CELL CONTACT SYSTEM FOR A BATTERY MODULE AND METHOD FOR MANUFACTURING SUCH CELL CONTACT SYSTEM - Patent application

Abstract

A cell contact system (15) for a battery module (10) having a plurality of battery cells (12) including a plurality of cell connectors (16) for conductively connecting cell terminals (36) of different battery cells (12) and a circuit board (18) having a plurality of signal lines each for passing measurements from one of the plurality of cell connectors (16) to a signal management circuit (20) or connection interface (22). The cell contact system (15) also includes at least one temperature sensing device (30) for measuring a temperature of the battery cell (12) at one of the plurality of cell connectors (16). At least one temperature detection device (30) is formed from a circuit board edge section (31) that is integral with the circuit board (18) and protrudes from the circuit board into the area of ​​each cell connector (16), a temperature sensor (32) mounted on the circuit board edge section (31), and a cell connector overlap section (33) of each cell connector (16), the cell connector overlap section (33) overlapping the temperature sensor (32) on the circuit board edge section (31).

Description

[Technical field]

[0001] The present invention relates to a cell contact system for a battery module having a plurality of battery cells, to a battery module having such a cell contact system, and also to a method for fabricating such a cell contact system. [Background technology]

[0002] For example, a cell management controller (CMC) that monitors the individual battery cells of a battery module to perform a charging process, voltage and state of charge balancing, temperature control process, etc. of the battery cells requires a cell contact system for contacting the battery cells to receive corresponding measurement signals for the potential and temperature of the battery cells. The cell contact system typically comprises a plurality of cell connectors for conductively connecting cell terminals of different battery cells and a printed circuit board having a plurality of signal lines for passing measurements from one of the plurality of cell connectors to a signal management circuit or a connection interface, respectively. Conventional cell contact systems usually require a great deal of effort in terms of manufacturing and assembly for connecting a signal source to the signal line system formed by the printed circuit board and for inserting a temperature detection device. In conventional cell contact systems, the temperature detection device generally includes a temperature sensor mounted on the cell connector or on a carrier element fixed to the cell connector and coupled to the printed circuit board via a connection element. As is known, the carrier element is fixed to the cell connector, for example by gluing, screwing, soldering or welding, and / or by a hook or tongue. Summary of the Invention [Problem to be solved by the invention]

[0003] It is an object of the present invention to provide an improved cell contact system which can be equipped with a temperature detection device in a simple manner.

[0004] This object is achieved by a cell contact system as defined in independent claim 1. The dependent claims relate to particularly advantageous refinements and developments of the invention. [Means for solving the problem]

[0005] A cell contact system according to the invention for a battery module having a plurality of battery cells comprises a plurality of cell connectors for conductively connecting cell terminals of different battery cells and a printed circuit board having a plurality of signal lines for respectively passing measurements from one of the plurality of cell connectors to a signal management circuit or connection interface. The plurality of cell connectors function as a power line system and the printed circuit board functions as a signal line system. The cell contact system also has at least one temperature detection device for measuring the temperature of a battery cell in one of the plurality of cell connectors. According to the invention, the at least one temperature detection device is formed from a printed circuit board edge section that is integrated with the printed circuit board and protrudes from the printed circuit board into the area of ​​the respective cell connector, a temperature sensor mounted on the printed circuit board edge section, and a cell connector overlap section of the respective cell connector, where the cell connector overlap section overlaps the temperature sensor on the printed circuit board edge section.

[0006] The use of a temperature detection device designed in this way has several advantages. Due to the integration of the temperature sensor on the printed circuit board by the protruding printed circuit board edge section, no additional measuring element on the printed circuit board separate or distinct from the printed circuit board, nor additional connection elements between the measuring element and the printed circuit board are required, therefore fewer components and fewer assembly steps are required to install the temperature detection device, which allows a simpler / more complex design of the cell contacting system and a simpler and more cost-effective production and assembly of the cell contacting system. Since a flat installation structure is possible, it is also possible to use the temperature detection device according to the invention to achieve a lower overall height of the cell contacting system compared to the use of conventional systems. The inventive structure of the temperature detection device can also be used particularly easily in combination with a rigid printed circuit board, which has further advantages since the rigid printed circuit board allows for easy handling during production and assembly, as well as the mounting of components, such as, for example, electronic circuit elements, on the rigid printed circuit board. The entire battery module can also be produced more easily and reliably, since the cell contacting system is easier to produce.

[0007] According to the present invention, the cell contact system includes a special temperature detection device. In principle, this design can be combined with any desired basic structure of the cell connector, any desired printed circuit board (preferably rigid, but also optionally flexible printed circuit board), any desired connection structure between the voltage tap point on the cell connector and the printed circuit board, and any desired dimensions of the battery module (i.e., in particular the number and size of the battery cells). The cell contact system can also include any desired number of temperature detection devices designed according to the present invention for temperature measurement at multiple (some or even all) cell connectors, which temperature detection devices can in principle comprise any desired type of temperature sensor (e.g. NTC temperature sensor, optionally SMD version).

[0008] In a preferred refinement of the invention, the at least one temperature detection device also has a thermally conductive layer between the temperature sensor and the cell connector overlap section of the respective cell connector. The thermally conductive layer serves to transfer heat from the cell connector to the temperature sensor. This thermally conductive layer of the temperature detection device can be attached to the temperature sensor or to the cell connector overlap section of the respective cell connector.

[0009] Preferably (but not necessarily) the cell connector overlap section of the temperature sensing device overlaps the entire printed circuit board edge section of the temperature sensing device.

[0010] The configuration of the temperature detection device may preferably be configured such that at least one of the following aspects is met: (i) the cell connector overlap section extends (at least partially) higher than other contact areas of the respective cell connectors; (ii) the printed circuit board edge section is positioned substantially in the same plane as the printed circuit board or at a deeper location than the printed circuit board; and (iii) the printed circuit board edge section is positioned substantially in the same plane as the respective cell connectors or at a deeper location than the respective cell connectors. Each of these statements relates to an upper side of the component that is avoided from the battery cells. Alternatively or additionally, the structure of the temperature detection device is also preferably configured such that the printed circuit board edge section has substantially the same layer thickness as the printed circuit board or a lower layer thickness than the printed circuit board.

[0011] In one refinement of the invention, the cell connectors each have two contact areas, each for a cell terminal of a battery cell, and a compensation area between the two contact areas, in which the temperature detection device is disposed in one of the two contact areas of the respective cell connector.

[0012] The invention also relates to a battery module comprising a number of battery cells and the above-described inventive cell contacting system, with which the same advantages can be achieved as those explained above in relation to the inventive cell contacting system.

[0013] The battery cells are connected to each other via cell connectors of the cell contact system and may be connected to a load or a charging system via electrical connections. The battery cells and the cell contact system are preferably both contained within a module housing. The invention is not limited to a particular type, number, size, or arrangement of the plurality of battery cells. The invention may be used in particular Li-ion battery modules.

[0014] Typically, the battery module also has at least one battery module controller for operating the battery module, which is connected to at least one signal management circuit (either integrated in the printed circuit board or connected to the printed circuit board via a connection interface as an external circuit). The module controller performs charging processes, voltage and state of charge balancing, temperature control processes, such as, in particular, cooling processes, at least in part, depending on the measurement signals received by the cell contact system.

[0015] The invention can also be advantageously used in battery modules for vehicles, especially electric and hybrid vehicles, especially automobiles and motorcycles, as well as in energy storage systems and other electrical devices (eg electronic appliances).

[0016] The invention also relates to a method of providing a cell contact system for a battery module having a plurality of battery cells, the cell contact system comprising a plurality of cell connectors for electrically conductively connecting cell terminals of different battery cells, and a printed circuit board having a plurality of signal lines for passing measurements from one of the plurality of cell connectors to a signal management circuit or a connection interface, the cell contact system having at least one temperature detection device for measuring the temperature of a battery cell at one of the plurality of cell connectors, i.e. a method for manufacturing such a cell contact system, comprising: providing the printed circuit board with at least one integrated printed circuit board edge section such that the printed circuit board edge section protrudes from the printed circuit board into the area of ​​the respective cell connector when the cell contact system is in an assembled state; mounting a temperature sensor on the printed circuit board edge section; and providing each cell connector with a cell connector overlap section such that the cell connector overlap section overlaps the temperature sensor on the printed circuit board edge section when the cell contact system is in an assembled state. The same advantages as those explained above in connection with the cell contact system according to the invention can be achieved in this way. The method also preferably includes inserting a thermally conductive layer between the temperature sensor and the cell connector overlap section of each cell connector, and wherein the components of the temperature sensing device are configured and positioned as described above in relation to the cell contact system.

[0017] The subject matter of the invention is defined by the appended claims. The above and further features and advantages of the invention will be better understood from the following description of preferred, non-limiting, exemplary embodiments, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0018] [Figure 1] FIG. 2 shows a perspective top view of a battery module according to an exemplary embodiment of the present invention. [Diagram 2] 2 shows a perspective partial plan view of a cell contacting system according to an exemplary embodiment of the invention for the battery module of FIG. 1. [Diagram 3] 3 shows a perspective partial plan view from FIG. 2, without a cell connector previously positioned in the area of ​​the temperature detection device. [Figure 4] 3 shows a perspective plan view of the cell connector of FIG. 2 positioned within the area of ​​a temperature detection device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] An exemplary embodiment of a battery module having a cell contacting system according to the present invention will now be described by way of example with reference to FIGS.

[0020] The battery module 10 includes a number of battery cells (e.g., Li-ion battery cells) 12. In this exemplary embodiment, the battery cells 12 are arranged next to each other in a top-to-bottom direction in Fig. 1, with a negative connection at the left or right end region in Fig. 1 and a positive connection at the right or left end region in Fig. 1, respectively, and the negative and positive connections of the battery cells 12 are arranged alternately, such that the negative connection of one battery cell is adjacent to the positive connection of an adjacent battery cell.

[0021] The battery module 10 also has a cell contact system 15 disposed above the battery cells 12, preferably on the carrier plate 14. The battery cells 12, together with the cell contact system 15, are typically disposed within a module housing (not shown).

[0022] The cell contact system 15 has a number of cell connectors 16 forming a power line system. In this exemplary embodiment, the cell connectors 16 each have two contact areas 16a, 16b and a (preferably elastic) compensation area 16c between the two contact areas 16a, 16b, and are attached to the battery cells 12 such that each cell connector 16 couples the negative connection of one battery cell 12 to the positive connection of an adjacent battery cell 12 via the two contact areas 16a, 16b of the cell connector 16, thereby forming a series circuit of the battery cells 12 within the battery module 10. The battery cells 12 can be further connected to a load or a charging system via the electrical connections of the battery module 10.

[0023] The cell contact system 15 also has a (preferably rigid) printed circuit board 18 that forms a signal line system and is arranged above the battery cells 12 over the entire length of the battery cell arrangement in the area between the two rows of cell connectors 16. The shape and size of the printed circuit board 18 can in principle be adapted to any desired structure of the battery module, in particular to any desired arrangement, size and number of battery cells. In this exemplary embodiment, the printed circuit board 18 is of a generally rectangular configuration. As shown in FIG. 1, the printed circuit board 18 also preferably has several holes as ventilation openings 19 to aid the cooling process of the battery cells 12 located below the printed circuit board 18.

[0024] Although not shown in FIG. 1 for simplicity and better understanding, the printed circuit board 18 has a number of signal lines each connecting a signal source of the cell connector 16 to an electronic signal management circuit 20. The signal management circuit 20 is configured to perform, for example, a voltage measurement method and to evaluate a measurement signal received from the signal source of the cell connector 16. In this exemplary embodiment, the signal management circuit 20 is integrated on the printed circuit board 18 and connected to a connection interface 22, through which the signal management circuit 20 can be connected to a battery module controller. This battery module controller functions, for example, to perform a charging process, voltage and state of charge balancing, temperature control processes, such as a cooling process, among others, which are performed at least in part depending on the measurement signals received by the cell contact system 15 or the measurement signals received by the signal management circuit 20. In an alternative embodiment of the invention, the signal management circuit 20 can also be designed externally from the printed circuit board 18. In this case, the signal lines of the printed circuit board 18 are directly connected to the connection interface 22, and the external signal management circuit is coupled to the connection interface 22 of the printed circuit board 18 and is also coupled to the battery module controller via a further connection interface. The cell contact system 15, the signal management circuit 20 and the battery module controller may collectively be referred to as a cell management controller (CMC).

[0025] 1 and 2, there are two kinds of signal sources in the cell contact system 15. First, all (selectively only most) of the cell connectors 16 each have a voltage tap point 24 as a first kind of signal source for measuring the voltage of the battery cell 12. In addition, for each pair (selectively as well as all) of the cell connectors 16, a temperature control device 30 is provided as a second kind of signal source for measuring the temperature of the battery cell 12.

[0026] The voltage tap points 24 may each be formed directly by the contact areas 16a, 16b of the cell connector 16. To connect the voltage tap points 24 to the signal lines of the printed circuit board 18, in each case at least one connection element 26 (in this exemplary embodiment in each case two connection elements) is coupled to the printed circuit board 18 and to the cell connector 16 at corresponding contacts 28a, 28b. The structure of these connection elements 26 is in principle arbitrary within the scope of the invention. As can be seen in Figs. 2 to 4, the connection elements 26 may be configured as press-in connection elements, for example made of metal and pressed into corresponding contacts 28a in the form of holes in the printed circuit board 18 and into corresponding contacts 28b in the form of holes in the cell connector 16. If the upper surface of the printed circuit board 18 and the upper surfaces of the contact areas 16a, 16b of the cell connector 16 are positioned substantially in the same plane, the connection sections of the connection elements 26 are configured, for example, such that the two pressed-in sections of the connection elements are positioned at approximately the same height. In addition, the connecting section of the connecting element 26 can be configured to be at least partially elastic.

[0027] The temperature measuring device 30 will now be described in more detail by way of example with reference to Figs. 2 to 4.

[0028] As best seen in FIG. 3, the temperature detection device 30 has a printed circuit board edge section 31 that is integrated with the printed circuit board 18 and that protrudes from the printed circuit board 18 into the area of ​​the respective cell connector 16, and the temperature sensor 32 is mounted on the printed circuit board edge section 31. In other words, the printed circuit board edge section 31 protrudes from the edge of the basic shape of the printed circuit board 18, which is substantially rectangular in this exemplary embodiment. The temperature sensor 32 is, for example, an NTC resistor or an NTC thermistor, optionally in an SMD version. As best seen in FIGS. 2 and 4, the temperature detection device 30 also has a cell connector overlap section 33 of the respective cell connector 16, which overlaps the temperature sensor 32 on the printed circuit board edge section 31. This cell connector overlap section 33 preferably overlaps substantially the entire printed circuit board edge section 31. Because the printed circuit board edge section 31 having the temperature sensor 32 is a component of the printed circuit board 18, no additional connection elements (such as, for example, connection element 26 for voltage tap point 24) are required to the printed circuit board 18 for a signal source for temperature detection.

[0029] 2, the temperature sensing device 30 also preferably includes a thermally conductive layer 34 between the temperature sensor 32 and the cell connector overlap section 33 so that the temperature sensor 32 can more effectively and reliably measure the temperature of the cell connector (and, consequently, the temperature of the battery cell). This thermally conductive layer 34 may be selectively attached to the temperature sensor 32 or the cell connector overlap section 32 of each cell connector 16. The thermally conductive layer 34 covers at least the temperature sensor 32, and selectively covers the entire cell connector overlap section 33 as well.

[0030] As can be seen in Figures 2-4, the printed circuit board 18 (with the integrated printed circuit board edge section 31 of the printed circuit board 18 and the temperature sensor 32 on the printed circuit board edge section 31) is first positioned on the carrier plate 14 above the battery cells 12 during assembly of the cell contact system 15. Then, the cell connectors 16 are positioned on the carrier plate 14 in the area of ​​the cell terminals 26 of the battery cells 12. The printed circuit board edge sections 31 of the temperature detection devices 30 are then respectively positioned in the sections of the cell terminals 26 in which the contact areas 16b of the cell connectors 16 are positioned. Thus, the cell connectors 16 have a cell connector overlap section 34 in the section of the contact areas 16b of the cell connectors 16, as shown in Figures 2 and 4. After the cell connectors 16 are in place, then the voltage tap points 24 of the cell connectors 16 are also connected to the printed circuit board 18 by coupling the connection elements 26 to the contacts 28a, 28b of the printed circuit board.

[0031] In the exemplary embodiment of Figs. 2-4, the upper surface of the printed circuit board edge section 31 is positioned substantially in the same plane as the upper surface of the printed circuit board 18, and the layer thickness of the printed circuit board edge section 31 can be somewhat thinner than the layer thickness of the printed circuit board 18. In particular, in the case of a thinner printed circuit board edge section 31, the upper surface of the printed circuit board edge section can alternatively also be positioned somewhat deeper than the upper surface of the printed circuit board 18. In addition, the upper surface of the printed circuit board edge section 31 is preferably positioned somewhat deeper than the upper surface of the respective cell connector 16, and the cell connector overlap section 33 preferably extends only slightly higher than the other contact areas 16b of the respective cell connector 16. In this way, a relatively flat design of the cell contact system 15 can be achieved over the entire area of ​​the temperature detection device 30. In addition, it is possible to configure the printed circuit board edge section 31 and / or the cell connector overlap section 34 to be at least partially elastic. Such flexibility can compensate for movement and expansion of the battery cells 12 that may occur, for example, during charge and discharge cycles.

[0032] The described battery module 10 having the cell contact system 15 according to the present invention can be used, for example, in vehicles, in particular electric and hybrid vehicles, in particular automobiles and motorcycles, or in energy storage systems, or other electrical devices (e.g., electronic household appliances).

[0033] The subject matter of the present invention is defined by the appended claims. The exemplary embodiments described above serve only to better understand the present invention and are not intended to limit the scope of protection defined by the claims. As will be clear to those skilled in the art, further embodiments are also possible within the scope of the present invention, in particular by omitting individual features from the exemplary embodiments described above or by adding additional features thereto. [Explanation of symbols]

[0034] 10 Battery Module 12 Battery Cells 14 Carrier Plate 15 Cell Contact System 16 Cell Connector (Power Line System) 16a, b Cell connector contact area 16c Cell connector compensation area 18 Printed circuit board (signal line system) 19 Ventilation opening 20 Signal management circuit 22 Connection Interface 24 Voltage Tap Points 26 Connection Elements 28a Connection element contacts on printed circuit boards 28b Connection element contacts on cell connector 30 Temperature detection device 31 Printed Circuit Board Edge Section 32 Temperature Sensor 33 Cell Connector Overlap Section 34 Thermal Conduction Layer 36 Cell terminal

Claims

1. A cell contact system (15) for a battery module (10) having a plurality of battery cells (12), comprising: a plurality of cell connectors (16) for conductively connecting cell terminals (36) of different battery cells (12); a printed circuit board (18) having a plurality of signal lines for passing measurements from one of the plurality of cell connectors (16) to a signal management circuit (20) or a connection interface (22), respectively; Equipped with the cell contact system (15) also having at least one temperature sensing device (30) for measuring a temperature of the battery cell (12) at one of the plurality of cell connectors (16); The at least one temperature sensing device (30): a printed circuit board edge section (31) integral with said printed circuit board (18) and protruding from said printed circuit board into the area of ​​each of said cell connectors (16); a temperature sensor (32) mounted on a top surface of the printed circuit board edge section (31), the top surface of the printed circuit board edge section (31) being positioned deeper than a top surface of the printed circuit board (18) and deeper than a top surface of each of the cell connectors (16); a cell connector overlap section (33) of each of the cell connectors (16), the cell connector overlap section overlapping the temperature sensor (32) on the printed circuit board edge section (31) on the top surface of the printed circuit board edge section; It is formed from A cell contact system (15).

2. 2. The cell contact system of claim 1, wherein the at least one temperature detection device (30) also has a thermally conductive layer (34) between a top surface of the temperature sensor (32) and the cell connector overlap section (33) of each of the cell connectors (16).

3. 3. The cell contact system of claim 2, wherein the thermally conductive layer (34) of the temperature detection device (30) is attached to the temperature sensor (32) or to the cell connector overlap section (33) of each of the cell connectors (16).

4. 4. The cell contact system of claim 1, wherein the cell connector overlap section (33) of the temperature sensing device (30) overlaps the entire printed circuit board edge section (31) of the temperature sensing device (30).

5. 5. The cell contact system of claim 1, wherein the cell connector overlap section (33) of the temperature detection device (30) extends higher than any other contact area (16a, 16b) of the respective cell connector (16).

6. 6. The cell contact system of claim 1, wherein the printed circuit board edge section (31) of the temperature detection device (30) is positioned in the same plane as the printed circuit board (18) or at a depth greater than the printed circuit board (18).

7. 7. The cell contact system of claim 1, wherein the printed circuit board edge section (31) of the temperature detection device (30) is positioned in the same plane as or deeper than each of the cell connectors (16).

8. 8. The cell contact system of claim 1, wherein the printed circuit board edge section (31) of the temperature detection device (30) has the same layer thickness as the printed circuit board (18) or a lower layer thickness than the printed circuit board (18).

9. 9. The cell contact system according to claim 1, wherein each of the plurality of cell connectors (16) has two contact areas (16a, 16b) respectively for cell terminals (36) of a battery cell (12) and a compensation area (16c) between the two contact areas (16a, 16b), and the temperature detection device (30) is disposed within the area of ​​one of the two contact areas (16a, 16b) of each of the cell connectors (16).

10. A plurality of battery cells (12); A cell contact system (15) according to any one of claims 1 to 9, A battery module (10).

11. A method of providing a cell contact system (15) for a battery module (10) having a plurality of battery cells (12), the cell contact system comprising: a plurality of cell connectors (16) for conductively connecting cell terminals (36) of different battery cells (12); and a printed circuit board (18) having a plurality of signal lines for passing measurements from one of the plurality of cell connectors (16) to a signal management circuit (20) or a connection interface (22), the cell contact system having at least one temperature sensing device (30) for measuring a temperature of the battery cell (12) at one of the plurality of cell connectors (16); The method further comprising: providing said printed circuit board (18) with at least one integrated printed circuit board edge section (31) such that said printed circuit board edge section protrudes from said printed circuit board into the area of ​​each of said cell connectors (16) when said cell contact system (15) is in an assembled state; mounting a temperature sensor (32) on a top surface of the printed circuit board edge section (31), the top surface of the printed circuit board edge section (31) being positioned deeper than a top surface of the printed circuit board (18) and deeper than a top surface of each of the cell connectors (16); providing a cell connector overlap section (33) on each of the cell connectors (16) such that the cell connector overlap section overlaps the temperature sensor (32) on the printed circuit board edge section (31) on the top surface of the printed circuit board edge section when the cell contact system (15) is in an assembled state; A method comprising:

12. The method of claim 11, further comprising interposing a thermally conductive layer (34) between a top surface of the temperature sensor (32) and the cell connector overlap section (33) of each of the cell connectors (16).

13. The method according to claim 11 or 12, wherein the components (31, 32, 33, 34) of the temperature detection device (30) are configured and positioned as specified in any one of claims 3 to 9.

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