Energy storage system with at least one energy storage cell for storing electrical energy, and method for producing such an energy storage system

Abstract

The invention relates to an energy storage system (1) with at least one energy storage cell (2) for storing electrical energy, wherein the energy storage cell (2) has at least one contact terminal (3), in particular in the form of a connection pole, and wherein a carrier (4), in particular in the form of a printed circuit board, is associated with the at least one energy storage cell (2), wherein the at least one contact terminal (3) of the energy storage cell (2) is galvanically connected via a solder connection in particular to a conductive track of the carrier (4), and wherein an adhesive layer (5) is formed at least partially or in some regions between the energy storage cell (2) and the carrier (4), via which adhesive layer the energy storage cell (2) is connected to the carrier (4) in an integrally bonded manner.

Description

[0001] August 25, 2025

[0002] Clarios Advanced Solutions GmbH M / JCI-542-PC CPS Technology Holdings LLC TR / akk

[0003] Energy storage system with at least one energy storage cell for storing electrical energy, and method for manufacturing such an energy storage system.

[0004] Description

[0005] The present invention relates to an energy storage system with at least one energy storage cell for storing electrical energy. According to a further aspect, the invention relates to a method for manufacturing such an energy storage system.

[0006] Energy storage systems of the type considered herein are used in many fields of technology. The present invention relates in particular to the field of energy storage systems for vehicles, wherein these are aircraft or watercraft, track-guided vehicles, or preferably road vehicles. Road vehicles are understood to include, in particular, passenger cars, trucks, buses, or motorhomes.

[0007] As part of optimizing the energy balance of vehicles, especially road vehicles, and particularly to reduce fuel consumption, existing vehicle batteries are being integrated into various concepts, for example in start / stop systems or energy recuperation during braking. Vehicles are also increasingly equipped with in-vehicle systems that require an electrical power supply.

[0008] Lead-acid batteries are typically used as starter batteries, but their low energy density makes them quite heavy. Lithium-ion batteries, on the other hand, have a relatively high energy density. Furthermore, lithium-ion batteries offer advantages such as a longer lifespan, lower self-discharge, improved fast-charging capability, and shorter maintenance intervals compared to conventional lead-acid batteries. MEISSNER BOLTE M / JCI-542-DE

[0009] 2

[0010] Overall, new requirements are being placed on energy storage systems, particularly batteries, that go beyond the previous requirement of being suitable for starting an internal combustion engine. At the same time, modern energy storage systems that meet these new requirements should ideally have the same installation space as existing batteries; that is, they should not require any additional installation space, and the external dimensions should remain largely unchanged. In general, due in particular to the increasing number of energy consumers, ever higher demands are being placed on the performance, weight, reliability, and manufacturing costs of energy storage systems in vehicles.

[0011] The invention is therefore based on the objective of providing an energy storage system with one or more energy storage cells for storing electrical energy, which offers improved properties for the aforementioned novel vehicle concepts with comparable external dimensions.

[0012] The invention is primarily aimed at making an energy storage system for series production, especially large-scale production, more efficient, particularly with regard to automated manufacturing processes in automotive applications. Furthermore, an improved assembly method for such energy storage systems is to be provided.

[0013] With regard to the energy storage system, the problem underlying the invention is solved by the subject matter of independent claim 1, with advantageous further developments of the energy storage system according to the invention being specified in dependent claims 2 to 9.

[0014] With regard to the manufacturing process, the problem underlying the invention is solved by the subject matter of dependent claim 10, with advantageous further developments of the inventive process being specified in dependent claims 11 and 12.

[0015] Accordingly, the invention relates in particular to an energy storage system with at least one energy storage cell for storing electrical energy, wherein the energy storage cell has at least one contract terminal, in particular in the form of a terminal pole, and wherein the at least one energy storage cell is associated with a carrier, in particular in the form of a printed circuit board. MEISSNER BOLTE M / JCI-542-DE

[0016] 3

[0017] It is provided that at least one contract terminal of the energy storage cell is galvanically connected via a soldered connection, in particular to a conductor track of the carrier or the circuit board.

[0018] In order to optimize the mechanical connection between the energy storage cell and in particular the carrier designed as a printed circuit board, it is provided according to the invention that at least partially or in certain areas an adhesive layer is formed between the energy storage cell and the carrier, via which the energy storage cell is materially bonded to the carrier.

[0019] The adhesive layer formed between the energy storage cell and the substrate performs a dual function: firstly, the bonded connection optimizes the mechanical connection between the energy storage cell and the substrate (especially the printed circuit board) provided by the soldered joint, thus eliminating the need for additional connections or frame elements. Secondly, the adhesive layer also acts as an insulator, electrically isolating the conductive traces of the substrate (especially the printed circuit board) from the energy storage cell.

[0020] According to implementations of the energy storage system according to the invention, the carrier has a top side facing at least one storage cell and a bottom side opposite the top side, wherein at least one solder lug or at least one solder pad, in particular a solder pad, is provided at least on the top side of the carrier, via which the at least contract terminal of the energy storage cell is galvanically connected, in particular to the conductor track of the carrier.

[0021] This design variant has the advantage that the galvanic connection between the at least one contract terminal of the energy storage cell and the solder pad or solder surface of the carrier can be made using a dip soldering or wave soldering process. This allows for particularly efficient manufacturing of the energy storage system. Of course, other soldering methods are also possible.

[0022] The at least one solder lug or soldering surface is designed in particular to connect the energy storage cell galvanically, especially to the MEISSNER BOLTE M / JCI-542-DE

[0023] 4

[0024] The conductor track of the carrier is mechanically connected to the contract terminal and electrically connected.

[0025] According to preferred implementations of the energy storage system, the carrier has a through-opening or bore in the area of ​​the at least one energy storage cell, through which the adhesive material necessary for forming the adhesive layer is introduced or can be introduced into the area between the carrier and, in particular, between the top of the carrier and the energy storage cell during the manufacture of the energy storage system.

[0026] By providing such a through-hole or bore, the adhesive material can penetrate from the back of the carrier into the area between the energy storage cell and the carrier. This allows for complete automation of the manufacturing process.

[0027] It is preferred that the through-opening or bore on the top of the carrier opens into an area which is preferably centrally and, in particular, substantially centrally aligned with an end face of the energy storage cell.

[0028] This design variant has the advantage that the adhesive layer can be applied locally in the form of adhesive pads. This saves material (adhesive material) and reduces the overall weight of the energy storage system.

[0029] In this context in particular, it is advantageous that, if the energy storage cell has several contract terminals, a central area of ​​the adhesive layer is formed equidistant to the at least two contract terminals in order to form a uniform, material-bonded connection between the energy storage cell and the substrate.

[0030] To effectively achieve electrical insulation using the adhesive layer, the distance between the carrier and, in particular, the top surface of the carrier facing an end face of the energy storage cell, and the energy storage cell, and especially the end face of the energy storage cell, should be at least 1 mm, preferably at least 2 mm, and even more preferably at least 3 mm. MEISSNER BOLTE M / JCI-542-DE

[0031] 5

[0032] The energy storage system according to the invention is particularly suitable for applications in which a supercap (supercapacitor) or ultracap (ultracapacitor) is used as the energy storage cell.

[0033] Such energy storage cells are characterized by excellent properties, in particular high cycle stability, long service life, large temperature range, high power density, high energy efficiency, high vibration resistance, high acceleration forces, and maintenance-free operation.

[0034] Of course, the invention is not limited to supercapacitors or ultracapacitors as energy storage cells. In other words, the invention also relates to energy storage systems in which the at least one energy storage cell is designed as an electrochemical accumulator. Suitable electrochemical accumulators include, in particular, a lithium-ion battery, a lithium-polymer battery, but also a nickel-cadmium battery or a nickel-metal hydride battery.

[0035] Preferably, the at least one energy storage cell is connected to a battery management system via the carrier, which is designed in particular as a printed circuit board.

[0036] It is advantageous for the carrier itself to be part of a battery management system assigned to the energy storage system.

[0037] The battery management system is an electronic circuit used to monitor and control the performance, safety, and lifespan of the individual energy storage cells within the energy storage system. The system monitors key parameters such as the state of charge (SoC), voltage, current flow, and temperature of each individual energy storage cell, as well as the overall energy storage system. This data is used to optimize the energy storage system's performance and to identify and, if necessary, resolve potential problems.

[0038] In the manufacturing process according to the invention, at least one energy storage cell and a carrier, in particular in the form of a printed circuit board, are first provided. Subsequently, the at least one contract terminal of the MEISSNER BOLTE M / JCI-542-DE

[0039] 6

[0040] The energy storage cell is electrically connected to a soldering lug or soldering surface of the carrier by soldering.

[0041] A plastic material is then inserted into a space between a surface of the carrier facing the energy storage cell and an end face of the energy storage cell facing the surface of the carrier.

[0042] In particular, it is provided that the plastic material is introduced into the space between the surface of the carrier facing the energy storage cell and the end face of the energy storage cell facing the surface of the carrier in such a way that at least partially or in certain areas an adhesive layer is formed between the energy storage cell and the carrier, through which the storage cell is bonded to the carrier and through which the energy storage cell is electrically insulated from the carrier.

[0043] As with the energy storage system according to the invention, it is advantageous in the manufacturing process according to the invention that the plastic material is injected from a surface of the carrier facing the energy storage cell to the underside of the carrier facing away from the energy storage cell via a through-hole or bore in the carrier into the space between the carrier and the energy storage cell.

[0044] The invention is described in more detail below with reference to the accompanying drawings.

[0045] They show:

[0046] FIG. 1 schematically and in an isometric view an area of ​​an exemplary embodiment of the energy storage system according to the invention, namely a number of energy storage cells which are connected both galvanically via soldered connections and materially via adhesive connections to a printed circuit board serving as a carrier; MEISSNER BOLTE M / JCI-542-DE

[0047] 7

[0048] FIG. 2 schematically and in an isometric view shows an area of ​​the energy storage system according to FIG. 1 before the galvanic and metallurgical connection of the energy storage cells to the circuit board;

[0049] FIG. 3 schematically and in an isometric view the area of ​​the energy storage system according to FIG. 2 after the galvanic connection of the contract terminals of the energy storage cells with corresponding solder pads of the circuit board;

[0050] FIG. 4 schematically and in an isometric view the process of injecting adhesive material from the outside of the printed circuit board into the area between the respective end faces of the energy storage cells and the printed circuit board;

[0051] FIG. 5 schematically and in an isometric view the area between the end face of an energy storage cell and the circuit board after the introduction of the plastic material according to FIG. 4; and

[0052] FIG. 6 schematically and in a partially cutaway view the area between the end face of an energy storage cell and the guide plate after the penetration of the plastic material.

[0053] The energy storage system 1 shown in the drawings comprises several energy storage cells 2, which in the exemplary embodiment are designed as supercapacitors (supercap) and each have a total of four contract terminals.

[0054] 3 on one end face of the energy storage cell 2. The respective energy storage cells 2 are galvanically connected to corresponding conductor tracks of a printed circuit board 4 via the contract terminals 3 using soldered connections. This is preferably done by dip soldering or wave soldering.

[0055] To ensure the soldered connection between the energy storage cells 2 and the circuit board

[0056] To improve / reinforce the 4, an adhesive layer 5 is formed between each energy storage cell 2 and the circuit board 4, via which the corresponding energy storage cell 2 is bonded to the circuit board 4. MEISSNER BOLTE M / JCI-542-DE

[0057] 8

[0058] In particular, it can be seen from the illustrations in FIG. 1 and FIG. 2 that the circuit board 4 has a top side 6 facing the energy storage cells 2 and a bottom side 7 opposite the top side 6, wherein the circuit board 4 has corresponding solder lugs 9 or solder pads via which the individual contract terminals 3 of the energy storage cells 2 are galvanically connected to conductor tracks of the circuit board 4.

[0059] The illustration in FIG. 2 further shows that the carrier or the circuit board 4 has a through-opening 8 in the form of a bore in the area of ​​each energy storage cell 2, through which the adhesive material necessary for the formation of the adhesive layer 5 is introduced into the area between the circuit board 4 and in particular the top surface 6 of the circuit board 4 and the respective energy storage cells 2 during the manufacture of the energy storage system, as indicated in FIG. 4.

[0060] The invention is not limited to the exemplary embodiment shown in the drawings, but results from a combination of all the features disclosed herein.

[0061] MEISSNER BOLTE M / JCI-542-DE

[0062] 9

[0063] Reference symbol list

[0064] 1 Energy storage system

[0065] 2 Energy storage cells

[0066] 3 Contract terminal

[0067] 4 Carrier / circuit board

[0068] 5 adhesive layers

[0069] 6 Top of the carrier

[0070] 7 Underside of the support 8 Through opening / bore

[0071] 9 solder lugs

Claims

August 25, 2025 Clarios Advanced Solutions GmbH M / JCI-542-PC CPS Technology Holdings LLC TR / akk Energy storage system with at least one energy storage cell for storing electrical energy, and method for manufacturing such an energy storage system. Patent claims 1. Energy storage system (1) with at least one energy storage cell (2) for storing electrical energy, wherein the energy storage cell (2) has at least one contract terminal (3), in particular in the form of a terminal pole, and wherein the at least one energy storage cell (2) is associated with a carrier (4), in particular in the form of a printed circuit board, wherein the at least one contract terminal (3) of the energy storage cell (2) is galvanically connected, in particular to a conductor track of the carrier (4) via a soldered connection, and wherein at least partially or in certain areas an adhesive layer (5) is formed between the energy storage cell (2) and the carrier (4), via which the energy storage cell (2) is metallurgically connected to the carrier (4).

2. Energy storage system (1) according to claim 1, wherein the carrier (4) has a top surface (6) facing the at least one energy storage cell (2) and a bottom surface (7) opposite the top surface (6), wherein at least one solder lug (9) or at least one solder pad, in particular a solder pad, is provided at least on the top surface (6) of the carrier (4), via which the at least one contract terminal (3) of the energy storage cell (2) is galvanically connected, in particular, to the conductor track of the carrier (4).

3. Energy storage system (1) according to claim 2, wherein the at least one solder lug (9) or the at least one solder surface is designed to mechanically hold and electrically connect the energy storage cell (2) via the contract terminal (3) which is galvanically connected in particular to the conductor track of the carrier (4). MEISSNER BOLTE M / JCI-542-DE 2 4. Energy storage system (1) according to one of claims 1 to 3, wherein the carrier (4) has a through-opening (8) or bore in the area of ​​the at least one energy storage cell (2), through which the adhesive material necessary for the formation of the adhesive layer (5) was or can be introduced into the area between the carrier (4) and in particular between the top (6) of the carrier (4) and the energy storage cell (2) during the manufacture of the energy storage system (1).

5. Energy storage system (1) according to claim 4, wherein the through-opening (8) or bore on the top side (6) of the carrier (4) opens into a region which is preferably centrally aligned with an end face of the energy storage cell (2) and in particular at least substantially centrally aligned.

6. Energy storage system (1) according to one of claims 1 to 5, wherein the at least one energy storage cell (2) has at least two contract terminals (3), in particular each in the form of a terminal pole, wherein a central area of ​​the adhesive layer (5) is formed equidistant to the at least two contract terminals (3).

7. Energy storage system (1) according to one of claims 1 to 6, wherein the distance between the carrier (4) and in particular the upper surface (6) of the carrier (4) facing an end face of the energy storage cell (2) and the energy storage cell (2) and in particular the end face of the energy storage cell (2) is at least 1 mm, preferably at least 2 mm and more preferably at least 3 mm.

8. Energy storage system (1) according to any one of claims 1 to 7, wherein the at least one energy storage cell (2) is designed as a supercapacitor or ultracapacitor; or wherein the at least one energy storage cell (2) is designed as an electrochemical accumulator.

9. Energy storage system (1) according to any one of claims 1 to 8, wherein the carrier (4) is part of a battery management system associated with the energy storage system (1). MEISSNER BOLTE M / JCI-542-DE 3 10. Method for manufacturing an energy storage system (1), in particular an energy storage system (1) according to any one of claims 1 to 9, wherein the method comprises the following process steps: (a) Providing at least one energy storage cell (2) and a carrier (4), in particular in the form of a printed circuit board; (b) electrically connecting at least one contract terminal of the energy storage cell (2) to a solder lug (9) or solder pad of the carrier (4) by soldering; and (c) Inserting a plastic material into a space between a surface of the support (4) facing the energy storage cell (2) and an end face of the energy storage cell (2) facing the surface of the support (4).

11. Method according to claim 10, wherein in step (c) the plastic material is introduced into the space between the surface of the carrier (4) facing the energy storage cell (2) and the end face of the energy storage cell (2) facing the surface of the carrier (4) in such a way that at least partially or in certain areas an adhesive layer (5) is formed between the energy storage cell (2) and the carrier (4), via which the energy storage cell (2) is bonded to the carrier (4).

12. Method according to claim 10 or 11, wherein in step (c) the plastic material is injected from a surface of the carrier (4) facing away from the energy storage cell (2) into the space between the surface of the carrier (4) facing the energy storage cell (2) and the end face of the energy storage cell (2) facing the surface of the carrier (4) via a through-opening (8) or bore in the carrier (4).

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