into contact at least in places transversely to the longitudinal axis of the housing with an inner wall of the housing.

[0008] The present object is achieved according to the invention by a battery cell assembly with a device as above and with a number of battery cells with a battery cell longitudinal axis, in which the electrical contacts are arranged on different sides along the battery cell longitudinal axis, preferably hollow cylindrical bar elements, in which preferably one battery cell is arranged in each housing, in which the battery cell housed in a relevant housing is brought into contact by the first holding element at least in places transversely to the housing longitudinal axis with an inner wall of the housing

[0009] The present objective is achieved according to the invention by a method of establishing electrical contact between a multitude of battery elements with the steps: a) providing a multitude of battery cells with a battery cell longitudinal axis, in which the electrical contacts are arranged on different sides along the battery cell longitudinal axis, preferably circular cylindrical bar cells; b) providing a device where several identical module holders are housed or can be housed one after the other inside the sheath so that preferably mutually corresponding housings of different module holders are aligned; c) introducing the battery cells into the corresponding housings and manufacturing a battery cell assembly with a multitude of battery cells, where battery cells arranged in aligned corresponding housings, arranged one after the other of different module holders form a rod of battery cells and are in contact with each other in pairs with their electrical contacts by making corresponding contact points; d) establishing electrical contact between a first electrical contact on the front side of the battery element rod, preferably by establishing contact between the connection and the first electrical contact on the front side of the battery element rod and by soldering the sheath on the front side on the side of the last electrical contact on the front side of the battery element rod.

[0010] Advantageous improvements of the ideas of the invention are also defined.

[0011] A device according to the invention for arranging battery cells with a longitudinal battery cell axis, for which the electrical contacts are arranged on different sides along the longitudinal axis of the battery element, preferably electrically insulating bar elements (round elements), has: an electrically insulating outer sheath for the battery elements; at least one electrical connection brought out in a guided manner, preferably on the front side of the sheath; at least one module holder housed in the sheath, made of an electrically insulating material;which module holder has a housing for a battery element, into which housing the battery element can be inserted along its longitudinal axis, it being understood that the (imaginary) extension of a longitudinal axis of the housing pierces the connection, which housing is held at a distance from the sheath and has at least one first elastic holding element, which first holding element is designed and is intended to bring a battery element housed or to be housed in the housing into contact at least in places transversely to the longitudinal axis of the housing with an inner wall of the housing. ;

[0012] If in the present case it is a question of "the (imaginary) extension of a longitudinal axis of the housing pierces the connection", this means that the (imaginary) extension of a longitudinal axis of the housing meets the connection so that electrical contact between the connection and the battery element is possible when the battery element is in the housing.

[0013] A battery cell assembly according to the invention comprises a device according to the invention and a number of battery cells with a battery cell longitudinal axis, in which the electrical contacts are arranged on different sides along the longitudinal axis of battery cells, preferably of cylindrical circular bar cells (round cells). Preferably, one battery cell is arranged in each housing of the device, it being understood that the battery cell housed in a corresponding housing is brought into contact by the first holding element at least in places transversely to the longitudinal axis of the housing with an inner wall of the housing.

[0014] A method according to the invention is used for establishing electrical contact between a multitude of battery cells. It comprises the steps of: a) providing a multitude of battery cells with a battery cell longitudinal axis, in which the electrical contacts are arranged on different sides along the battery cell longitudinal axis, preferably circular cylindrical bar elements; b) providing a device according to the invention, where several identical module carriers are accommodated one after the other inside the sheath, it being understood that corresponding receptacles of different module carriers are preferably aligned with each other; c) introducing the battery cells into the corresponding receptacles and manufacturing a battery cell assembly, where battery cells arranged in corresponding receptacles laying, aligned, arranged one after the other form a battery cell rod and are in contact with each other in pairs with their electrical contacts by producing corresponding contact points; d) establishing electrical contact between a first electrical contact on the front side of the battery cell rod and a last electrical contact on the front side of the or each battery cell rod, preferably by establishing contact between the connector and the first electrical contact on the front side of the battery cell rod and by closing the sheath on the front side on the side of the last electrical contact on the front side of the battery cell rod or by bringing it into contact.

[0015] By means of the device according to the invention or its use for the production of a battery cell assembly according to the invention or for electrical contacting within the scope of the method according to the invention, the welding of contact sheets is no longer necessary. The battery cells can be arranged - similar to a well-known torch - one after the other in the manner of a so-called "battery rod" and are thus in direct contact in pairs on the front side without the need for contact sheets which are expensive to weld. The first holding element ensures a defined, reliable positioning of the battery cells and thus compensates for possible production tolerances at least with regard to a diameter of the battery cells.The first holding element can also be used advantageously in the sense of broad functional integration for the purpose of electrical contacting or for potential balancing between the battery cells. The details relating thereto are described in more detail below.

[0016] The battery rods can be brought into contact easily when, in the context of an improvement of the device according to the invention, the housing opens towards the connection and on a side facing the connection. Thus, the contacts (front side) of a battery element contained in the housing are easily accessible from the outside.

[0017] The provision of said sheath and the module holder also makes it possible to achieve a further functional integration in the housing of the battery cell assembly, which consequently has a sealing (sheath) and support (module holder) function, which was not known in this way from the described state of the art.

[0018] It will now be appropriate to address in more detail advantageous improvements of the underlying idea of ​​the invention, as defined.

[0019] A first improvement of the device according to the invention provides that the first holding element is an elastic element, preferably an elastic tab or an elastic fastener. Such variants of the first holding element can be produced, for example, as particularly easily and easily cut pieces. lower costs and remarkably fulfill the function for which they were designed, namely to bring a battery element housed or to be housed in the housing into support at least in places transversely to the longitudinal axis of the housing with an inner wall of the housing to position it reliably and durably.

[0020] A further improvement of the device according to the invention provides that the first holding element is manufactured from an electrically conductive material, preferably a metal, or is coated with such a material. The specific advantage of such a configuration has already been emphasized above. It is thus possible to achieve electrical contacting of the battery cells, in particular for the purpose of potential equalization between battery cells connected in parallel. In addition, metal holding elements are particularly well suited to the use described above as an elastic element.

[0021] In a further improvement of the device according to the invention, it may be provided that the first holding element is designed to make electrically conductive contact with a battery cell housed or to be housed in the housing, which has already been emphasized above. This preferably goes hand in hand with the already mentioned configuration of the first holding element made of a metallic material. Alternatively or additionally, it may also be provided to provide printed conductive tracks in the area of ​​the housing or the like for electrically conductive contact with a battery cell housed or to be housed in the housing.

[0022] In order not only to reliably position the battery cells inside the module holder, but also to fix the module holder itself inside the sheath, a further highly preferred improvement of the device according to the invention may provide that the first holding element is designed and arranged to clamp the module holder against an inner wall of the sheath. Thus, the first holding element may correspondingly perform a dual function, which may reduce the number of components required and may result in corresponding savings. However, the clamping of the module holder against the sheath may also take place at least by means of another holding element different from the first holding element without restricting the invention. This other holding element may otherwise have the same characteristics as the first holding element.

[0023] The module holder can advantageously be removed from the sheath and can be inserted back into the sheath as part of a further improvement of the device according to the invention. This makes it possible to improve the ease of maintenance and assembly and to simplify the manufacture of a battery cell assembly according to the invention. The sheath can be made to accommodate one or - preferably - several module holders. module according to the desired size of the battery cell assembly, which also applies to the number of battery cell slots per module holder.

[0024] In order for the battery cells to be mounted in the housing reliably and without play, which advantageously goes hand in hand with a corresponding compensation of tolerances, a highly preferred improvement of the device according to the invention provides that the inner wall of the housing has on its periphery at least one projecting part extending in the direction of the longitudinal axis of the housing, preferably two projecting parts extending in the direction of the longitudinal axis of the housing, ideally continuously over (the entire) longitudinal dimension of the housing, it being understood that in particular the first holding element and the projecting parts are arranged in a homogeneous distribution over a periphery of the housing.When - as described - two projecting parts are present, together with the first element a so-called three-point mounting can result, which is highly preferred for static reasons.

[0025] A further improvement of the device according to the invention provides that a first free space is formed or remains at least in places between the inner wall of the housing and a battery element housed or to be housed in the housing. Said free space can be used - without restriction - to introduce a thermoregulation fluid or the like for thermoregulating (for cooling) in particular the battery element during operation.

[0026] A further improvement of the device according to the invention provides that the module support has a multitude of housings with longitudinal axes parallel to one another, which housings are arranged regularly in the form of rows and columns. Thus, it is possible to connect a large number of battery cells to one another with a relatively small space requirement, which is regularly a condition for the use of battery cells in the field of electromobility. The invention is not limited to a row and column arrangement of the battery cells or housings. Other alternative arrangement models, such as a concentric hexagonal or circular arrangement or even irregular arrangements, are possible.

[0027] An improvement of this idea may provide that at least one second elastic holding element is arranged between two adjacent housings in a row or column with the additional features, described above in detail, of the first element, which relate to the production as an elastic element (elastic tab or elastic clip) in a metallic (electrically conductive) material and the electrical contacting of a battery element. Furthermore, it may also be provided that the first holding element and the second holding element are electrically connected together. conductive. Thus, it is possible to easily establish the connection already mentioned many times between different battery elements, in particular for the purpose of potential balancing. Furthermore, as a further development of the present idea, it is possible to produce the first holding element and the second holding element in one piece - integrally, which also applies when including the other holding element mentioned above.

[0028] For the purpose of broad functional integration, it may also be provided within the framework of a further improvement of the device according to the invention that an electronic card (Printed Circuit Board - PCB) or another conduction assembly is present inside the sheath, it being understood that the first holding element (or the other holding element) establishes an electrically conductive contact with the electronic card or the conduction assembly. Thus, it is possible to assemble the battery element or the battery elements in an electrically conductive manner to the electronic card or to the conduction assembly so that, for example, monitoring or control of the battery elements can be carried out by means of an electrical circuit present on the electronic card or the conduction assembly or assembled thereto, for example and without restriction, temperature monitoring or the like.

[0029] It may also be provided in an improvement of the present idea that the electronic card or the conduction assembly cooperates electrically with a battery management system (BMS) preferably also housed in the sheath. The BMS can be implemented for extensive control and monitoring of the battery cells or a set of battery cells during ongoing operation. Due to its arrangement in the sheath of a device according to the invention, it can be optimally protected against external attacks. Furthermore, subsequent additional means of connection or wiring can be omitted.

[0030] A further improvement of the device according to the invention provides that several identical module carriers are housed or can be housed one after the other inside the sheath. These module carriers are preferably module carriers with a multitude of receptacles for battery cells with longitudinal axes parallel to each other, which are arranged in the form of rows and columns, which has already been emphasized above. The fact that corresponding receptacles of different module carriers are aligned with each other has proven to be particularly advantageous since this greatly simplifies the arrangement of the battery cells.

[0031] Preferably, the sheath is closed or can be closed in a corresponding improvement of the device according to the invention on one side, preferably reversibly. It can be provided, for example, that the sheath is permanently closed. with respect to the environment on the side of the electrical connection extended in a guided manner (front side). A reversible closure of the sleeve can take place on the opposite side - without restriction - for example by using a corresponding cover part, which is screwed onto the sleeve in order to close it. This cover part or a corresponding closure part offered as an alternative can also have an electrical connection extended in a guided manner (front side) in order to be able to electrically contact battery cells accommodated in the device on both sides in order to create an electrical circuit.

[0032] The invention is not limited to the reversible closure of the sheath, as described above. Nevertheless, a possibility of reversible closure of this type facilitates the simplicity of maintenance of the device.

[0033] A further improvement of the device according to the invention, on the other hand, provides that front-side closing elements are provided for closing a sheath, otherwise preferably made as a tubular sleeve, which closing parts are assembled, preferably welded, by a permanent material bond to the sheath.

[0034] Another highly preferred improvement of the device according to the invention provides that a second free space is still provided between the sheath and the module support, which can also serve to introduce or convey a thermoregulation fluid, for example for thermoregulating the PCB. The first free space described above is preferably in fluid communication with the second free space so that a common flow space is formed for the thermoregulation fluid.

[0035] At least one inlet duct and at least one outlet duct for the temperature control fluid can be provided on the sheath in order to be able to introduce the temperature control fluid into the first free space and / or into the second free space and to be able to evacuate it from these. Said inlet and outlet ducts are preferably located in the area of ​​the closing parts mentioned above for closing (front side) the sheath. The inlet or outlet ducts can be designed as connecting pieces for connecting the temperature control circuit of the device, as described above, to a temperature control circuit implemented or present externally in the device and to corresponding supply and transport means, as is frequently present in particular in motor vehicles.

[0036] The present invention is however in no way limited to such a configuration; on the contrary, a specific thermoregulation circuit with corresponding supply and transport means may also be present for the device itself.

[0037] A first improvement of the set of battery elements according to the invention provides that the first holding element establishes an electrically driver with a battery cell housed in the housing. We have already outlined the corresponding advantages and possibilities in detail above.

[0038] An improvement of the battery cell assembly according to the invention further provides that in the presence of several identical module supports, as described above, and a multitude of battery cells, the battery cells arranged in aligned corresponding housings, arranged one after the other of different module supports, form a rod of battery cells and are in contact with each other in pairs with their electrical contacts by producing corresponding contact points. Thus, it is possible to easily produce a series connection of battery cells without requiring any additional contact system for this purpose.

[0039] The fact of assembling, preferably welding, by material bonding the battery elements of a rod of battery elements on said contact points in an improvement of the assembly of battery elements according to the invention has proven to be particularly advantageous. This can take place by laser welding or by friction welding without the invention being limited to these types of welding. Thus, a durable and more reliable electrical contact is ensured between the various battery elements.

[0040] The joining of the battery cells of a battery cell rod to each other already before their introduction into the device according to the invention has proven to be particularly advantageous for handling, in particular during assembly. Thus, it is no longer necessary to handle a plurality of individual battery cells, but only a reduced number of battery cell rods, in which the individual battery cells are already permanently joined to each other in an electrically conductive manner. This results in corresponding advantages in terms of production and cost savings.

[0041] An alternative type of configuration provides for installing between the elements of a (battery) cell rod a safety element which is designed and is intended to separate, in the event of an electrical and / or thermal overload, the battery cell in question physically from the (battery) cell rod. The safety element can be designed as a safety fuse, for example in the form of a fine metal wire. Alternatively, an electrically insulating element, having sufficient pressure stability, with a conductive coating or with a connection dimensioned to correspond to the triggering current between the cell contacts, preferably designed as an outer coating or optionally an internally located metal wire, can be used. A safety element of this type is preferably systematically provided between two directly adjacent battery cells in a cell rod.

[0042] The intact cells remaining in the cell rod can be reintegrated into the assembly by a connection technique or can remain there, in the case of a corresponding improvement, by means of the elastic elements for the purpose of potential equalization (first and / or second holding elements, as described above). A vehicle driven by means of such an improvement of the battery cell assembly according to the invention still operates in this way. The greater the number of cells connected in parallel, the more advantageous this is.

[0043] It has already been pointed out that the device according to the invention may have, in a corresponding improvement, a first and / or a second free space, which may be filled with a temperature-regulating fluid or may be traversed by a fluid of this type. A corresponding improvement of the battery cell assembly according to the invention therefore provides that the first free space and / or the second free space are in fact filled and / or traversed with or by a temperature-regulating fluid of this type. Said temperature-regulating fluid may in particular be a dielectric, which acts as an electrical insulator and ensures that no unwanted electrical connections can occur within battery cell assemblies.Preferably, the first free space and the second free space are connected to each other in this context by a fluid communication technique, which has the effect in particular that only an individual circuit for the temperature control fluid is required, which again simplifies production and operation and contributes to a corresponding reduction in costs.

[0044] In further developing the method according to the invention, it may initially be provided that in a further step e), which may directly follow in particular step d) defined above, battery cells arranged in parallel within a module carrier are assembled in an electrically conductive manner. It has already been emphasized that this can take place in particular easily via the second holding element or a suitable multitude of such holding elements when this or these are or are produced in a corresponding manner, which has already been exhaustively emphasized above.

[0045] A further improvement of the method according to the invention provides that before step c) a number of battery cells are always assembled in pairs via their electrical contacts to each other into a battery cell rod consisting of two or more battery cells, which has already been emphasized above. Preferably, this assembly takes place by friction welding or by laser welding without the invention being limited thereto in particular by interposing a safety element. The fact that the number of battery cells in a battery cell rod corresponds to a number of aligned housings arranged one on top of the other after each other of different module holders has proven to be particularly advantageous. Thus, all aligned recesses of the individual module holders are filled or can be filled with a single battery cell rod because all the battery cells are already electrically conductively connected (connected in series) to each other inside the battery cell rod, so that basically it only remains to ensure that the battery cell rod is properly electrically contacted on both end faces. This produces a high tolerance compensation with regard to the dimensions of the individual battery cells, especially in the longitudinal direction, and considerably reduces production costs.The presence on at least one side of an elastic means or an elastically deformable connecting means has proven to be particularly advantageous for the purpose of bringing the battery element rods into contact on the front side.

[0046] In order to prevent unwanted electrical connections from occurring when inserting the battery cell rods into the module holders, which could result in a corresponding configuration in particular of the first holding element and which could lead to destruction of battery cells, a highly preferred improvement of the method according to the invention provides that in the best case, each battery cell rod is provided before step c) with an electrically insulating, peripherally closed covering, for example a covering made of paper or a plastic film. This covering is preferably intended to lie tightly on the periphery of the battery cell or the battery cell rod so as not to prevent the insertion of the battery cell rod into the receptacles of the module holders. The front-side contacts preferably remain free.However, due to the electrically insulating covering of the battery cell rod, it is not possible to make an unwanted and potentially harmful electrical contact when it is inserted into the module holder. Such contacting of the battery cells or the battery cell rod is only possible after the electrically insulating covering has been removed. A further improvement of the method according to the invention provides for this purpose that after step c) or before putting the battery cell assembly into operation, the described covering is removed. This can preferably simply take place by pulling it in the direction of a longitudinal axis of the respective battery cell rod, advantageously towards the (front) side of the sheath, which has not been closed with a corresponding closing element.

[0047] After removal of the wrapping, the various battery elements can then be assembled laterally, in particular by means of the first and / or the second holding element, electrically conductive to each other or to other constituent elements of the device according to the invention, such as the electronic card described above, as is necessary or provided for the operation of the set of battery elements. This takes place due to the elastic configuration of said elastic means preferably in complete autonomy.

[0048] The following description groups together by way of example certain particularly advantageous configurations of the present invention, which have proven, according to the applicant, to be particularly practical. However, it will be noted that the invention is in no way limited to the combinations of characteristics described below, so that the scope of protection of the application normally emerges from the claims and the general description above.

[0049] It is preferably proposed to assemble the battery cells or round cells into rods or bars. In addition to the welding method already mentioned, brazing of the battery cells can also take place in this context. However, the provision of a laser weld seam or the use of an ultrasonic welding method have proven to be particularly advantageous because in this way the heat input into the battery cells can be kept as low as possible.

[0050] Within the scope of the present description, the terms "cell bar", "cell rod", "round cell rod" and "battery cell bar" or "battery cell rod" or the like are used as synonyms unless otherwise expressly mentioned.

[0051] The round element bars can be produced according to a desired module configuration (e.g. 6S xP, in other words x times 6 battery cells in series) and then can be arranged in the desired quantity within each module holder parallel to each other, it being understood that the fixing takes place by the desired module holder. In doing so, the module holders are adapted, in particular within the framework of said housings, to the geometry and dimensions of the battery cells (preferably round cells). Thus, a so-called cell block results.

[0052] It has already been pointed out that the fastening of the battery cells or cell bars within the module holders preferably takes place by a three-point mounting or a three-point suspension. This can be formed, or formed, in the manner already described, by two projecting parts or contact elements made in the module holder, made or composed of plastic material and a spring element, which spring element preferably consists of a metallic spring material, as has already been described in detail above. The spring element is thereby designed in such a way that when the round elements (bars) are inserted, these are pressed against the two parts protruding from the module support.

[0053] To prevent a short circuit of the cell, particularly when inserting it into the module holder, a sufficiently large area made of a non-conductive material may be provided in addition to the provision of a suitable wrap described above or alternatively on the cell housing of the battery cell itself, which area may preferably consist of a coating, which is applied during the welding process for joining the battery cells. In addition or alternatively, a sufficiently high filling speed may be employed to prevent damage to the battery cells during inserting. The use of a joining aid portion (wrap) as described above, which prevents a short circuit when passing through the module holder and is removed again after assembly, is preferred. Advantageously, the joining aid portion can then be reused.Thus, it is not necessary to produce the non-conductive area described above, which again can simplify production. The said joining aid part, which forms the wrapping described above, can be produced, for example, as a thin-walled plastic or paper tube and can also find application as transport / storage protection for element rods or element bars.

[0054] Compensation of tolerances with regard to the round element diameter is possible thanks to the prestressed three-point mounting of the battery elements already described. When in particular the individual (battery) elements are rigidly assembled to one another within a bar, a single holding element (elastic element) is sufficient per element or per housing. However, the invention is not limited to configurations with only one holding element.

[0055] The production of the holding elements or elastic elements from sheet metal by bending-stamping and their joining in one plane to one another to form a plate of elastic elements has proven to be particularly advantageous. Thus, all holding elements (elastic elements) can be placed and mounted in the module carrier in one work step. Variants with injection-molded, clipped or placed holding elements or plates of elastic elements are possible in this case.

[0056] Said holding elements or elastic elements or elastic element plates form, in addition to the mechanical fixation due to the elastic prestressing in the case of a corresponding material selection, also the potential equalization of battery cells electrically connected in parallel. The fact that contact in a battery management system or additional wiring is possible via the holding elements or elastic elements or elastic element plates has already been emphasized. It has already been proposed above to arrange the BMS on an electronic card, which is threaded and mounted in a similar manner to the element rods in the sheath, it being understood that preferably electrical contact with the element rods is also ensured to save production costs. Preferably, both module supports and the sheath (together) have space for arranging the or at least one electronic card.

[0057] The possibility of configuring the module holder or the module holders in such a way that a (dielectric) cooling fluid can ensure immersion cooling of each battery cell in the battery holder in order to preferably homogeneously surround and cool the battery cells has already been pointed out.

[0058] In order to bring the battery cell assembly into contact, current collecting plates or the like are provided in a corresponding improvement, which are preferably arranged on the respective ends of the battery rods or the sheath and respectively form or have a central connection or conductor. A connection to the battery rods by welding or the like can again take place here; however, the production of the corresponding contact simply by force connection, as has already been essentially described, can also be sufficient.

[0059] The already mentioned sheath, which can be implemented as a thin-walled enclosing element into which the cell blocks are threaded with the current collecting sheets, in other words in particular the module supports with the battery cells, advantageously serves to seal the system. The thin-walled enclosing element can be implemented, for example, as a plastic tube or a metal tube and is adapted in its (small) cross-section to the corresponding dimensions of the module supports. It fulfills the function of sealing against the outside and can also impart dimensional stability to the entire assembly by means of axial warping. (Further) elastic elements for warping the module supports in the sheath can be provided on the module supports, as already explained.

[0060] In the case of corresponding requirements, the enclosing element itself may have a fully or partly flexible section, in particular in the manner of a bellows to compensate for elongations and tolerances, in particular thermally induced elongations during ongoing operation. Preferably, said flexible section - as already suggested - has corrugations, in particular annular corrugations, which are preferably formed inwards.

[0061] As a rule, closure elements or the closure parts already mentioned are provided on the front sides of the enclosing element, which are supposed to be electrically insulated and sealed with respect to said current collecting sheets. Furthermore, said closing elements can optionally support the electronic card (PCB) and corresponding contacting elements. Moreover, the inlet and outlet conduits can be provided here for the thermoregulation fluid, which has already been highlighted above as well. The fastening of the closing elements to the enclosing element or to the sheath can take place by welding or by edging without the invention being limited to a defined type of fastening.

[0062] Mounting the closing element or closing elements under mechanical prestressing also makes it possible to avoid welding of the current collecting plates. The electrical contact is then produced by what is called Hertzian pressure.

[0063] The closure element or closure elements may be designed such that attachment and positioning are provided for handling aid systems, such as assembly robots, and for mounting in an upper battery housing.

[0064] The invention is in no way limited to the use of round cells, in other words to battery cells with a circular cross-section, but it can be used just as well for battery cells with a non-round cross-section.

[0065] The advantages that can be achieved by the invention, at least within the scope of the aforementioned improvements, include the essential functional integration (sealing and warping within the outer enclosing element), the essential reduction in the number of components, the possible lightweight construction, the possibility of replacing various cell bars, the modular structure, the reduction or elimination of wiring costs, the possible compensation of tolerances with regard to the diameter of the battery cells as well as the direct connection of the cells without intermediate conductive elements having significant assembly costs (contact plates) as required according to the state of the art.

[0066] Other properties and advantages of the present invention emerge from the following description of the exemplary embodiments using the figures, in which:

[0067] [Fig.l] illustrates a longitudinal section of a set of battery elements according to the invention,

[0068] [Fig.2] illustrates a partial cross-section of a module carrier with battery cells housed therein;

[0069] [Fig.3] illustrates a possible wiring of battery elements; and

[0070] Figure 4 illustrates a proposed alternative wiring of battery elements.

[0071] [Fig.l] illustrates, under the reference number 1, a set of battery elements with a multitude of battery elements made as round elements or bar elements of the type described, eight of which are identifiable at least in part in [Fig.l]. The battery elements are designated generally by the reference numeral 2 (see figures 2 and following) and specifically by the reference numerals 2n, 22b 2n, 222, 2n, 223,2in, 22n, it being understood that 2n indicates the total number of battery elements 2. Each of the battery elements 2n has two electrical contacts on the front side (plus pole and minus pole), which are designated by way of example with the reference numerals 2a and 2b in [Fig.l] only for one battery element 2i2. Consequently, the electrical contact 2b is formed by the sheath 2c of the battery elements 2n, ... or comprises it. To prevent a short circuit of the battery cells 2n, ... an axial zone 2d composed of an electrically insulating material is arranged between the contact 2a and the contact 2b.Battery cells of this type (round cells, bar cells) are known to those skilled in the art. It has already been emphasized that the invention is not limited to the use of 2n battery cells with a circular cross-section.

[0072] While the battery cells 2n, 2i2, 2n, ... are connected in series in that different contacts 2a, 2b are always in contact, the battery cells 2n and 22i or 2i2 and 222 or 213 and 223, etc. are connected in parallel. For this purpose, holding elements or elastic elements 3b are provided, which connect the battery cells 2n, 22b etc. connected in parallel together in an electrically conductive manner, which will be discussed in detail below.

[0073] The battery cells 2lb 22b etc. connected in parallel are arranged in each case in a common module holder 3 made of an electrically insulating material such as plastic or the like, which will also be discussed in detail below. Each module holder 3 has receptacles 4 for receiving a battery cell 2n, ... in each case. The module holders 3 are arranged aligned one after the other in a sleeve-like sheath 5, which is closed on the end side by a closing element 6 in each case. In this case, the sheath 5 and the closing element 6 are connected to each other by material bonding on their periphery under the reference number 56. Collecting plates 7, which bring the corresponding contacts 2a, 2b of the battery cells 2n, ... into contact on the end side, are provided inside the sheath 5 in the area of ​​the closing elements 6.Furthermore, inlet ducts or outlet ducts 8 for a dielectric (temperature control fluid) 9 passing through the sheath 5 are located in the area of ​​the closing elements 6. According to the illustration in [Fig. 1], it is essential to know which of the connections shown under the reference number 8 serves as the inlet duct or outlet duct for the temperature control fluid 9.

[0074] The collection plates 7 are electrically connected to a respective connection electrical or an electrical conductor for the battery cell assembly 1. These conductors are designated in [Fig.l] by the reference number 10. They are electrically insulated by elements 11 arranged on the front side relative to the closing elements 6 or to the sheath 5.

[0075] The battery cells 2n, 2n, 2n, ... or 22b 222, 223, ... respectively connected in series may have to be joined to each other by material bonding and in an electrically conductive manner in so-called battery cell rods before insertion into the module holders 3 or into the sheath 5 to simplify handling. All the module holders 3 are designed identically at least with regard to their dimensions, geometry and housings 4, as shown, so that in particular the housings 4 are aligned in a longitudinal direction L, which extends parallel to a longitudinal axis (not shown) of the individual battery cells 2n, ....

[0076] At least two different free spaces are provided inside the sheath 5 as flow space for the thermoregulation fluid 9, which are designated in [Fig.l] by the reference numeral 12a and 12b. The (first) free space 12a is provided inside each housing 4 for a battery element 2 and an inner wall 4a of the respective housing 4. The second free space 12b is provided between a respective module carrier 3 and the sheath 5. Preferably, the two free spaces 12a, 12b are connected to each other by a fluid communication. Furthermore, there is a fluid communication connection between the free spaces 12a, 12b of the respective module carriers 3 so that preferably a single, continuous flow space for the thermoregulation fluid 9 results between the inlet duct and the outlet duct 8.

[0077] Furthermore, an electronic circuit board (PCB) 13 is arranged inside the sheath 5, which has electronic components (not shown) as well as electrical contacts 13a. The PCB 13 can be mounted on the elements 11 and cooperate electrically with other electronic components 14, which other electronic components 14 are arranged in the same way in the area of ​​the closing elements 6 on the front side (on the elements 11) to realize for example a battery management system (BMS).

[0078] According to the configuration of [Fig.l], the (second) free space 12b also still extends all around the PCB 13 in order to be able to cool the latter by means of the thermoregulation fluid 9.

[0079] According to the representation of [Fig.l], said additional electronic components 14 are arranged on both sides of the battery cell assembly 1. The invention is however in no way limited to such a configuration, but also includes battery cell assemblies, in which 14 additional electronic components of this type are located on only one side of the assembly. In addition, a connection (not shown) for the exchange of data and information from the BMS with the central battery control can be optionally present.

[0080] In order to fix the battery cells 2 inside the module holders 3 and the module holders 3 inside the sheath 5, a number of holding elements 3a, 3b, 3c can be provided per module holder 3, which has already been partly emphasized above, which are preferably designed as elastic elements or metal elastic tabs. The invention is not limited to providing the holding elements 3a - 3c as separate components; on the contrary, they can also be designed integrally or be assembled into a common component. The holding element 3a ensures that a battery cell 2 housed in the receptacle 4 of the module holder 3 rests on the inner wall 4a of the receptacle 4, as shown by way of example in [Fig. 1]. The battery element 2 concerned (here specifically the battery element 2n) is thus reliably positioned in the housing 4.

[0081] The holding element 3b acts correspondingly for the battery cell 222 within its housing 4, which is not designated in more detail in [Fig.l] for reasons of clarity, and at the same time connects the battery cell 2[2 with its electrical contact 2b to the corresponding electrical contact of the battery cell 222 in an electrically conductive manner in the manner of a parallel connection (potential balancing). The holding element 3c ensures a defined arrangement of the module carrier 3 concerned with the battery cells 2n and 222 housed within the sheath 5 and at the same time brings the PCB 13 under the reference number 13a into electrically conductive contact. Thus, the BMS (see above) in particular can cooperate with the battery cells 2n and 222.This naturally also applies to other battery cells, for example 2n and 22i battery cells or 2n and 223 battery cells as well as 2in and 22n battery cells.

[0082] It has already been emphasized that not all elements have been provided with reference numbers in [Fig.l] for reasons of clarity. In particular, all essential elements are repeated from module support 3 to module support 3 so that it is basically sufficient to exhaustively describe one of said module supports 3 with its housings 4 and its other details, such as in particular the holding elements 3a to 3c.

[0083] The battery elements 2 are all produced identically, so that here too it is not necessary to describe each individual battery element 2 in more detail.

[0084] It has already been emphasized that advantageously all the battery cells 2n, 2n, 2n, 2in, etc. connected in series have been advantageously assembled to each other before introduction into the battery cell assembly 1 by material bonding in the area of ​​their contacts 2a, 2b or their front-side contact points.

[0085] The reference number L denotes, by way of example, a longitudinal axis of each receptacle 4, which extends for the battery cell assembly 1 according to [Fig. 1] parallel to a longitudinal axis (not shown) of each individual battery cell (bar cell) 2. The receptacles 4 of the module supports 3 are designed correspondingly so that the battery cells 2 can be inserted only in the direction of their respective longitudinal axis into the receptacles 4. As is also shown in [Fig. 1], the receptacles 4 open on the front side in each case to allow the battery cells 2 to come into contact with each other and in the area of ​​the collecting plates 7, as the figures illustrate.

[0086] [Fig. 2] illustrates a detail of a cross-section of a module carrier 3, it being understood that [Fig. 2] shows two receptacles 4 inside the module carrier 3, in which a battery cell 2 is housed respectively. The crosses in [Fig. 2] symbolize (further) battery cells or their center points, which are arranged correspondingly inside the module carrier 3 in the form of lines (horizontally) and columns (vertically). The section plane in [Fig. 2] is oriented transversely to the longitudinal axis L shown in [Fig. 1].

[0087] The geometric configuration of the housings 4 with respect to their respective cross-section is essential in [Fig.2]; the reference numbers 3a and 3b respectively designate a holding element so as to correspond to the representation of [Fig.l].

[0088] As is apparent from [Fig. 2], the housings 4 have on their inner wall 4a on their periphery respectively two projecting parts 4b, which extend further into the plane of the figure and from it. The holding element 3a is placed on the inner wall 4a of the housing 4 in such a way that the projecting parts 4b and the holding element 3a are arranged in such a way that they are distributed substantially homogeneously over the periphery of the other circular recess in the cross section.

[0089] Thus, the holding element 3a designed as an elastic element presses the battery cells 2 against the two protruding parts 4b so that a highly favorable three-point assembly results. The holding element 3b can at the same time electrically conductively assemble adjacent battery cells 2 in a corresponding configuration, which has already been emphasized.

[0090] In principle, all the housings 4 are made correspondingly in the set of battery elements 1 according to [Fig.l].

[0091] The two holding elements 3a, 3b can be assembled to each other in an electrically conductive manner by a structure located outside the drawing plane of [Fig.2], which has already been emphasized.

[0092] Furthermore, an alternative embodiment is possible in which the holding elements (spring elements) are integrated into the module carrier 3 for warping and for tolerance compensation, and the potential equalization and contacting of the battery cells are reproduced on printed conductive tracks. In this case, the PCB 13 can be dispensed with if the conductive tracks transfer the potentials directly to the BMS via the module carriers 3. In this case, spring elements are also preferably provided on the front side for this purpose, which are coated in an electrically conductive manner and establish electrical contact with the following module during assembly. It is also possible to coat any protruding part 4b as long as a short circuit is excluded.

[0093] The sheath 5 (see [Fig.l]) as well as - with the exception of the element 13a - the other attachment of the battery elements 2 to a PCB (see reference number 13 in [Fig.l]) are not shown in [Fig.2].

[0094] Finally, different wirings of a multitude of battery elements 2 (not all are designated) into a set of battery elements 2 are shown in Figures 3 and 4.

[0095] The circuit with the first holding element made of an electrically conductive material, preferably metal, or coated with an electrically conductive material, basically corresponds to the assembly shown in [Fig.l]. Correspondingly, the conductors 10 are provided on opposite end sides of the battery cell assembly 1. By way of deviation from [Fig.l], four cell rods 2' connected in parallel are provided, it being understood that the electrical contacting of battery cells 2 connected in parallel is not shown in [Fig.3] for the purpose of potential equalization (see [Fig.l]).

[0096] Another wiring possibility is shown in Figure 4; there are de facto only two cell rods 2' connected in parallel; and the conductors 10 are located on a common front side (left) of the battery cell assembly.

[0097] Both connection variants can be implemented without any problem in the case of the invention, it being understood that only the configuration of the closing elements 6 on the front side (see [Fig.l]) together with the collection plates 7 and the conductors 10 is important.

Claims

Claims

1. Device for arranging battery cells (2) with a battery cell longitudinal axis, in which the electrical contacts (2a, 2b) are arranged on different sides along the battery cell longitudinal axis, preferably hollow cylindrical bar elements, which device has: - an electrically insulating outer sheath (5) for the battery cells (2); - at least one electrical connection (7, 10) preferably guided out on the front side of the sheath (5); - at least one module carrier (3) housed in the sheath (5), made of an electrically insulating material;which module holder (3) has at least one receptacle (4) for a battery cell (2), into which receptacle (4) the battery cell (2) can be inserted along its longitudinal axis, into which the extension of a longitudinal axis (L) of the receptacle (4) pierces the connection (7, 10), which receptacle (4) is held at a distance from the sheath (5) and has at least one elastic first holding element (3a, 3b), which first holding element (3a, 3b) is designed and is intended to bring a battery cell (2) housed or to be housed in the receptacle (4) into contact at least in places transversely to the longitudinal axis (L) of the receptacle (4) with an inner wall (4a) of the receptacle (4).;

2. Device according to claim 1, wherein the first holding element (3a, 3b) is an elastic element, preferably an elastic tab or an elastic leg.

3. A device according to claim 1 or claim 2, wherein the first holding element (3a, 3b) is made from an electrically conductive material, preferably metal, or is coated with an electrically conductive material.

4. Device according to claim 3, wherein the first holding element (3a, 3b) is designed to establish electrically conductive contact with a battery cell (2) housed or to be housed in the housing.

5. Device according to one of claims 1 to 4, wherein the first holding element (3c) is made and is arranged to assemble by clamping the module support (3) in the sheath (5).

6. Device according to one of claims 1 to 5, wherein the module support (3) can be removed from the sheath (5) and can be inserted back into the sheath (5).

7. Device according to one of claims 1 to 6, wherein the inner wall (4a) of the housing (4) has on its periphery at least one projecting portion (4b) extending in the direction of the longitudinal axis (L) of the housing (4), preferably two projecting portions extending in the direction of the longitudinal axis (L) of the housing (4), continuously at most preferably over one longitudinal dimension of the housing (4), in which in particular the first holding element (3a - 3c) and the projecting portions (4b) are arranged in a homogeneous distribution over a periphery of the housing (4).

8. Device according to one of claims 1 to 7, wherein a first free space (12a) is provided at least in places between the inner wall (4a) of the housing (4) and a battery element (2) housed or to be housed in the housing (4).

9. Device according to one of claims 1 to 8, wherein the module carrier (3) has a multitude of housings (4) with longitudinal axes (L) parallel to each other, which housings (4) are preferably arranged regularly in the form of rows and columns.

10. Device according to claim 9, wherein at least one second elastic holding element (3b) with the additional features of the first holding element (3a, 3b) according to any one of claims 2 to 4 is arranged between two adjacent housings (4) in a row or in a column, wherein preferably the first holding element (3a) is connected in an electrically conductive manner to the second holding element (3b).

11. Device according to any one of claims 1 to 10 with reference to claim 4, wherein an electronic card (13) or a conduction assembly, preferably with printed conductive tracks, is present or present inside the sheath, and wherein the first holding element (3c) establishes an electrically conductive contact with the electronic card (13) or the conduction assembly.

12. Device according to claim 11, wherein the electronic board (13) or the conduction assembly cooperates electrically with a battery management system (14) preferably housed in the sheath (5).

13. Device according to one of claims 1 to 12, wherein several identical module carriers (3), in particular according to claim 9, are housed or can be housed one after the other inside the sheath (5) so that preferably corresponding housings (4) of different module supports (3) are aligned.

14. Device according to one of claims 1 to 13, wherein the sheath (5) is closed or can be closed on both front sides, preferably reversibly.

15. Device according to one of claims 1 to 14, wherein a second free space (12b) is provided between the sheath (5) and the module support (3), wherein preferably the first free space (12a) according to claim 8 and the second free space (12b) are in fluid communication.

16. Battery cell assembly (1) with a device according to one of the preceding claims and with a number of battery cells (2) with a battery cell longitudinal axis, in which the electrical contacts (2a, 2b) are arranged on different sides along the battery cell longitudinal axis, preferably hollow cylindrical bar elements, in which preferably one battery cell (2) is arranged in each receptacle (4), in which the battery cell (2) housed in a respective receptacle (4) is brought into contact by the first holding element (3a, 3b) at least in places transversely to the longitudinal axis (L) of the receptacle (4) with an inner wall (4a) of the receptacle (4).

17. A battery cell assembly (1) according to claim 16, wherein the first holding member (3a - 3c) makes electrically conductive contact with a battery cell (2) housed in the housing (4).

18. Battery cell assembly (1) according to claim 16 or 17 with a device according to claim 13 and with a multitude of battery cells (2), wherein battery cells (2) arranged in aligned corresponding housings (2), arranged one after the other of different module carriers (3) form a battery cell rod (2') and are in contact with each other in pairs with their electrical contacts (2a, 2b) by realizing corresponding contact points.

19. Battery cell assembly (1) according to claim 18, wherein the battery cells (2) of a battery cell rod (2') are assembled, preferably welded, to each other by material bonding at the contact points.

20. A battery cell assembly (1) according to claim 19, wherein the battery cells (2) of a battery cell rod (2') have been assembled, preferably welded, to each other at the contact points before introduction into the device, in particular preferably by friction welding or by laser welding, in which, more preferably, a safety element is arranged between two battery cells (2) of a battery cell rod (2').

21. Battery cell assembly (1) according to one of claims 16 to 20, wherein the first free space (12a) according to claim 8 and / or the second free space (12b) according to claim 15 are filled and / or are traversed by a thermoregulating fluid (9), preferably a dielectric, wherein preferably the first free space (12a) and the second free space (12b) are connected in fluid communication.

22. Method for establishing electrical contact between a multitude of battery cells (2), with the steps: a) providing a multitude of battery cells (2) with a battery cell longitudinal axis, in which the electrical contacts (2a, 2b) are arranged on different sides along the battery cell longitudinal axis, preferably circular cylindrical bar cells; b) providing a device according to claim 13; c) introducing the battery cells (2) into the corresponding housings (4) and manufacturing a battery cell assembly (1) according to claim 18;d) establishing electrical contact between a first electrical contact on the front side of the battery cell rod (2'), preferably by establishing contact between the connection and the first electrical contact (2a) on the front side of the battery cell rod (2') and by soldering the sheath (5) on the front side on the side of the last electrical contact (2b) on the front side of the battery cell rod (2').;

23. Method according to claim 22, wherein battery cells (2) arranged in parallel in step e) within a module carrier (3) are assembled in an electrically conductive manner, preferably via the second holding element (3b).

24. A method according to claim 22 or 23, wherein a number of battery cells (2) are assembled, before step c), in pairs, via their electrical contacts (2a, 2b) to each other in a battery element rod (2'), preferably by friction welding or laser welding, in particular by interposing a safety element, in which the number of battery elements (2) corresponds to a number of aligned housings (4), arranged one after the other, of different module supports (3).

25. A method according to claim 24, wherein each battery element rod (2') is provided, before step c), with a peripherally closed electrically insulating wrap, preferably made of paper or plastic film.

26. Method according to claim 25, wherein the wrapping is removed after step c) or before putting the battery cell assembly (1) into operation, preferably by removal in the direction of a longitudinal axis of the respective battery cell rod (2').

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