Contact adapter, bus bar, contact system, method for contacting plural batteries, and assembly method for manufacturing plug connection battery pack

Abstract

To provide a contact system, a contact adapter, and a bus bar which improve process time, post processing, quality, and reversibility, in an assembly step of connecting plural battery cells to a cell contact system through a connection part and constituting a battery pack.SOLUTION: A contact adapter has a central contact adapter 110'''' extending in an axial direction A and a peripheral contact adapter 120'''', wherein the bottom surface of the central contact adapter is brought into contact with a central terminal of a battery, and a bottom plate of the peripheral contact adapter is arranged in a circular terminal of the battery. A bus bar includes central bus bar parts 210 and 210'''', and peripheral bus bar parts 220 and 220'''', the central bus bar part is brought into contact with the central contact adapter, the peripheral bus bar part is brought into contact with the peripheral contact adapter, and 2×13 pieces of batteries can be brought into contact with each other in parallel.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a contact adapter and a corresponding busbar. The invention further relates to a contact system having such a contact adapter and such a busbar, and to a method for contacting a plurality of batteries. The invention further relates to an assembly method for making a pluggable battery pack. [Background technology]

[0002] Currently, multiple battery cells are connected to a cell contact system through seamless connections by welding or gluing, thus achieving parallel and series connections. For battery packs with more than 1000 individual cells, this method has drawbacks in terms of process time, post-processing, quality, and reversibility. Summary of the Invention [Problem to be solved by the invention]

[0003] The underlying problem of the present invention is to provide a cell contact system that meets at least one of the above requirements in a better, cheaper or simpler way. [Means for solving the problem]

[0004] The above problem is solved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims.

[0005] In a general solution, a pluggable battery pack having a plurality of batteries is fabricated by an assembly method. The method first includes providing a carrier structure having cell contacts for contacting a plurality of batteries, each battery having two concentric terminals disposed together on one end face of the battery that extend in an axial direction. The method then includes inserting the plurality of batteries into the carrier structure to electrically connect at least two cells via the cell contacts. The carrier structure having cell contacts is provided before the plurality of batteries are inserted to contact the batteries in the battery pack.

[0006] For a better understanding of the present invention, the present invention will be described in more detail using the embodiments shown in the following drawings, in which the same parts are given the same reference numerals and element names. In addition, individual features or combinations of features of the various examples shown and described may themselves represent independent inventive or inventive solutions.

[0007] The present invention will now be described with reference to the drawings.

[0008] This is shown by the following: [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 2 is a view showing the end faces of the contact adapter and the battery before the contact adapter is attached. [Figure 2] 10A and 10B are diagrams showing the end faces of the contact adapter and the battery after the contact adapter has been attached. [Figure 3] FIG. [Figure 4] FIG. 1 shows a busbar with a contact ring. [Figure 5] 5 is a cross-sectional view of the contact system with part of the busbar according to FIG. 4. [Figure 6] 5 is a cross-sectional view of a contact system for a module having several busbars according to FIG. 4. [Figure 7]FIG. 7 is a top view of the contact system of FIG. 6. [Figure 8] FIG. 1 illustrates a plurality of bus bars and insulators. [Figure 9] FIG. 1 shows a contact system with a battery cell. [Figure 10] FIG. 10 is a flowchart of an assembly method. [Figure 11] FIG. 1 illustrates a battery pack having multiple battery cells. [Figure 12] FIG. 2 is a diagram showing a plurality of battery cells. DETAILED DESCRIPTION OF THE INVENTION

[0010] Batteries are becoming increasingly important, especially in the field of electromobility. In this regard, extensive requirements are placed on them.

[0011] For example, it may be necessary to use battery cells in which both terminals are on a common plane; that is, the positive (+) terminal and the negative (-) terminal are next to each other on the face or side of the battery. Generally, batteries are bipolar, that is, the positive and negative terminals are on opposite sides of the battery. Thus, batteries in which both poles are located on the same plane may be referred to as "unipolar batteries." One advantage of such "unipolar" battery cells is that they may be more compact and easier to handle.

[0012] In addition, there are various designs of battery cells that are used depending on the application and requirements of the battery, such as cylindrical cells, prismatic cells, or pouch-type cells.

[0013] In a "monopolar" cell having a cylindrical shape, the terminals are typically arranged concentrically, as shown in FIG. 12, for example. FIG. 12 shows a cell system 1000 consisting of a group of six battery cells. Each battery cell has a central terminal 1110, which is typically circular and is, for example, the positive (+) terminal here. The central terminal 1110 is typically surrounded by an annular terminal 1120, which is, for example, the negative (-) terminal here. An insulating region 1130 is present between the two terminals. In other words, the two terminals 1110, 1120 and the insulating region 1130 are arranged concentrically.

[0014] Concentricity refers to the arrangement of multiple shapes or structures that have the same center point, in this case the center point of the central terminal 1110. The annular terminal 1120, which is spaced apart from the concentric terminal in the radial direction R, has the same center point as the central terminal 1110 and is therefore concentrically arranged.

[0015] In the following description of cylindrical cells, reference will be made to a cylindrical coordinate system, where the cell extends in an axial direction A and the distance from the axis is represented by the radial axis R. Finally, the circumferential direction U represents the azimuthal angle.

[0016] In addition to the battery cell geometry and terminal arrangement, electrical parameters are also usually defined. These include, among others, the total voltage, capacity, or power. This can be achieved by appropriate series and / or parallel connection of the battery cells, which requires the use of a cell contact system.

[0017] As explained above, the above-mentioned problems are solved by an assembly method, in particular by a contact system consisting of a contact adapter, a busbar and an insulator.

[0018] The contact adapters allow the contacts to be changed from axial to radial. By arranging the peripheral contact adapters around the central contact adapter, i.e. extending in the circumferential direction U, a partial form fit can be achieved, which allows multiple batteries to be plugged together via the contact system.

[0019] The busbar allows for series connection via a bent current busbar section that equalizes the axial height difference between the peripheral contact heights of two adjacent cells.

[0020] In other words, the problem is solved by a contact adapter that is placed on the terminal to establish a plug connection. This placement is done at the cell level, for example by welding, and assembly into a battery pack is then done only by plug connection, thereby simplifying the process. Different adapter heights at the (+) and (-) terminals allow cells in one segment to be connected at different height levels, thereby realizing a simple modular structure.

[0021] The busbar allows for a plug connection in series with a good current conducting material such as copper. The plug connection can be optimized to generate a high contact force by means of an additional rigid spring element (e.g. a steel spring ring). This provides a friction fit in addition to a form fit. This ensures the required current carrying capacity, low component costs, reliability against vibrations and long-term stability.

[0022] Furthermore, the same busbar can be used multiple times. Adaptation of the busbar is only required for the first and last segments. This allows the busbar to be cost-effectively manufactured as stamped parts. In addition, the modular structure allows for improved tolerance compensation by connecting smaller sections of the cell pack together. At the same time, various circuit configurations, e.g., various numbers of battery cells in series or parallel, can be easily realized.

[0023] Furthermore, the required insertion force is reduced because only a small group of cells in the module are connected at the same time, rather than all the cells. The circuit design can be adapted to accommodate various types of connections between the terminals and the cell contact system.

[0024] To avoid the welding process, the adapter can be directly incorporated into the cell design.

[0025] The first example relates to a contact adapter for connecting two concentric terminals, positioned together on the end faces of a battery extending in the axial direction (A), to a bus bar for connecting multiple such batteries. For a description of such a cell, see the description of Figure 10 above.

[0026] The contact adapter of the first example includes a central contact adapter extending in the axial direction (A) and peripheral contact adapters for being disposed around the central contact adapter.

[0027] These two parts are provided separately. They are made of conductive material. They may be connected to the battery cell by gluing or welding. In particular, the connection is then non-removable, i.e., it cannot be disconnected without causing damage. The connection with the contact adapter is formed at the cell level, so it can be made in a compact and easily controllable environment, which allows for a high level of precision at the cell level. Alternatively, both parts of the contact adapter are integrally connected to the battery cell.

[0028] The peripheral contact adapter extends circumferentially around the central contact adapter. Thus, the peripheral contact adapter extends around the center it forms with the central contact adapter. The peripheral contact adapter may completely surround the central contact adapter, i.e., 360° in the circumferential direction. Minor deviations from this, e.g., manufacturing-related discontinuities due to the manufacturing of the peripheral contact adapter as a stamped and formed part, are conceivable. As a result of this arrangement, when two adjacent contacts are connected in series, the contacts cross over each other. This is because the peripheral contact adapter must be passed radially to make contact with the central contact adapter.

[0029] The central contact adapter has a bottom surface for attaching the central contact adapter to the central terminal of the battery, a tip portion opposite the bottom surface for passing through the central contact opening of the bus bar, the tip portion rising from the bottom surface to the central contact height, and a side surface extending between the tip portion and the bottom surface, the side surface having a central contact portion for contacting the central terminal of the central contact opening of the bus bar in the radial direction R.

[0030] This arrangement allows the contact direction at the central terminal of the battery to be reversed, ie from a contact direction perpendicular to the axial direction to a contact direction in the radial direction.

[0031] The tip of the center contact adapter preferably has a smaller diameter than the base, which allows the base to achieve maximum contact surface with the battery's center terminal, and the center contact adapter simultaneously acts as a guide for aligning the busbar with the battery cell, allowing for greater tolerances during plugging.

[0032] Advantageously, the central contact has a diameter greater than the tip and less than the base, so that the height at which the busbar abuts the central contact can be defined.

[0033] The peripheral contact adapter has a bottom plate for attachment to the annular terminal of the battery and a hollow contact cylinder rising from the bottom plate to a peripheral contact height in an axial direction A. The hollow contact cylinder, also called a contact lamella, has a peripheral contact portion for contacting the peripheral terminal of the peripheral contact opening of the busbar in a radial direction R.

[0034] This arrangement allows the contact direction of the annular terminal of the battery, i.e., the contact direction perpendicular to the axial direction, to be changed to the contact direction in the radial direction. This arrangement can also be used for terminals other than annular terminals of the battery.

[0035] The hollow contact cylinder is a flat, thin, strip-like element. The bottom plate serves as a carrier structure for the hollow contact cylinder. The hollow contact cylinder extends parallel to the central contact adapter. As a result, the central contact adapter and hollow contact cylinder can be connected to the busbar in a single plug-in operation.

[0036] According to a first example, the central contact height is greater than the peripheral contact height.

[0037] The space required for radial contact is created by the assembly height in the axial direction A. Different assembly heights allow contact at two different heights, thereby overcoming the problem of crossing contacts. The busbars described below allow for a system in which identical, compact busbars can be used for the connections. These compact busbars can then be connected with reduced insertion forces, allowing for improved installation tolerances, and the flat busbars reduce the effects of vibrations, for example, resulting in a stable contact system in the long term.

[0038] A second example relates to the contact adapter according to the first example, wherein the central contact adapter further comprises a shoulder element that protrudes radially from a side surface, and the shoulder element makes it possible to limit the movement of the busbar in the axial direction.

[0039] A third example relates to a contact adapter according to one of the previous examples, wherein the central contact adapter is rotationally symmetrical with respect to the axial direction, which makes it particularly easy to align the battery with the busbar. It is particularly preferred if the central contact adapter forms a pin.

[0040] A fourth example is a contact adapter according to one of the above examples, in which the hollow contact cylinder is integrally connected to the bottom plate, which makes it particularly easy to manufacture the peripheral contact adapter, for example as a stamped and bent part.

[0041] A fifth example relates to a contact adapter according to one of the previous examples, wherein the hollow contact cylinder and the bottom plate have an L-shaped profile, and the bottom plate allows for axial restriction of the movement direction of the bus bar.

[0042] A sixth example relates to a contact adapter according to one of the previous examples, wherein the bottom plate is configured rotationally symmetrical with respect to the axial direction. In particular, the bottom plate is annular. Additionally or alternatively, the hollow contact cylinder is configured rotationally symmetrical with respect to the axial direction. In particular, the hollow contact cylinder has a plurality of separate contact webs. This makes it particularly easy to align the battery with the busbar.

[0043] A seventh example relates to a busbar for series contacting of a plurality of batteries by a contact adapter according to one of the above examples, each battery having two concentric terminals arranged together on one end face of the battery extending in the axial direction A.

[0044] For a description of the contact adapter and battery, please refer to the description above.

[0045] The busbar includes a central busbar section, a peripheral busbar section, and a bent busbar section.

[0046] These three parts are closely connected. For example, the busbars are stamped and bent from a single sheet of metal. They are made of a conductive material, preferably copper. This allows the busbars to be connected in series, and this arrangement provides sufficient space for the insulators.

[0047] The central busbar portion has a central contact opening for passing a central contact adapter having axially extending sides and a central terminal for radially contacting the sides of the central contact adapter. This arrangement allows the busbar to be plugged into the central contact adapter in the axial direction. Furthermore, this arrangement allows for a partial form-fit connection of the busbar and the central contact adapter.

[0048] The central terminal may be arranged on the inner surface of the central contact opening or may form the central contact opening, which allows for a particularly compact structure. In addition, the central terminal may contribute to a frictional connection. Thus, the central terminal may simultaneously increase electrical conductivity, for example, by removing an oxide layer during connection.

[0049] The peripheral busbar section has peripheral contact openings for passing through hollow contact cylinders of the peripheral contact adapter, which extend in the axial direction A to the peripheral contact height, and peripheral terminals for radially (R) contacting the peripheral contact sections of the hollow contact cylinders at the peripheral contact section height. This arrangement allows the busbar to be plugged into the peripheral contact adapter in the axial direction. Furthermore, this arrangement allows for a partially form-fit connection of the busbar and the peripheral contact adapter.

[0050] The peripheral terminals may advantageously form the inner surface of the peripheral contact opening, which allows for a particularly compact design. Furthermore, the peripheral terminals can contribute to a frictional connection, thus simultaneously increasing the electrical conductivity, for example, since an oxide layer is removed during connection.

[0051] Furthermore, the busbar has bent busbar sections disposed between the central busbar section and the peripheral busbar section, such that the bent busbar sections function to compensate for the height difference between the peripheral contact height and the peripheral contact height in the axial direction A.

[0052] The bend in the axial direction A allows the contacts of two adjacent cells to cross over in order to connect them in series. The height difference makes it particularly easy to insert insulation in the intermediate area. This has the particular advantage that several identical, compactly configurable busbars can be used for the connection. These compact busbars can then be connected with reduced insertion forces, allowing for improved installation tolerances, and the contact system has long-term stability, since the flat busbars can, for example, reduce the effects of vibrations.

[0053] An eighth example relates to a busbar according to example seven, wherein the central terminal has a plurality of separate contact wings projecting axially from the central contact opening. Additionally or alternatively, the peripheral terminals have a plurality of separate contact wings projecting axially from the peripheral contact openings. The separate contact wings allow for easy manufacturing as a stamped and formed part. Furthermore, the contact wings can be positioned inside the openings, resulting in a compact structure. Furthermore, the separate contact wings allow for adjustment of requirements such as clamping force and insertion force.

[0054] A ninth example relates to the busbar according to example 7 or 8, wherein the busbar further comprises contact rings, the contact rings being axially arranged in the central contact opening and / or the peripheral contact openings. The contact rings may enable an increase in the contact surface in the axial direction. The larger surface results in a reduced contact resistance.

[0055] Advantageously, the central terminal and / or the peripheral terminals surround a contact ring, for example by using contact wings as described in Example 8. The terminals can thus be made from a highly conductive material such as the busbar and / or be integral with the busbar, further reducing the contact resistance.

[0056] A tenth example relates to a busbar according to example 9, where the contact ring is made of a harder material than the busbar. Typically, the two parts, the busbar and the contact adapter, are made of a material that has good electrical conductivity but is soft, such as copper. The contact ring may be made of a harder material, thereby increasing the frictional connection, also known as force closure. This allows for a higher contact force, thereby reducing contact resistance. Furthermore, the rigid contact ring helps remove oxide layers, either directly by the contact ring or indirectly through the contact terminals, as described above in examples 8 and 9.

[0057] An eleventh example relates to the busbar according to example 9 or 10, wherein the contact ring has slots. The slots allow for setting the contact force of the contact ring. In this case, the slots extend in the radial direction.

[0058] A twelfth example relates to a busbar according to one of examples 7 to 11, wherein the diameter of the central contact opening is smaller than the diameter of the peripheral contact openings, thereby increasing the contact surface, since both openings are adapted to the diameter of the respective contact adapter. The diameters are measured radially.

[0059] A thirteenth example relates to the busbar according to any one of examples 7 to 11, wherein the central busbar section, the bent busbar sections, and the peripheral busbar sections all follow a club shape in a plane perpendicular to the axial direction, and the peripheral busbar sections form a wider end of the club that tapers toward the central busbar section in the bent busbar sections. As a result, the busbar can be made compact, and the force required to compensate for the height difference due to the bent busbar sections can be minimized.

[0060] A fourteenth example relates to a contact system including a plurality of contact adapters according to one of examples 1 to 6, a busbar according to one of examples 7 to 13, and an insulator, wherein the insulator has an insulator portion extending perpendicular to the axial direction, the insulator portion completely covering at least the peripheral busbar portion to prevent short-circuiting between the peripheral contact adapters and the central contact adapter of one of the plurality of batteries, thereby enabling the contact system to connect two batteries in series.

[0061] A fifteenth example relates to a method for contacting a plurality of batteries, the method comprising: Attaching a contact adapter according to one of Examples 1 to 6 to each of a plurality of batteries; A series connection of two battery cells to a bus bar according to one of Examples 7 to 13; The peripheral bus bar portion of the battery cell is covered with an insulator. Includes.

[0062] A sixteenth example relates to an assembly method for making a plug-connected battery pack including a plurality of batteries, the assembly method comprising: providing a carrier structure having cell contacts for contacting a plurality of batteries, each battery having two concentric terminals disposed together on one end face of the battery extending in an axial direction; inserting the plurality of batteries into a carrier structure to electrically connect at least two batteries via cell contacts; Including, A carrier structure with cell contacts is provided prior to plugging together a plurality of batteries to create a pluggable battery pack.

[0063] A battery pack (or battery module) is an arrangement of multiple battery cells that work together to provide greater capacity and power than individual batteries.

[0064] The carrier structure allows for the retention of components of the battery pack, including, among other things, batteries, for which see Examples 1 to 15 above.

[0065] Additionally, the carrier structure includes cell contacts, which may be made of an insulating material such as plastic, and which may be made of a conductive material such as metal to electrically contact the battery.

[0066] A carrier structure with cell contacts is provided prior to insertion of the battery, allowing contact with the battery through a frictional connection only, without the need for a material connection such as welding or soldering.

[0067] In a friction connection, parts are held together by frictional forces. These frictional forces occur when parts are pressed together. In a material connection, parts are joined by molecular or atomic forces, forming a solid, non-removable connection. This connection is formed by bonding the materials together, often through melting or chemical processes.

[0068] This means that instead of incorporating the cell contacts into a pre-assembled battery, the battery is plugged into the cell contacts, and is thus removably held in the carrier structure.

[0069] By inserting the battery into a carrier structure, assembly, repair and disassembly is made easier for the user.

[0070] A seventeenth example relates to an assembly method according to example 16, wherein at least the battery cell has a contact adapter according to one of examples 1 to 6, and / or the cell contact includes a bus bar according to one of examples 7 to 13.

[0071] An eighteenth example relates to an assembly method according to example 16 or 17, wherein multiple batteries are plugged into the carrier structure sequentially, which simplifies assembly, particularly since tolerances for cell alignment can be more easily maintained.

[0072] A 19th example relates to the assembly method according to one of Examples 16 to 18, wherein each battery has a bottom surface opposite to the end surface, and the assembly method further includes covering the bottom surfaces of the plurality of batteries with a cell fastening portion to fasten the batteries to the battery pack. This prevents unintentional loosening of the batteries inserted into the battery pack. The cell fastening portion may be, for example, a housing that surrounds the battery pack and, in particular, seals the battery pack against a medium. Advantageously, the cell fastening portion is held by a carrier structure. Alternatively or additionally, the batteries may be fastened by screws.

[0073] In the nineteenth example, it is particularly preferred to cover the bottom surface after plugging into the carrier structure.

[0074] A twentieth example relates to the assembly method according to one of Examples 16 to 19, wherein the carrier structure further comprises a thermal coupling element for thermally coupling the cell contacts with the thermal conduction element and / or a thermal conduction element for transferring heat from the battery pack including the cell contacts, thereby enabling efficient dissipation of temperature from a plug-connected battery pack having a higher contact resistance than a material-lock connection due to a frictional connection.

[0075] In the twentieth example, it is particularly preferred if the thermal coupling element comprises an electrically insulating material, so that it can be thermally connected to the cell contacts. Additionally or alternatively, the thermally conductive element may have a higher thermal conductivity than the thermal coupling element. For example, the conductive element may be made of metal, or the thermally conductive element may be equipped with an active cooling unit, such as a liquid cooling system. Additionally or alternatively, the conductive element may have cooling fins.

[0076] 1 shows a contact adapter having a central contact adapter 110 and a peripheral contact adapter 120. The central contact adapter 110 and the peripheral contact adapter 120 are made from a conductive material, such as copper.

[0077] The central contact adapter 110 is adapted to be attached to the bottom surface 112 at the central terminal 1110 of the battery 1100. The peripheral contact adapter 120 is adapted to have its bottom plate 122 disposed on the annular terminal 1120 of the battery 1100. In particular, the central contact adapter 110 and the peripheral contact adapter 120 may be disposed on the terminals 1110, 1120 of the battery 1100 by welding, adhesive bonding, or similar connection techniques. Alternatively, they may be manufactured integrally with the battery. An disposed state is shown, for example, in FIG. 2.

[0078] The peripheral contact adapters 120 are disposed around the central contact adapter 110. In other words, the peripheral contact adapters 120 are disposed facing at least two opposite side surfaces of the central contact adapter 110. In the cross-sectional views of FIGS. 1 and 2, the extent of the contact adapters in the circumferential direction U is not shown. The central contact adapter 110 and the peripheral contact adapters 120 may have the same symmetry as the battery in the circumferential direction U. In particular, if the battery is a cylindrical cell as shown in FIG. 10, they may be rotationally symmetric about the axial direction A.

[0079] 1 and 2, the bottom surface 112 of the central contact adapter 110 may cover an area equal to that of the central terminal 1110 of the battery. In particular, the dimensions in the radial direction R may be the same or approximately equal, although this is not required. For example, as shown for the bottom plate 122 of the peripheral contact adapter 120, the area of ​​the bottom plate 122 may be larger than that of the annular terminal 1120.

[0080] 1 and 2, the inner radius of the bottom plate 122 of the peripheral contact adapter 120 in the radial direction is larger than the outer periphery of the bottom surface 112 of the central contact adapter 110. This prevents short circuits between the central contact adapter 110 and the peripheral contact adapter 120. The radial dimensions of the bottom surface 112 and the bottom plate 122 are determined by the size of the battery terminals 1110, 1120, the required insulation distance, and the available contact surface.

[0081] To attach the contact adapter 100 to the battery cell 1100, the central contact adapter 110 and the peripheral contact adapter 120 may be held by a receptacle (not shown) and thereby attached to corresponding terminals of the battery 1100 in a single process step. This receptacle may remain in place, for example to function as additional insulation.

[0082] Alternatively, the two portions 110 and 120 of the contact adapter 100 may be attached to the battery cell 1100 sequentially in two process steps.

[0083] In both cases, the illustrated configuration is preferred because the process steps for attaching the contact adapters are performed at the cell level, allowing high tolerances to be maintained and enabling the central contact adapter 110 to be aligned with the peripheral contact adapters 120 with high precision.

[0084] In addition to extending in the radial direction R, the central contact adapter 110 and the peripheral contact adapter 120 also extend in the axial direction A.

[0085] The central contact adapter 110 has a pin shape in the axial direction, also referred to as a pin, i.e., a columnar structure. The central contact adapter 110 has the aforementioned bottom surface 112, which may be formed as a base plate having a thickness in the axial direction A.

[0086] Adjacent the bottom surface 112, the central contact adapter 110 includes a shoulder having a shoulder element 116. The shoulder is adjacent one end of the bottom surface 110, and the shoulder element 116 may have a smaller diameter than the bottom surface 110 in the radial direction.

[0087] A tip portion having a tip 114 abuts a shoulder element 116 of the central contact adapter 110. The tip 114 may have a smaller diameter in the radial direction R than the tip portion, which may have a smaller diameter in the radial direction R than the shoulder element 116.

[0088] In the contact system 10, for example as shown in FIG. 5, the shoulder element 116 limits the movement of the busbar 200 in the axial direction A.

[0089] 1 and 2, the peripheral contact adapter 120 comprises the aforementioned bottom plate 122. From this bottom plate 122, a hollow contact cylinder 124 extends in the axial direction A. Although not visible in the cross-sectional view of FIG. 1, the bottom plate 122 may be annular. The hollow contact cylinder 124 may follow the edge of the bottom plate 122 in the form of a strip, or may consist of multiple contact webs. The peripheral contact adapter 120 can therefore be particularly easily manufactured as a stamped and bent part.

[0090] The bottom plate 122 may be annular. It has an inner diameter R1 and an outer diameter R2. A hollow contact cylinder 124 may be disposed at the inner diameter R1. In the schematics of Figures 1 and 2, the hollow contact cylinder 124 is disposed perpendicular to the bottom plate 122. However, it is also possible for the hollow contact cylinder to be disposed at an acute angle 124 with respect to the axial direction A at the bottom plate.

[0091] In the assembled state as shown in FIG. 2 , the central contact adapter 110 has a central contact portion 118 on a side extending between the tip 114 and the bottom surface 112. Specifically, the central contact portion 118 is disposed between the shoulder element 116 and the tip 114. Similarly, the peripheral contact adapter 120 has peripheral contact portions 128 disposed in a hollow contact cylinder 124. As shown in FIG. 2 , the peripheral contact portions 128 and the central contact portion 118 are radially separated from one another. Additionally, the contact adapter 100 increases the contact area of ​​the battery in the axial direction A.

[0092] 2 that the hollow contact cylinders 124 extend to a peripheral contact height Hp. The tips 114 extend to a central contact height Hz. The central contact height Hz is at a greater mounting distance from the battery in the axial direction A than the peripheral contact height Hp. Due to these different heights, contact can be achieved using a busbar 200 as described in FIGS. 3-5. Furthermore, alignment of the busbar 200 with the contact adapter is facilitated because the busbar 200 is first aligned with the pin-shaped tip of the central contact adapter.

[0093] As mentioned above, the contact adapter 100 of FIGS. 1 and 2 contacts the battery and the bus bar 200 shown in detail in FIGS.

[0094] 3 includes a central busbar portion 210, peripheral busbar portions 220, and bent busbar portions 230 disposed between the central busbar portion 210 and the peripheral busbar portion 220. The busbar 200 extends perpendicular to the axial direction A, i.e., in the radial direction R and the circumferential direction U.

[0095] Here, busbar 200 comprises a group of 2x13 central busbar sections 210, 210', 210'', a group of 2x13 peripheral power busbar sections 220, 220', 220'', and a group of 13 bent busbar sections 230, 230''. This multiple sections allows for parallel contact of a group of 2x13 cells at one terminal and 2x13 cells at the other terminal, with each terminal then contacting the other terminal in series via busbar 200.

[0096] In another example, not shown, the central busbar portion includes only one central busbar portion 210 and one peripheral busbar portion 220. Each pair of central busbar portion 210 and peripheral busbar portion 220 allows two adjacent terminals to be connected in series.

[0097] Each central busbar section 210 of the busbar 200 includes a central contact opening 212 surrounded by sides. The central contact opening 212 is larger in diameter in the radial direction R than the central contact adapter tip 114. Extending from one side of the central contact opening 212 is a central terminal 218, which consists of a group of five separate contact wings. As will be described below in FIG. 4 , these wings are bent, thereby increasing the contact surface in the axial direction A.

[0098] Like the central busbar portion 210, each of the peripheral busbar portions 220 has a peripheral contact opening 222. The peripheral contact opening 222 is larger in the radial direction R than the diameter of the hollow contact cylinder 124 of the peripheral contact adapter 120. A peripheral terminal 228 extends from the peripheral contact opening 222. In this case, the peripheral terminal 218 consists of a group of five separate contact wings. As will be described below with respect to FIG. 4, these wings are bent, which increases the contact surface in the axial direction A.

[0099] The bent busbar section 230 is disposed between the central busbar section 210 and the peripheral busbar section 220. As shown in Figure 5, the busbar 200 is bent in the axial direction A at the bent busbar section. The arrangement of the bent busbar section 230 allows for serial contact at different heights in the axial direction A. Thus, the bends can compensate for the height difference between the height of the peripheral contact section 128 in the axial direction A and the peripheral contact height Hp of the adjacent cell.

[0100] 10, i.e., a hexagonal arrangement that is particularly space-saving for cylindrical cells, the central busbar portion 210, the bent busbar portions 230, and the peripheral busbar portions 220 are club-shaped in a plane perpendicular to the axial direction A, as shown in FIG. 3. The peripheral busbar portions form the wider ends of the clubs that taper to the central busbar portion at the bent busbar portion. This allows for easy manufacturing of the busbar 200, as bending in the bent busbar portion 230 does not affect bending in the bent busbar portion 230'' due to the recess between the central busbar portions 210 and 210''.

[0101] 4 shows that busbar 200 may also have a contact ring 250 for each central busbar section and each peripheral busbar section, respectively. Contact ring 250 is disposed in each of the central contact openings and each of the peripheral contact openings 222 in the axial direction A. Contact ring 250 may have slots 252 that divide contact ring 250 in the radial direction R.

[0102] The wings of the central terminal and the wings of the peripheral terminal 228 are bent around the contact ring 250. Thus, as shown in Figure 5, the contact surface between the busbar 200 at the peripheral terminal 228 and the peripheral contact portion 128 at the peripheral contact adapter 110 is maximized in the axial direction A. The same is true for the central terminal 218 and the central contact portion 118.

[0103] The contact ring 250 increases the contact pressure between the peripheral terminal 228 and the peripheral contact 128. The contact pressure may be set by the material selection of the contact ring 250 and the slots 252. It is particularly preferred if a material such as steel is used for the contact ring 250, which is harder than a bus bar made from, for example, copper.

[0104] Figure 5 shows a contact system 10 having a plurality of contact adapters. For a description of the contact adapters, see particularly Figures 1 and 2. Additionally, the contact system includes a plurality of bus bars. For a description of the bus bars, see particularly Figures 3 and 4.

[0105] Furthermore, the contact system 10 includes an insulator 300. The insulator 300 has an insulator portion extending perpendicular to the axial direction A. The insulator portion completely covers the peripheral busbar portion 220''', which prevents short circuits through the central busbar portion 210''' of the busbar 200, i.e., between the peripheral contact adapter 120''' and the central contact adapter 110''' of a single battery cell of the multiple batteries.

[0106] The series connection of multiple groups of cells is shown in Figures 6 and 7. Figure 6 is a cross-sectional view similar to Figure 5, and Figure 7 shows a top view of the multiple groups of cells in Figure 6.

[0107] The method of assembly is shown in Figures 2, 8, and 9. First, as shown in Figure 2, a contact adapter 100 is attached to each battery cell. Next, a plurality of identical bus bars 200, 200' are provided. Additionally, conforming ends 202 and 204 are provided. Additionally, a plurality of insulators 300, 300', 300'' are provided.

[0108] 9, the busbars 200, 200′ may first be pre-assembled with the insulators 300, 300′, 300″ by means of a carrier structure 400. With the pre-assembled busbars having the insulators received therebetween, the battery cells may then be plugged in with the contact adapters. This provides a preferred plug-in system.

[0109] Figure 9 shows the solution with the contact adapter 100 and busbar 200 described above, although these are not required. In general, an assembly method for producing a pluggable battery pack, such as that shown in Figure 10, may be pluggable without these elements.

[0110] FIG. 10 is a flow chart of an assembly method for making a plug-connect battery pack.

[0111] In step S2, the assembly method includes providing a carrier structure, such as carrier structure 400, having cell contacts for contacting a plurality of batteries, each of which is one of batteries 1100 shown in FIG. 11. Each battery has two concentric terminals 1110, 1120 co-located on an end face of battery 1100 extending in axial direction A.

[0112] The cell contacts may include bus bars 200 as shown in FIGS.

[0113] The assembly method then includes step S4 of inserting the plurality of batteries into a carrier structure to electrically connect at least two batteries via cell contacts, thereby holding and connecting the two batteries in series or parallel. In particular, the cell contacts are provided on the carrier structure before the plurality of batteries are plugged together to create a plug-connect battery pack.

[0114] Each of the battery cells may have a contact adapter 100 according to Figures 1 and 2. For pluggable battery packs, see in particular Figures 5 to 7. In particular, multiple batteries may be plugged into the carrier structure in series, as shown for example in Figure 9.

[0115] Each of the batteries may have a bottom surface opposite the end surface, and the assembly method may further include step S6, in which the bottom surfaces of the plurality of batteries are covered with cell fixing parts to fix the batteries to the battery pack.

[0116] A pluggable battery pack 1 is shown in Figure 11. A plurality of batteries 1100 are disposed in the battery pack 1. Each battery 1100 has two concentric terminals disposed together on an axially extending end face of the battery 1100. Each battery may have multiple contact adapters, such as the central contact adapter 110 and peripheral contact adapter 120 described above.

[0117] Additionally, the battery pack 1 includes cell contacts, such as the busbar 200 described above. The busbar 200 includes a central busbar portion 210 and a peripheral busbar portion 220. Although not shown in the drawings, other cell contacts may be used. For example, the cell contacts do not necessarily include bent busbar portions.

[0118] Furthermore, the battery pack 1 includes a carrier structure 400. The carrier structure 400 may be pot-shaped as shown in Fig. 11. Alternatively, the carrier structure 400 may be plate-shaped, for example as shown in Fig. 9. The above-mentioned cell contacts, for example the bus bars 200, are received in the carrier structure 400. In particular, the cell contacts are non-detachably connected to the carrier structure 400. Non-detachable here means that the two parts cannot be separated without destroying at least one of them.

[0119] Furthermore, the carrier structure 400 may include further components, such as a thermal coupling element 410 for thermally coupling the cell contacts to the thermal conduction element 420 and / or a thermal conduction element 420 for transferring heat from a battery pack having the cell contacts. In particular, the components 410 and 420 are permanently connected to the carrier structure 400. Thus, the thermal coupling element 410 may have an electrically insulating material to electrically insulate the cell contacts from the thermal conduction element 420. This also allows the thermal conduction element 420 to be made of an electrically conductive material. Although not shown in FIG. 11 , the thermal conduction element 420 may include active cooling and / or cooling fins.

[0120] Furthermore, a connecting element (not shown) may be provided at one edge of the carrier structure 400 to close the battery pack with the housing component 430, which may be, for example, a plate-shaped bottom element. A cell fastening portion 440 may be provided between the housing component 430 and the battery 1100 to fasten the battery 1100 to the battery pack 1. For example, the cell fastening portion 440 may comprise an elastic material, and the housing component 430 may comprise a rigid material. The housing component 430 being rigid compared to the cell fastening portion 440 makes it possible to protect the battery 1100 from external influences, while the cell fastening portion 440 being elastic compared to the housing component 430 makes it possible to easily maintain tolerances and easily fasten the batteries 1100 in place relative to each other.

[0121] Although not shown in the drawings, the battery may have a shape different from a cylinder. Instead of a circle, any polygon may form the base of the cylinder, with the opening then having a corresponding perimeter that follows the polygon. The same applies to the contact ring, which then forms a contact polygon. [Explanation of symbols]

[0122] 1 battery pack 10 Contact System 100 Contact Adapter 110 Center Contact Adapter 112 bottom 114 Tip 116 Shoulder element 118 Central contact part 120 Peripheral Contact Adapter 122 Bottom Plate 124 Hollow Contact Cylinder 128 Peripheral contact area 200 Busbar 202, 204 End 210 Central busbar section 212 Central contact opening 218 Center terminal 220 Peripheral busbar section 222 Peripheral Contact Opening 228 Peripheral terminal 230 Bent busbar section 250 Contact Ring 252 slots 300 Insulator 400 Carrier Structure 410 Thermal coupling elements 420 Heat Transfer Elements 430 Housing Components 440 Cell fixing part 1000 cell system 1100 batteries 1110 Center terminal 1120 Ring terminal 1130 Insulation Area

Claims

1. A contact adapter (100) for contacting two concentric terminals (1110, 1120) arranged together on an end face of a battery (1100) extending in an axial direction (A), the contact adapter having a bus bar (200) for connecting a plurality of the batteries (1000); The contact adapter (100) a central contact adapter (110) extending in the axial direction (A), said central contact adapter (110) comprising: - a bottom surface (112) for attachment to the central terminal (1110) of said battery (1100); - an opposite tip (114) for passing through a central contact opening of said busbar (200), said tip (114) rising from said bottom surface (112) to a central contact height (Hz); and a side surface extending between said tip (114) and said bottom surface (112) having a central contact portion (118) for contacting in the radial direction (R) with a central terminal (218) of said central contact opening (222) of said busbar (200); a central contact adapter (110) comprising: - a peripheral contact adapter (120) for placement around said central contact adapter (110), said peripheral contact adapter (120) comprising: - a bottom plate (122) for attachment to the ring terminal (1120) of said battery (1100), and a hollow contact cylinder (124) rising from the bottom plate (122) in the axial direction (A) to a peripheral contact height (Hp), the hollow contact cylinder having a peripheral contact portion (128) for contacting a peripheral terminal (228) of the peripheral contact opening (220) of the busbar (200) in the radial direction (R); a peripheral contact adapter (120) comprising: Equipped with The central contact height (Hz) is greater than the peripheral contact height (Hp); A contact adapter (100).

2. The central contact adapter (110) further comprises a shoulder element (116); The shoulder element (116) projects from the side surface in the radial direction (R). The contact adapter (100) of claim 1.

3. The central contact adapter (110) is rotationally symmetrical with respect to the axial direction (A), In particular, said central contact adapter (110) forms a pin; A contact adapter (100) according to claim 1 or 2.

4. said hollow contact cylinder (124) being integrally connected to said bottom plate (122); and / or The hollow contact cylinder (124) and the bottom plate (122) have an L-shaped profile. A contact adapter (100) according to any one of claims 1 to 3.

5. the bottom plate (122) and / or the hollow contact cylinder (124) are configured to be rotationally symmetric about the axial direction (A); In particular, the bottom plate (122) is annular and / or the hollow contact cylinder (124) comprises a plurality of separate contact webs. A contact adapter (100) according to any one of claims 1 to 4.

6. 6. A busbar (200) for contacting a plurality of batteries (1100) in series using the contact adapter (100) according to any one of claims 1 to 5, wherein each battery (1100) has two concentric terminals (1110, 1120) arranged together on an end face of the battery (1100) extending in the axial direction (A), and the busbar (200) comprises: a central contact opening (212) for passing through a central contact adapter (110) having a side extending in the axial direction (A); and A central terminal (218) for radially (R) contacting the side surface of the central contact adapter (110). a central busbar portion (210) having a peripheral contact opening (222) for passing through a hollow contact cylinder (124) of a peripheral contact adapter (220) extending in the axial direction (A) to a peripheral contact height; and a peripheral terminal (228) for contacting the peripheral contact portion (128) of said hollow contact cylinder in said radial direction (R) at the peripheral contact height; a peripheral busbar portion (220) having a bent busbar portion (230) disposed between the central busbar portion (210) and the peripheral busbar portion (220) to compensate for the height difference between the peripheral contact portion height and the peripheral contact height (Hp) in the axial direction (A); Equipped with Busbar (200).

7. the central terminal (218) and / or the peripheral terminal (228) comprise a plurality of separate contact wings; The contact wings protrude in the axial direction (A) from the central contact opening (212) or the peripheral contact opening (222). The busbar (200) of claim 6.

8. Further comprising a contact ring (250); the contact ring (250) is disposed in the central contact opening (212) and / or the peripheral contact opening (222) in the axial direction; In particular, the contact ring (250) is made from a harder material than the busbar (200), and / or The contact ring (250) has a slot (252). The busbar (200) according to claim 6 or 7.

9. the diameter of the central contact opening (212) is smaller than the diameter of the peripheral contact opening (222); and / or the central busbar portion (210), the bent busbar portion (230) and the peripheral busbar portion (220) all follow a club shape in a plane perpendicular to the axial direction (A); The peripheral busbar sections (220) form the wider ends of the rods that taper towards the central busbar section (210) at the bent busbar sections (230). The busbar (200) according to any one of claims 6 to 8.

10. A contact system (10) comprising a plurality of contact adapters (100) according to any one of claims 1 to 5, a busbar (200) according to any one of claims 6 to 9, and an insulator (300), The insulator has an insulator portion extending perpendicular to the axial direction, the insulator portion completely covers the peripheral busbar portion (220) to prevent a short circuit between the peripheral contact adapter (120'''') and the central contact adapter (110'''') of one of the plurality of batteries; Contact system (10).

11. A method for contacting a plurality of batteries (1100), the method comprising: Attaching the contact adapter (100) according to any one of claims 1 to 5 to each of the plurality of batteries (1100); connecting two battery cells (1100) in series to a busbar (200) according to any one of claims 6 to 10; covering the peripheral busbar portion (220) with an insulator (300); A method comprising:

12. An assembly method for making a plug-connected battery pack (1) having a plurality of batteries (1100), comprising: The assembly method includes: - providing a carrier structure (400) having cell contacts for contacting the plurality of batteries (1100), each battery (1100) having two concentric terminals (1110, 1120) disposed together on end faces of the battery (1100) extending in an axial direction (A); - plugging the plurality of batteries (1100) into the carrier structure (400) to electrically connect at least two batteries (1100) via the cell contacts; Including, - the carrier structure (400) with the cell contacts is provided before plugging in the plurality of batteries (1100) to create the pluggable battery pack (1); Assembly method.

13. the plurality of batteries are plugged into the carrier structure in sequence; In particular, at least the battery comprises a contact adapter (100) according to any one of claims 1 to 6 and / or the cell contact comprises a busbar (200) according to any one of claims 7 to 13. The assembly method of claim 12.

14. Each battery (1100) has a bottom surface opposite the end surface, and the assembly method includes: Covering the bottom surfaces of the plurality of batteries with a cell fixing portion to fix the batteries to the battery pack. further comprising In particular, the covering of the bottom surface is carried out after plugging into the carrier structure (400).

14. The assembly method according to claim 12 or 13.

15. the carrier structure (400) further comprises a thermal coupling element for thermally coupling the cell contacts to a thermal conduction element and / or a thermal conduction element for transferring heat from the battery pack having the cell contacts; In particular, the thermal coupling element comprises an electrically insulating material and / or the heat conducting element has a higher thermal conductivity than the thermal coupling element, and optionally the heat conducting element comprises an active cooling portion and / or comprises cooling fins.

15. The assembly method according to any one of claims 12 to 14.

Images