Holder for battery cells, battery sub-module comprising such a holder, and battery module comprising same

Abstract

The invention relates to a holder (102, 104) for battery cells, in particular round cells (200), comprising a receiving element (110, 130) and at least one electrical contact element (150), having at least one contact strip (160, 170, 180), wherein the receiving element (110, 130) has a contacting side (112, 132) which has an end face, and a connecting side (114, 134), wherein at least one battery cell receptacle row (127, 128; 136, 146, 148) is formed in the receiving element (110, 130) and has a plurality of battery cell receptacles (126, 136), wherein for receiving battery cells (200) the battery cell receptacles (126, 136) are in the form of recesses in the receiving element (110, 130) each of which recesses extends along a receptacle central axis (M110, M130) from the connecting side (114, 134) in the direction of the contacting side (112; 132), wherein the battery cell receptacles (126, 136) of a battery cell receptacle row (126, 127, 128; 136, 146, 148) lie along a row central line (L160, L170, L180), wherein the receiving element (110, 130) has on its contacting side (112, 132) a channel-like depression (K160, K170, K180) along the row central lines (L160, L170, L180), wherein the contact strip (160, 170, 180) has at least one main section (162, 172, 182). The invention is characterised in that at least two contact lugs (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b..) branch off in each case from the main section (162, 172, 182) from two opposite sides, wherein the contact element (160, 170, 180) is embedded in the receiving element (110, 130) in such a way that the main section runs parallel to the row central line (L160, L170, L180), and in that the contact strips (160, 170, 180) are held in the receiving element (110, 130) by virtue of contact lugs (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b..) being surrounded at least in some regions by portions of the receiving element (110, 130).

Description

[0001] Holder for battery cells, battery sub-module having such a holder, and battery module with it

[0002] The invention relates to a holder for battery cells, in particular cylindrical cells, for the production of a battery module, as well as a battery sub-module produced with the holder, and a battery module produced with a battery sub-module.

[0003] WO 2022 / 237986 A1 discloses a generic battery module and a battery holder in which the battery cells are arranged in a row, the battery cells of a row being connected at their positive and negative terminals to a positive terminal contact element and a negative terminal contact element, each contact element having a contact tab in the area of ​​the terminal contacts that extends laterally away from a main strand of the contact element. The contact tabs are bent at their free end such that their contact surface is parallel to the battery cell axis. The contact elements are welded to the terminals such that the contact tabs of the positive terminal extend away from the battery cell, and the contact tabs of the negative terminal overlap the battery cell.For the series connection of two battery rows, the battery rows are placed next to each other so that the end sections of the associated contact tabs overlap and can be welded together. To fix the battery cells in place, they are held in semi-circular holders that extend over the axial dimension of the battery cells.

[0004] This design has the disadvantage that the production of such a battery module is complex with regard to the welding of the electrical contact points.

[0005] The object of the invention is to provide a holder that enables simple parallel contacting, a battery submodule formed from such holders, and a battery module that allows efficient cooling of the terminals with a flowing cooling medium, in particular a liquid medium. Furthermore, the design of the holder according to the invention is intended to enable high efficiency and scalability in the assembly of battery modules.

[0006] The problem is solved for a holder by the characterizing features of claim 1 in conjunction with its preamble features, for a battery submodule by the characterizing features of claim 16 and for the battery module by the characterizing features of claim 20.

[0007] The dependent claims constitute advantageous further developments of the invention.

[0008] According to the invention, a holder for battery cells, in particular cylindrical cells, comprises a receiving element and at least one electrical contact element, which in turn has at least one contact strip made of an electrically conductive material. The contact strip serves to electrically connect the poles of one side of battery cells inserted into the holder.

[0009] The receiving element has a contacting side with an end face and a connecting side, wherein at least one battery cell receiving row is formed in the receiving element, which has a plurality of axially parallel battery cell receivings.

[0010] The end face is formed by the flat areas of the surface of the contacting side of the receiving element.

[0011] A battery cell receptacle for at least partial receptacle mounting of battery cells is formed in the form of recesses in the receptacle element and extends along a receptacle central axis from the connection side towards the contacting side.

[0012] The battery cell holder can preferably be cylindrical.

[0013] The battery cell receptacles can also have a polygonal or circumferentially wave-like cross-sectional contour. The contour line of the cross-sectional contour touches an incircle whose center defines the receptacle's central axis. According to another design, the battery cell receptacle can also have axially extending, radially inwardly directed ribs, which, preferably viewed in cross-section, are distributed around the circumference of an incircle, thus ensuring a linear alignment, particularly for cylindrical battery cells. This allows tolerances in the cross-section of the batteries to be compensated for.

[0014] The battery cell mounts of a battery cell mount row are aligned axially along a row centerline. The row centerline is parallel to the end face and connects the center axes of the mounts within a battery cell mount row.

[0015] The receiving element has a channel-like recess along the row centerline on its contact side, forming a transverse channel. This transverse channel extends along the row centerline across the entire cross-section of the receiving element. This allows the flow of a cooling medium, particularly a liquid, within the transverse channel from one side of the receiving element to the other at the contact side of the holder, thus enabling simple cooling of the terminals of the inserted battery cells.

[0016] The contact strip has a main strand, which is inserted into the receiving element such that its main strand runs parallel to the row centerline. At least two contact tabs branch off from the main strand from each of two opposite side faces, essentially perpendicular to the row centerline.

[0017] The contact strip is held in the receiving element by contact tabs being at least partially enclosed by portions of the receiving element. This secures the contact strip without affecting the transverse channel on the contacting side. Preferably, the contact tabs are overmolded, so that the contact strip is partially embedded in the receiving element, but in particular, the free end areas of the contact tabs remain open for contacting.

[0018] By fixing the contact strip to the mounting element, ideal alignment and fixation of the battery cells relative to the contact strip is ensured, guaranteeing reliable contact between the poles. This allows for efficient welding of the battery cell poles within the holder.

[0019] According to a preferred embodiment, the contact tabs in the holder are bent such that they extend at their outer ends in a plane perpendicular to the receiving center axis. This allows the contact strip to be contacted in the same contact direction as the battery cell terminals. This facilitates easy access for connecting additional conductors to the contact tabs.

[0020] In a further preferred embodiment, the contact tabs are bent such that their outer ends extend at least to the end face of the contacting side of the receiving element, thus making them accessible at the end face of the receiving element. Preferably, the contact tabs are bent twice for this purpose. Firstly, to extend obliquely from their lower position at the bottom of the transverse channel to the end face, and secondly, at the level of the end face, so that the end region of the contact tab runs parallel to the end face. Due to the parallel end region, the contact tab forms a flat contacting surface. In this way, the connected poles can be easily contacted on the upper side.

[0021] According to a particularly preferred embodiment, each terminal connection is assigned two contact tabs extending on both sides of the contact strip. This allows an electrical connection to be established via two contact surfaces per terminal of a battery cell, thereby ensuring a large conductor cross-section.

[0022] In a further advantageous embodiment, the receiving element has through holes that are parallel to the receiving center axis and through which a contact lug is accessible from the connection side of the receiving element. This allows a conductor resting on the contact lug to be connected to the contact lug from the connection side.

[0023] The contact lugs can be solid or have a mounting hole through which the conductor placed on them can be joined, particularly with a connecting element. A preferred connecting element is a screw that is screwed through the contact lug and into the conductor. The design of the contact lug is adapted to the joining method used.

[0024] In a further embodiment, the fastening can also be achieved in a material-bonded form.

[0025] This can be achieved by welding, in particular friction stir welding or laser beam welding. Other, one-sided joining methods for connecting the contact lugs to a conductor resting on them are also conceivable, for example soldering or bonding. This means that, according to the invention, both the pole with the contact strip and the contact lug with a conductor resting on the contact lug can be joined, in particular welded, in the same axial orientation.

[0026] The through-holes allow joining at the contact lugs from both sides, so that joining is possible even when the end face of the receiving element is no longer accessible. In this respect, the through-holes completely penetrate the receiving element.

[0027] The through-holes have a minimum in-circle diameter. This is preferably between 10% and 20% of the in-circle diameter of the battery cell receptacle. This ensures that sufficient cross-sectional area is available for the joining process.

[0028] The through-holes can thus be used for supplying joining elements, joining materials, joining tools, and / or for supplying energy, in particular from a laser, through the receiving element to the contact tabs. The diameter of a through-hole can vary along the length of the recess or be designed with a constant in-circle diameter. If the through-holes are cylindrical, the in-circle diameter can correspond to the circle diameter.

[0029] According to a preferred embodiment, at least one of the through holes has a non-circular cross-section. This allows orientation based on the cross-sectional contour.

[0030] In a further advantageous embodiment, the main strand of the contact strip has projections in the area of ​​the mounting center axes that extend towards the battery cell mountings. These projections bridge the distance to the battery cell terminal. The projections can be dome-shaped or formed as a stamped and bent projection in the form of a tab bent out of the main strand. Preferably, the projection can be resilient relative to the main strand, thus compensating for tolerances in the length of the battery cells or the mounting element.

[0031] The position can be chosen such that, in the area of ​​the central axis of the mounting, the distance of the side of the main strand facing the battery cell mounting from the end face of the mounting element is greater than 10% of the incircle diameter of the battery cell mounting. If a projection is present on the main strand, the distance is measured to the underside of the projection.

[0032] This roughly defines the channel depth of the transverse channel for guiding the cooling medium.

[0033] A transverse channel has a channel width in addition to its channel depth. The channel width is at least 25% of the incircle diameter of the battery cell receptacle. The channel can have a constant channel width or bulges in the area of ​​the battery cell receptacles.

[0034] In an advantageous embodiment of the invention, the receiving element comprises at least three battery cell receiving rows. In particular, the number of parallel battery cell receiving rows is a multiple of three. Preferably, the battery cell receiving rows of adjacent receiving rows are arranged offset along the row centerlines. The offset arrangement allows for a space-saving arrangement. The number of three adjacent battery cell receiving rows allows for a symmetrical arrangement around the center of the three battery cell receiving rows.

[0035] In particular, the three parallel battery cell mounting rows contain essentially identical contact strips.

[0036] This means that the essential part of the contact strips, at least in the area of ​​the poles, and especially in the design of the contact flags, is identical.

[0037] At their end, at least at one end of the main strand, the contact strips have a connecting bridge. This connecting bridge serves to make contact with another contact strip, for example, with a monitoring unit. The connecting bridges can also be interconnected. For example, connecting bridges can be cross-connected to connect battery cells of the connected recording arrays in parallel.

[0038] The design of the connecting bridges of the contact strips can vary. This is particularly relevant because, for example, with three contact strips, an L- or Z-shaped connecting bridge can be attached to each of two main strands, thus reducing the distance between the three connecting bridges. Preferably, the connecting bridges are positioned so close together that they are spaced at most two main strand widths apart. This small distance allows multiple connecting bridges to be easily integrated into a single connector, for example, or to be easily short-circuited together.

[0039] Preferably, a symmetrical geometry is used for the connecting bridge such that, if necessary, identical connecting bridges can be used for connection with two external contact strips.

[0040] In this way, a three-beam contact element can be manufactured from only two components: a main strand with contact tabs and a connecting bridge. Alternatively, the contact element, comprising a contact strip and a connecting bridge, can also be manufactured as a stamped part. In particular, several contact strips can be manufactured as a group, so that, for example, three contact elements located next to each other in the receiving element are always stamped as a group. This enables cost-effective and efficient manufacturing.

[0041] According to a particularly preferred embodiment, the contact strips are stamped or rather stamped-bent parts made of a conductive material, in particular copper or a copper alloy.

[0042] The receiving element is preferably a plastic injection molded part, in which the contact strips are overmolded in such a way that they are fixed in the receiving element.

[0043] The receiving element can have walls that form the battery cell receptacle. The walls can preferably be formed from a solid surface. Alternatively, openings in the walls are also conceivable.

[0044] The invention further relates to a battery sub-module according to claim 16, comprising previously described holders according to the invention.

[0045] A battery submodule according to the invention comprises a submodule, wherein each submodule includes a first holder and a second holder according to the invention, as well as battery cells. The first holder and the second holder are each connected to each other at their connecting side, such that two opposing battery cell receptacles of the respective holders form a receiving space for holding a battery cell. Battery cells are received in the receiving spaces, the poles of which are each electrically connected to the respective contact strips.

[0046] In this way, a sub-module that can be contacted on both sides, as described above, can be provided, which allows a cooling medium to be guided across the poles on both pole sides and can be manufactured efficiently.

[0047] According to a preferred embodiment, the first holder and the second holder are designed with regard to their connection such that they each possess corresponding guide structures that interact when connected. These can be configured to connect the contacting sides and / or the connecting sides.

[0048] In a further advantageous embodiment, a battery submodule according to the invention comprises a first submodule and a second submodule, each having a first contact side and a second contact side. The arrangement is such that the contact tabs of the first contact side of the first submodule are in electrically conductive contact with the opposing contact tabs of the second contact side of the second submodule. In this way, the battery submodule according to the invention can be easily scaled due to the stackability of the submodules.

[0049] In this way, the adjacent battery cell rows of the sub-modules are connected in series in a scalable manner, whereby the parallel connection of the battery cell rows of a sub-module is made possible via the connection of the contact strips.

[0050] According to the arrangement according to the invention, a first sub-module and a second sub-module alternate in a stack. The first sub-module and the second sub-module are preferably matched to each other at their contact surfaces such that the holders lying next to each other in the stack are guided and, in particular, aligned.

[0051] The first and second sub-modules can preferably be identical, so that even with an alternating arrangement, a large number of identical sub-modules can ultimately be stacked on top of each other. Preferably, the contact tabs of the adjacent sub-modules are joined, in particular by a metallurgical bond. This ensures high stability and reliable electrical contact.

[0052] According to a particularly advantageous embodiment, the opposing contact tabs of the adjacent holders are welded together. To manufacture such a battery sub-module, the contact tabs of the first holder of a sub-module are first joined to the corresponding contact tabs of a preceding sub-module in the stack. This is done through the through-holes of the first holder. Joining methods can include, for example, screwing or material-bonding. If the second holder also has through-holes, the assembly can be carried out analogously with the second holder.

[0053] Only then is the next sub-module completed by placing the second holder onto the first. Subsequently, the terminals of the battery cells housed in the next sub-module are preferably connected to the respective contact strips, ideally by welding. The battery sub-module can then be extended by another sub-module following the same procedure.

[0054] If the poles of the battery cells are to be joined to the contact strip, the battery cells are inserted into the first holder and connected to the contact strips by a material bond, preferably by welding, before the first holder is attached to the preceding second holder.

[0055] According to a further aspect of the invention, this relates to a battery module according to claim 20, comprising a housing in which a previously described battery sub-module according to the invention is received. A first contact side and a second contact side are located at the free ends of the battery sub-module, wherein the contact tabs at the free ends are welded to at least one current distribution plate.

[0056] The housing is preferably liquid-tight, so that immersion cooling of the battery cells, especially the poles of the battery cells, can take place.

[0057] The design of the current distribution plates at the free ends of the battery submodule allows both the interconnection of the serially connected battery cell arrays and the provision of current for the battery module. According to a preferred embodiment of the invention, a current distribution plate is multilayered, with a first thinner layer welded to the contact tabs and a thicker layer welded to the thinner layer.

[0058] In a further advantageous embodiment, the material thickness of the first layer preferably corresponds approximately to the material thickness of the contact strip.

[0059] The power distribution plate can preferably have features that are preferably located along the row centerlines, particularly in the area of ​​the respective receiving center axes.

[0060] If the power distribution plate is made of two layers, the second layer may have through holes in this area. If the power distribution plate is a single piece, a blind hole may be provided in this area, with the material thickness of the remaining material approximately corresponding to the material thickness of the contact strip.

[0061] This allows the contact strip, especially in the area of ​​the poles, to be directly contacted by the power distribution plate. This, together with the contacting of the contact tabs, ensures the largest possible conductor cross-section at the transition from the battery sub-module to the power distribution plate.

[0062] According to a further advantageous embodiment, the power distribution plate can have through holes around the blind holes.

[0063] Further advantages, features and application possibilities of the present invention will become apparent from the following description in conjunction with the exemplary embodiments shown in the drawings.

[0064] In the drawing, this means:

[0065] Fig. 1 shows a perspective view of a holder according to the invention;

[0066] Fig. 2 is a perspective view of a holder according to the invention; Fig. 3 is a sectional view of the representation according to Fig. 2;

[0067] Fig. 4 shows detail A of the sectional view according to Fig. 3;

[0068] Fig. 5a shows detail B of Fig. 2;

[0069] Fig. 5b shows a partial top view of the connection side of the receiving element according to Fig. 2;

[0070] Fig. 6 shows a partial sectional view of a connection between two holders according to the invention;

[0071] Fig. 7 shows a perspective view of a battery submodule according to the invention;

[0072] Fig. 8a shows a perspective view of a battery submodule according to the invention;

[0073] Fig. 8b shows an enlarged view of the transition area between two sub-modules of the battery module according to Fig. 8;

[0074] Fig. 9 shows a perspective view of a battery module according to the invention;

[0075] Fig. 10 shows a perspective view of a contact element;

[0076] Fig. 11 shows a perspective view of another embodiment of a contact element, and

[0077] Fig. 12 shows a schematic top view of a battery module according to the invention.

[0078] Fig. 1 shows a perspective view of a holder 102 according to the invention for battery cells, in particular cylindrical cells 200. The holder 102 comprises a receiving element 110 and three electrical contact elements 150 for contacting the poles of the inserted cylindrical cells 200. A contact element 150 comprises three contact strips 160, 170, 180. The contact strips 160, 170, 180 are made of an electrically conductive material. The receiving element 110 is made of plastic and has a contacting side 112 with an end face and a connecting side 114. The contact strips 160, 170, 180 are overmolded with the receiving element 110 as metallic inserts.

[0079] The receiving element 110 has nine battery cell receiving rows 127, 128, 129, wherein in the present example each battery cell receiving row has eight battery cell receivings 116. A battery cell receiving 116 is provided for at least partially receiving a battery cell 200 and is designed in the form of recesses in the receiving element 110.

[0080] The recesses extend along a central axis M110 from the connection side 114 towards the contacting side 112. The battery cell receptacles are described in more detail in Figures 4 and 6.

[0081] The battery cell receptacles 116 of a battery cell receptacle row 127, 128, 129 lie along a row centerline L160, L170, L180, which is parallel to the end face and connects the receptacle center axes M110 of the battery cell receptacle row 127, 128, 129. The receptacle element 110 has a channel-like recess K160 on its contacting side 112 along the row centerline L160.

[0082] The channel-like depression K160 extends along the row centerline L126 over the entire cross-section of the receiving element 110 and forms a transverse channel.

[0083] The contact strips 160, 170, 180 each have a main strand 162, 172, 182, from which at least two contact tabs 164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b branch off from each of the two opposite sides of the main strand 162, 172, 182. The contact element, in particular the contact strips 160, 170, 180, are described in more detail in Figures 10 and 11.

[0084] The contact strips 160, 170, 180 are received in the receiving element 110 such that the main strand 162, 172, 182 runs parallel to the row centerline L160, L170, L180. The contact strips are held in the receiving element 110 by the fact that contact tabs 164a, 166a; 164b, 166b are at least partially enclosed by the receiving element 110. Thus, the end regions of the contact tabs 164a, 166a; 164b, 166b are accessible and can be contacted. Nevertheless, the contact strips 160, 170, 180 are positively locked in all directions. For guidance and connection with a further holder for the production of a battery submodule according to the invention, the holder 102 has guide pins 126a on its contacting side 102.

[0085] Fig. 2 shows a further perspective view of another embodiment of a holder 104 according to the invention, comprising a receiving element 130 in which, as in the holder 102 according to Fig. 1, contact strips 160, 170, 180 are received, whereby for the sake of clarity only three, contact strips 160, 170, 180 are explicitly labelled. The holder 104 is essentially identical to the holder 102 described in Fig. 1. The only difference is that, instead of the guide pins 126a, 126b, the receiving element 130 has guide grooves 136 which can be connected to the guide pins 126a, 126b of a holder 102 of the design according to Fig. 1 in order to connect the contacting surfaces 112, 132 of the holders 102, 104 to each other.

[0086] The holder 104 according to Fig. 2 also has battery cell receiving rows 137, 138, 139, along which channel-like recesses are present in the receiving element 130, which are explained in more detail with reference to detail B in Fig. 5.

[0087] Fig. 3 shows a sectional view of the representation according to Fig. 2 along section line AA. The contact strips 160, 170, 180 are mounted on the contacting side 132 and define the battery cell receptacles 136 in the contacting direction. Battery cells 200 are inserted into the battery cell receptacles 136 of the receiving element 130 from the connection side 134, as described in more detail in Fig. 7, until their terminals contact the respective contact strip 160, 170, 180.

[0088] The height HB of the battery cell holders 136 is adapted to the type of arrangement. In the present example, the height corresponds to half the axial dimension of a battery cell 200. The same applies to a corresponding holder 102, according to Fig. 1, so that with two connected holders, namely a first holder 102 and a second holder 104, the battery cells 102 are completely enclosed and each of their poles contacts the respective contact strip 160, 170, 180.

[0089] Fig. 4 shows detail A of the sectional view according to Fig. 3 in an enlarged representation. The contact strips 160, 170, 180 are received in the receiving element 130 such that the contact tabs 184e and 186e, as well as the contact tabs 164e, 166e, are held axially in the receiving element 130 in the area where they are bent. This type of retention applies in this embodiment to all contact tabs of all contact strips of the respective holder 102, 104. The battery cell receptacles 136 are designed in the form of a cylindrical recess, as explained in more detail in Fig. 5b. The battery cell receptacles 136 each have a receiving center axis M130.Since the poles of the battery cell mounted in the battery cell holder 136 are to be located there, the main strands 162, 172, 182 of the contact strips 160, 170, 180 have protrusions 168e, 188e to improve the contact of the poles and to allow for tolerance compensation with regard to manufacturing tolerances. In particular, the distance DB from the end face to the underside of the protrusion 168e, 188e, ... is relatively large, so that sufficient space is available for fluid flow between the poles and the level of the end face, thus enabling effective temperature control of the battery cells.

[0090] Furthermore, through holes 180 are provided in the receiving element 130 parallel to the center axes M130. The through holes 138 extend over the entire height of the receiving element 130 and are arranged such that the contact lugs 164e, 166e, 184e, 186e are accessible from the connection side 134 of the receiving element 130 through the through holes 138. This allows the contact lugs 164e, 166e, 184e, 186e to be joined, in particular welded, to conductors resting on the contact lugs from the connection side 134 of the receiving element 130. This enables welding of the contacts even if the contacting side is not accessible. When the pole of the battery cells is welded to the respective main strand, the welding directions for welding the poles and for welding the contact tabs 164e, 166e, 184e, 186e are axially parallel.

[0091] Fig. 5a shows another view of detail B of Fig. 2. This detail relates to an area of ​​the receiving element 110, where the contact strips are hidden in this illustration to better show the contour of the receiving element 130. The channel-like recess K180, which extends along the battery cell receiving row 139, can be seen in the illustration. Liquid cooling medium can be guided through this channel-like recess K180 along the battery cell receiving row 139, over the terminals of the battery cells, across the entire extent of the receiving element 130. The same applies to all battery cell receiving rows of the receiving element 130.

[0092] Fig. 5b shows a partial top view of the receiving element 130 according to Fig. 2, looking at the connection side 134. In this view, the battery cell receptacles 136 are visible in their circular cross-section. The receptacle center axes M130 are defined by the center of the incircle, and the diameter Dz by the diameter of the incircle. In this case, the incircle corresponds to the circular cross-section. A high packing density can be achieved with the circular cross-section, but other shapes, especially polygonal designs, are also conceivable. As in Fig. 5a, the triangular contour of the through holes 138 is also visible, the diameter DD of which is determined by the incircle diameter of the cross-section. The battery cell receptacles 136 are limited at their edges by stop surfaces 135 in the direction of the contact strips 160, 170, 180. This prevents the battery cells 200 from acting on the contact strips 160, 170, 180.This improves stability and makes handling easier.

[0093] Fig. 6 shows a partial sectional view in which a first holder 102 according to the invention is connected to a second holder 104 according to the invention via their respective contact sides 112, 132. The contact tabs 184e and 166e lie on top of each other and can be joined together through the through holes 118, even if the second receiving element 130 is no longer accessible at its contact side 132.

[0094] The holders 102, 104 shown here are joined together with their connecting sides 134, 114 to form a sub-module. The receiving elements 110, 130 are matched in their heights HA, HB such that the sum of HA and HB equals the axial dimension, i.e., the length of a battery cell. In the present embodiment, HA and HB are equal, thus each corresponding to half the length of the battery cell.

[0095] Fig. 7 shows a submodule 50 of a battery submodule in a perspective view. The submodule 50 comprises a first holder 102, a second holder 104 and, in this case, 72 battery cells 200.

[0096] The battery cells 200 are welded to their respective contact strips 160, 170, and 180 at their poles. To assemble the sub-module 50, for example, the first receiving element 110 is fitted with battery cells 200. Furthermore, the contact strips 160, 170, and 180 of the first receiving element 110 are welded to the poles of the battery cells 200. In this case, three contact strips 160, 170, and 180 each form a contact element 150.

[0097] The battery cells 200, each connected via a contact element 150, form a block B1, B2, B3. The battery cells 200 of the three adjacent contact elements 150 form three blocks B1, B2, B3, which in the present embodiment are to be connected in series. Alternatively, the adjacent contact strips 160, 170, 180 can also be left unconnected, resulting in individual rows of eight, each of which can be connected in series with rows of eight from another module. The connection of the first receiving element 110 to the second receiving element 130 is made flush via the guide pins 126b, which interact with the guide grooves 146. This ensures that the contact tabs of the contact strips are aligned. In addition, the guide pins 126b have a slight interference with the guide grooves, so that once the two receiving elements are joined, they provide a connection with high strength and rigidity.

[0098] In the event that a stack of sub-modules 50 is to be produced to manufacture a larger battery sub-module 80, the first receiving element 110 with its received battery cells 200 is first connected, in particular welded, to a second receiving element 130, for example, located above the first receiving element 110 (see Fig. 8a).

[0099] The joining of the superimposed contact flags is done through the through holes 118 of the first receiving element 110, before the next first holder 104 is assembled with its connecting side 134 with the connecting side 114 of the first holder 102 that has just been joined.

[0100] The guide grooves 146 of the second receiving element 130 extend over the entire height of the second receiving element 130, so that they can interact with guide pins 126b, which are arranged on the connection side 112 of the first receiving element 110. This ensures that the first receiving element 110 is aligned with the second receiving element 130 when connected via the connection side 114. Furthermore, the guide grooves 146 can also interact with the guide pins 126a, so that the contacting sides 112, 132 of the holders 102, 104 are aligned and can be firmly connected.

[0101] When the second holder 104 is connected to the first holder 102, the poles of the battery cells 200 can be connected to the respective contact strips 160, 170, 180, preferably welded.

[0102] Fig. 8a shows a perspective view of a battery submodule 80 according to the invention, in which two first holders 102 and two second holders 104 are connected to each other as described above.

[0103] In this arrangement, six blocks of 24 parallel-connected battery cells 200 can be connected in series. To connect the 24 battery cells 200 in parallel, three adjacent contact strips 160, 170, 180 are joined together in this embodiment to form a contact element 150. The contact strips 160, 170, 180 extend beyond the receiving element with their connecting webs 169, 179, 189. They can serve as measuring points for analyzing the blocks. If the contact strips are not connected together, individual rows can be tested.

[0104] Furthermore, it can be seen how the guide pins 126a, 126b alternately engage in the guide grooves 146 of the stacked sub-modules 50 to form a rigid battery sub-module 80.

[0105] In this way, a large number of sub-modules can be connected to form a battery sub-module 80, as required.

[0106] Fig. 8b shows an enlarged view of the transition area between the sub-modules 50. It is clearly visible how the channel-like recesses in the receiving elements 110, 130 combine to form fully enclosed channels K160, K180; K170, K170; K180, K160 with a channel height twice the channel height KH of the respective receiving element 110, 130. Liquid cooling medium, in particular, can be guided through these channels to temperature-control the poles.

[0107] Fig. 9 shows a battery module 10 with a battery sub-module 80, which has 5 sub-modules 50. The battery sub-module is connected at its free ends to current distribution plates 20, 22, 24, 26 such that a series connection of 15 blocks of 24 parallel-connected battery cells 200 is formed. The contacts 14, 16, to which the battery module is connected, are connected to the current distribution plates 20 and 26.

[0108] Furthermore, the directions of the arrows are used to illustrate the flow of the cooling medium. Thus, on one side of the battery submodule 80, a main flow H1 can occur in a first direction, and on the opposite side, a main flow H2 can occur in a second direction, resulting in a transverse flow through the channels over the poles of the battery cells.

[0109] Fig. 10 shows a perspective view of a contact element 150 with three contact strips 160, 170, 180. The contact strips 160, 170, 180 each have, as previously described, a main strand 162, 172, 182, from which at least two contact tabs 164a, 164b, 164e, 164a, 166b, 166e; 184a, 184b, 186a, 186b branch off from the main strand 162, 172, 182 from two opposite sides, in particular side surfaces. The contact strips 160, 170, 180 are stamped and bent parts that are stamped from a sheet material preferably more than 0.3 mm thick. The contact tabs 164a, 164b, 164e, 166a, 166b, 166e; 184a, 184b, 186a, 186b are doubly bent so that they extend upwards from the plane of the main strand 162, 172, 182, where they are bent a second time so that the end regions of the contact tabs again extend parallel to the surface of the main strand. A pair of contact tabs 164a, 166a; ... 164e, 166e; is provided for each pole contact.On the main strand 162 in the area of ​​the pole contact there are features 168a, ..., 168e, which in the present embodiment are also a U-shaped punched and bent contact tab 168a.

[0110] The double-bent contact tabs and the bent contact plate create a resilient system that can compensate for manufacturing tolerances, particularly axial ones. The contact plates 168a, 168e, and 188a are designed to achieve the largest possible area of ​​resilient contact between the poles.

[0111] The contact tabs 164a, 164b, 164e, 164a, 166b, 166e; 184a, 184b, 186a, 186b have a constant width. This ensures easy manufacturing. In the present embodiment, L-shaped connecting webs 189, 169 are attached to the end regions of the outer main strands 162, 182, and a straight connecting web 179 is attached to the central main strand 172. The connecting webs 169, 179, 189 can be connected to each other. These can be connected, for example, by a weld or a clamp, thereby short-circuiting the poles that touch the contact element. Alternatively, the connection can be punched out. In an alternative embodiment, the connecting webs 169, 179, 189 can also be individually incorporated into a connector.

[0112] Figure 11 shows another embodiment of contact strips 300 according to the invention. In this embodiment, mounting holes 330 are provided in the end regions of the contact lugs 324a, 326a, 326e, 324e. When two such contact strips 300 are positioned next to each other, with the contacting sides of two holders connected, the two contact strips can be screwed together through the mounting holes 330. The screws then have a head diameter that is smaller than the diameter DD of the through holes 118, 138 of the receiving elements 110, 130.

[0113] Furthermore, in this embodiment, the contact strips 320 have identical connecting webs 329. As previously described, the connecting webs 329 can be connected to each other and, in particular, to correspondingly opposing contact strips 300 to produce a battery submodule according to the invention.

[0114] Fig. 12 shows a schematic top view of a battery module 10 according to the invention. The battery module comprises a liquid-tight housing 16 in which a battery sub-module 80 is received, the sub-module being provided at its free ends with current distribution plates 24, 26, one of which is connected to the terminal 14. A liquid cooling medium flows around the battery sub-module 80 for temperature control and, as indicated by the arrows, flows transversely through the transverse channels and parallel to the housing according to the main flows H1 and H2.

[0115] The housing 16 may preferably also have channels 18, which are also supplied with a cooling medium for heat exchange with the cooling medium contained in the housing 16.

[0116] The power distribution plates 24, 26 are designed in two layers, comprising a lower thinner layer 32 and an upper thicker layer 34. The upper thicker layer 34 has through holes 36 in the area of ​​the contact lugs, so that the thinner layer 32 is accessible.

[0117] This design can also be implemented as a plate with corresponding blind holes.

[0118] The lower, thinner layer is adapted in its material thickness to the material thickness of the contact strips, especially the contact tabs.

Claims

P a t e n t a n s p r ü c h e 1. Holder (102, 104) for battery cells, in particular cylindrical cells (200), comprising a receiving element (110, 130) and at least one electrical contact element (150), having at least one contact strip (160, 170, 180), wherein the receiving element (110, 130) has a contacting side (112; 132) having an end face and a connecting side (114, 134), wherein at least one battery cell receiving row (127, 128; 136, 146, 148) is formed in the receiving element (110, 130), which has a plurality of battery cell receivings (126, 136), wherein the battery cell receivings (126, 136) for at least partial receiving of battery cells (200) are formed in the receiving element (110, 130) each extending along a The central axis of the battery cell receptacles (M110, M130) extends from the connection side (114, 134) towards the contacting side (112;132), wherein the battery cell receptacles (126, 136) of a battery cell receptacle row (126, 127, 128;136, 146, 148) lie along a row centerline (L160, L170, L180) which is parallel to the end face and connects the receiving center axes (M110, M130) of the battery cell receiving row (126, 127, 128; 136, 146, 148), wherein the receiving element (110, 130) has a channel-like recess (K160, K170, K180) on its contacting side (112, 132) along the row centerlines (L160, L170, L180), wherein the contact strip (160, 170, 180) has at least one main strand (162, 172, 182), characterized in that at least two contact tabs extend from each of two opposite sides of the main strand (162, 172, 182). (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b;184a, 184b, 186a, 186b ..) branch off, wherein the contact element (160, 170, 180) is embedded in the receiving element (110, 130) such that the main strand runs parallel to the row center line (L160, L170, L180), and that the contact strips (160, 170, 180) are held in the receiving element (110, 130) by contact flags (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b ..) being at least partially enclosed by sub-areas of the receiving element (110, 130).

2. Holder according to claim 1, characterized in that the contact flags (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b ..) are overmolded by the receiving element (110, 130), in particular completely.

3. Holder according to claim 1 or 2, characterized in that the contact flags (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b ..) are bent such that they extend at their outer ends in a plane that is orthogonal to the receiving central axis (M110,M130).

4. Holder according to claims 1 to 3, characterized in that the contact flags (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b ..) are bent in such a way that they extend at their outer ends to at least the end face of the contacting side (112, 132) of the receiving element (110, 130).

5. Holder according to one of the preceding claims, characterized in that the receiving element (110, 130) has through holes (118, 138) which are parallel to the receiving central axis (M110, M130) and through which a contact flag (164a, 164b, 166a, 166b; 174a, 174b, 176a, 176b; 184a, 184b, 186a, 186b ..) is accessible from the connecting side (114, 134).

6. Holder according to claim 4, characterized in that the through holes (118, 138) have a minimum incircle diameter (DD) which is between 10% and 20% of the incircle diameter (Dz) of the battery cell receptacle (126, 136).

7. Holder according to claim 4 or 5, characterized in that at least one of the through holes (118, 138) has a non-circular cross-section.

8. Holder according to one of the preceding claims, characterized in that the main strand of the contact strip (160, 170, 180) has projections in the area of ​​the receiving central axes (M110, M130) which extend in the direction of the battery cell receivings (116, 136).

9. Holder according to one of the preceding claims, characterized in that the receiving element (110, 130) has at least three parallel battery cell receiving rows (127, 128, 129; 137, 138, 139), wherein the battery cell receivings of adjacent battery cell receiving rows (127, 128, 129; 137, 138, 139) are arranged offset along the row center lines.

10. Holder according to one of claims 5 to 8, characterized in that in the three parallel receiving rows (127, 128, 129; 137, 138, 139) identical contact strips (160, 170, 180) are received in the area of ​​the main strand (162, 172, 182), the main strands (162, 172, 182) of which transition into connecting webs (169, 179, 189).

11. Holder according to claim 9, characterized in that each connecting web (169, 179, 189) is welded to a main strand (162, 172, 182) and in particular the connecting webs (169, 179, 189) of a contact element (150) are welded together.

12. Holder according to one of the preceding claims, characterized in that the contact strips (160, 170, 180) comprise a stamped or stamped-bent part.

13. Holder according to one of the preceding claims, characterized in that the receiving element (110, 130) is a plastic injection molded part.

14. Holder according to one of the preceding claims characterized in that the contact element (150) has two contact tabs (164a, 166a, ...; 174a, 176a, ...; 184a, 186a, ... ) in the area of ​​each intersection of the main strand (162, 172, 182) with a receiving central axis (M110, M130), which branch off on both sides from the main strand (162; 172; 182), preferably at right angles, from the main strand (162; 172; 182).

15. Holder according to one of the preceding claims, characterized in that in the area of ​​the receiving central axis (M110, M130), the distance (DB) of the end face of the receiving element (110, 130) is greater than 10% of the diameter (Dz) of the incircle of the cross-section of the battery cell receiving (116, 136).

16. Battery submodule (80), comprising at least one submodule (50), comprising at least one first holder (102) and one second holder (104) according to any one of the preceding claims 1 to 15, and battery cells (200), wherein the first holder (102) and the second holder (104) are each connected to each other at their connecting side (114), 134) and each pair of opposing battery cell receptacles (116, 136) form a receiving space for holding a battery cell (100), wherein each receiving space contains a battery cell (200) whose poles each bear electrically to the respective main strand (162, 172, 182) of the associated contact element (150).

17. Battery sub-module according to claim 16, characterized in that the first holder (102) and the second holder (104) have corresponding guide structures (146, 126b) on their respective connection side (114, 134) and / or their respective contacting side (102, 104) which interact in the connected state.

18. Battery submodule (80), comprising at least two submodules according to claims 16 to 17, wherein a first submodule (50) and a second submodule (50) each have a first contacting side (134) and a second contacting side (114), wherein contact tabs (164a, 166a, ...; 174a, 176a, ...; 184a, 186a, ... ) of the first contacting side (114) of the first submodule (50) are connected to opposite contact tabs (164a, 166a, ...;174a, 176a,...; 184a, 186a,... ) of the second contacting side (134) of the second submodule (50) are electrically conductive.

19. Battery sub-module according to claim 18, characterized in that the contact tabs (164a, 166a, ...; 174a, 176a, ...; 184a, 186a, ... ) of the first contacting side (114) of the first sub-module (50) are connected to the contact tabs opposite them. (164a, 166a, ...;174a, 176a,...; 184a, 186a,... ) of the second contacting side (134) of the second sub-module (50) are joined by joining, in particular by screwing or laser welding.

20. Battery module comprising a battery sub-module according to one of claims 16 to 19, characterized in that a first contacting side (114) and a second contacting side (134) are located at the free ends of the battery sub-module (80), wherein the contact tabs (164a, 166a, ...;174a,176a,...; 184a, 186a,... ) are welded to a current distribution plate (20, 22, 24, 26).

21. Battery module according to claim 20, characterized in that the current distribution plate (20, 22, 24, 26) is formed in multiple layers, wherein a first layer is welded to the contact tabs (164a, 166a,...; 174a, 176a,...; 184a, 186a,... ) and a second layer is welded to the first layer, wherein the material thickness of the first layer is thinner than the material thickness of the second layer.

22. Battery module according to claim 21, characterized in that the material thickness of the first layer corresponds approximately to the material thickness of the contact strip (160, 170, 180).

23. Battery module according to claim 22, characterized in that the first layer (32) has, in particular, dome-shaped, elevations extending in the direction of the battery cell receptacle, wherein the elevations are arranged along the row centerlines and are located in particular in the area of ​​the poles.

24. Battery module according to one of claims 19 to 23 characterized in that the thicker layer (34) is provided with through holes (36) whose arrangement is designed such that they extend coaxially to the protrusions.

25. Battery module according to claim 21, characterized in that the current distribution plate is provided with blind holes, the arrangement of which corresponds to the arrangement of the centers and the remaining residual base thickness preferably corresponds approximately to the thickness of the contact tabs.

26. Battery module according to claim 25, characterized in that the current distribution plate has several through holes around the blind holes.

Images