WO2011160958A2

WO2011160958A2 - Hv battery connector

Info

Publication number: WO2011160958A2
Application number: PCT/EP2011/059564
Authority: WO
Inventors: Rolf Jetter; Christoph Kosmalski
Original assignee: Tyco Electronics Amp Gmbh
Priority date: 2010-06-21
Filing date: 2011-06-09
Publication date: 2011-12-29
Also published as: DE102010024519A1; WO2011160958A3; TW201222941A

Abstract

The present invention relates to a connection device (1) for the electrical connection of at least two battery cells (100), with at least two connecting parts (2a, 2b), which each have a contact section (3 a, 3b) which is designed to be able to be connected to a battery contact (101) of the battery cells (100), with, at least in a mounting state (C) of the connection device (1), the connecting parts (2a, 2b) being connected together by an electrical conductor (5) which at least partially bridges the spacing (x₁₀₁) between the battery contacts (101), and also to a connecting part (2a, 2b) of a connection device (1) which can be connected to a battery contact (101), with a contact section (3a, 3b) which is designed to be able to be connected to the battery contact (101) and a connection section (4a, 4b) which holds an electrical conductor (5), to a battery cell (100) and to the use of a contact element (9a) for conductor bars or backplanes. In order to compensate for manufacturing tolerances, provision is made according to the invention for the electrical conductor (5), at least in the mounting state (C), to be held displaceably by at least one connecting part (2a, 2b) in the direction of the spacing (x₁₀₁), for the electrical conductor (5) to be designed as a pin contact (5) and for the at least one battery contact (101) to be designed to be complementary to at least one connecting part (2a, 2b) of a connection device (1).

Description

HV BATTERY CONNECTOR

The present invention relates to a connection device for the electrical connection of at least two battery cells, in particular of a high-voltage (HV) battery, with at least two connecting parts which each have a contact section which is designed to be able to be connected to battery contacts of the battery cells, with, at least in a mounting state of the connection device, the connecting parts being connected together by an electrical conductor which at least partially bridges the spacing between the battery contacts.

Furthermore, the invention relates to a connecting part of a connection device which can be connected to a battery contact, with a contact section which is designed to be able to be connected to the battery contact and a connection section which holds an electrical conductor.

Further, the invention relates to a battery cell with at least one battery contact.

Finally, the invention relates to the use of a contact element for conductor bars or backplanes.

HV batteries are increasingly used in the automotive industry for storing energy for electric vehicle propulsion systems. Since the electrical drives briefly require large currents, the connection devices used between the cells of the batteries must possess a correspondingly high conductivity. Furthermore, the connection devices must compensate for manufacturing tolerances of the spacings between the battery cells. Furthermore, the connection devices must contact the battery contacts reliably, i.e. absolutely without interruption, in the event of vibrations in the vehicle. Despite these high physical demands on the connection devices, they should be simple to mount and as inexpensive as possible to produce.

Connection devices for the electrical connection of battery cells, connecting parts of these connection devices, the battery contacts and the use of contact elements are known per se. Mostly cables are used as connection devices, the ends of which cables are provided with the connecting parts, which are screwed tightly to the battery contacts. Due to the flexibility of the cables, compensation of manufacturing tolerances of the batteries is ensured. However, the cable connections are costly to produce and to mount. The cable may be soldered or crimped to the connecting part, which causes increased production expense and susceptibility to faults in the connection region between the cable and contact element. The "Rapid Lock" system offered by the applicant is known as an alternative for connecting parts which are screwed to contacts. With this system, the contact element is plugged on to a contact, designed as a pin or stud, of an electrical device. In the mounting position, the contact element can be latched to the pin. A spring member which is constricted concavely in cross-section by the receptacle may be arranged in a cylindrical receptacle of the contact element for the stud.

In the "Rapid Lock" system, the connecting part or the contact element received therein is likewise provided with a cable. Use of the "Rapid Lock" system in a connection device or battery bridge for HV batteries is thus far not known. In view of the disadvantages of the prior art described above, it is an object of the present invention to provide a reliable connection device for battery cells which compensates for tolerances, but is as simple as possible to handle and to produce.

In the connection device referred to first hereinbefore, this object is achieved in that the electrical conductor, at least in the mounting state, is held displaceably in the direction of the spacing by at least one connecting part.

For the connecting part referred to first hereinbefore, the object is achieved in that the electrical conductor is designed as a pin contact.

In the battery cell referred to first hereinbefore, the object is achieved in that the at least one battery contact is designed to be complementary to at least one connecting part of a connection device in accordance with the present invention.

For the use of a contact element known per se, referred to first hereinbefore, the object is achieved by using the contact element as a socket contact in a connecting part for the displaceable receiving of an electrical conductor, designed as a pin contact, in a connection device for the electrical connection of two battery contacts. The solution according to the invention can be supplemented and improved further as desired by the following further embodiments which are each advantageous per se:

Thus, in accordance with a first advantageous embodiment of a connection device according to the invention, displaceable receiving of the electrical conductor on the connecting part can be realised in simple manner in that the electrical conductor and at least one of the connecting parts form a plug-in connection. For this, the connecting parts may for example be provided with connection sections for connection of the electrical conductor which are designed as a plug element and mating plug element which can be fitted together in a spacing direction of the connection device. The spacing direction may be the direction which runs parallel to a straight line between the two battery contacts which are to be coupled or the centre lines thereof.

The connection device can be produced in simple manner in particular by having at least one of the connection sections which comprises the electrical conductor. For this, the connection section or a contact element comprised thereby and the electrical conductor may for example be formed in one piece.

According to a further possible embodiment of the connection device, the configuration of the at least one connecting part or the connection section thereof as a socket contact can permit simple fitting-together of the connecting part and the electrical conductor. For this, a connection contact of the connecting part can be configured in simple manner as a socket contact.

According to a further advantageous embodiment of the connection device, at least one of the connecting parts may be provided with a securing element by means of which it can be locked on one of the battery contacts. The securing element may for example be a bolt which is to be pushed or a latch element which can engage in a bolting or latching aid on the battery contact. Thus the connecting part or the connection device can be fastened to the battery undetachably and detachably again in simple manner.

At least one of the connecting parts can be provided with a securing element which can be brought into engagement with at least one of the battery contacts and at least in a secured state of the connecting part or of the connection device in a projection along a connection direction of the connection device can be overlapped, at least in sections, with the respective battery contact.

According to a further possible embodiment, the connection device can better compensate for tolerances and compensate for vibrations in that, at least in the mounting state, the electrical conductor is held in resiliently movable manner. Resiliently movable holding of the electrical conductor can be achieved in simple manner, according to a further advantageous embodiment, in particular in that, at least in the mounting state, at least one spring member is arranged between the electrical conductor and at least one of the connection sections and/or between at least one of the connecting parts and the respective battery contact, and holds the electrical conductor in resiliently movable manner relative to the respective battery contact relative to the at least one connection section or the at least one connecting part. In such case, the spring member or members may form a part of a current transmission route through the connection device. Thus the electrical conductor or the connection device can be mounted virtually floating and permit better compensation of tolerances and compensation of vibrations, which means that continuous contact with constant resistance values can be ensured.

According to a further possible embodiment, protection against contact of the live parts of the connection device can be realised in simple manner in that in each case at least one casing body surrounds at least one connection contact of the connecting parts, at least in sections, and in that the casing bodies overlap at least in the mounting state. The overlapping can be realised in simple manner in that the casing bodies engage in each other displaceably relative to each other. Thus compensation of tolerances is possible despite the connection device being encased.

With the connecting part referred to first hereinbefore, the solution according to the invention can be improved according to a first further embodiment in that a connection direction of the connecting part which is prescribed by the contact section extends substantially perpendicular to a bridging direction of the connecting part which is prescribed by the connection section. The bridging direction may extend parallel to the spacing direction of the connection device. Thus the connecting part can hold a battery contact or an electrical conductor or be held displaceably both in the connection direction and in the bridging direction up to a certain degree, by means of which for example two degrees of freedom can be ensured for compensation of tolerances. In such case it may be advantageous if the contact section is designed as a socket contact. Thus the connecting part can be simply plugged onto the battery contact, which may be designed as a pin contact. By plugging the connecting part onto the battery contact, the connecting part or a connection device comprising it can be mounted simply and quickly. Consequently, a mounting method is conceivable in which, for connecting two battery cells, the connection sections of the connecting parts can be connected via an electrical conductor, with in each case a contact section of the connection device which is coupled to be electrically conductive with the connection sections is connected to the respective battery contact and the electrical conductor being received displaceably at least in the spacing direction on at least one of the connection sections relative to the connection section located opposite in each case.

The invention is explained in greater detail below by way of example using several embodiments with reference to the appended drawings. The embodiments merely represent possible configurations in which individual features, as described above, can be realised and omitted independently of each other. In the description of the embodiments, for simplicity the same features and elements are provided with the same reference numerals.

Fig. 1 shows a diagrammatic perspective view of a connection device according to the invention which connects battery contacts of two battery cells together;

Fig. 2 shows a diagrammatic perspective view of a first and a second connecting part of a connection device according to the invention;

Fig. 3 shows a connection device according to the invention which is ready to be plugged on to the battery contacts of two battery cells;

Fig. 4 shows a diagrammatic perspective view of a connection device according to the invention which bridges the spacing between the two battery contacts shown in Fig. 3; and

Fig. 5 shows a diagrammatic perspective sectional view of the connection device shown in Fig. 4 along the section line D-D in Fig. 4.

First, a connection device 1 according to the invention is described with reference to Fig. 1 , which shows the connection device 1 and a plurality of battery cells 100. The connection device 1 comprises a first connecting part 2a and a second connecting part 2b. The connecting parts 2a, 2b are fitted together and plugged in each case onto a battery contact 101 of adjacent battery cells 100. Thus the connection device 1 is in a mounting state C, in which it connects together the battery contacts 101 in a spacing direction X of the connection device 1 and can compensate for tolerances both in the spacing direction X and in a lateral direction Y and a connection direction Z of the connection device 1.

Fig. 2 shows the connection device 1 in a pre-mounting state A. In the pre-mounting state A, the connecting parts 2a, 2b are assembled to such an extent that they can be joined for further mounting in the spacing direction X. The connecting parts 2a, 2b have in each case a first contact section 3 a and a second contact section 3b respectively, and a first connection section 4a and a second connection section 4b respectively. The connecting parts 2a, 2b can be plugged in the connection direction Z on to the battery contacts 101 with the contact sections 3a, 3b. At the connection sections 4a, 4b, the connecting parts 2a, 2b can be fitted together in the spacing direction X.

An electrical conductor 5 protrudes in the spacing direction X from a plug section 6b of the second connecting part 2b. The plug section 6b is formed to be complementary to a plug receptacle 6a of the first connecting part 2a. Thus the first connecting part 2a in the connection section 4a forms a plug element 7a and the second connecting part 2b in the connection section 4b forms a mating plug element 7b.

Further, the contact section 3a of the first connecting part 2a is provided with a securing element 8a which is designed to be able to be brought into engagement with the battery contact 101. The contact section 3b of the second connecting part 2b is likewise equipped with a securing element 8b which is designed to be able to be brought into engagement with the battery contact 101.

Fig. 3 shows the connection device 1 in an assembled state B, in which the mating plug element 7b is introduced into the plug element 7a and therefore is no longer visible from the outside. The connection device 1 in the assembled state B is ready to be pushed on to the battery contacts 101 in the connection direction Z. The battery contacts 101 project from the battery cells 100 counter to the connection direction Z and have a cylindrical cross-section. In the transition between a peripheral surface 102 and an end face 103 of the battery contacts 101, the battery contacts 101 are provided with a chamfer 104 which facilitates plugging of the connection device 1 onto the battery contacts 101. A plate-shaped securing aid 105 projects counter to the connection direction Z from the end face 103 of the battery contacts 101 and is designed to cooperate with the securing elements 8 a, 8b.

Fig. 4 shows the connection device 1 in the mounting state C, in which it is plugged onto the battery contacts 101 and overcomes a spacing xioo between the battery cells 100 which is variable corresponding to the respective manufacturing tolerances.

Fig. 5 shows the connection device 1 illustrated in Fig. 4 along the section line D - D shown in Fig. 4 in the mounting state C. The connecting part 2a comprises a contact element 9a which forms a hollow-cylindrical battery contact receptacle 10a in the contact section 3 a. A cylinder-like spring member 11 which is biconcavely constricted in cross-section is arranged in the battery contact receptacle 10a. The spring member 11 in the battery contact receptacle 10a of the contact section 3a secures the battery contact 101 in resiliently movable manner in the spacing direction X and in the lateral direction Y, and displaceably in the connection direction Z. Thus the spring member 11 in the battery contact receptacle 10a contributes to compensation of tolerances in the spacing direction X, the lateral direction Y and the connection direction Z.

The contact element 9a forms a connection contact 12a in the connection section 4a of the connecting part 2a. On the connection contact 12a there is formed a connection contact receptacle 13a of the socket contact in which a further spring member 11 is arranged. The further spring member 11 , which is likewise cylindrical and biconcavely constricted in cross- section, encompasses the electrical conductor 5, which is thus received displaceably in the spacing direction X and in resiliently movable manner in the lateral direction Y and the connection direction Z in the connection section 4a of the connecting part 2a.

The electrical conductor 5 is formed as a connection plug contact 13b or pin contact which is formed on a connection contact 12b of a mating contact element 9b of the connecting part 2b. On the mating contact element 9b there is formed a battery contact receptacle 10b which is likewise hollow-cylindrical. A further spring member 11 which is cylindrical and biconcavely constricted in cross-section is arranged in the battery contact receptacle 10b, which member radially engages around the battery contact 101 on its inner side and is supported outwards radially in the battery contact receptacle 10b. Due to the arrangement of the contact element 9a and mating contact element 9b shown in Fig. 5, the electrical conductor 5, at least in sections, bridges a spacing xioi between centre lines Mioi of the battery contacts 101. The battery contacts 101 are held displaceably in the connection direction Z, and the electrical conductor 5 in the form of the connection plug contact 13b designed as a pin contact is held displaceably in the spacing direction X, in the respective contact receptacles 10a, 10b or 13a respectively. Due to the displaceable holding, compensation of tolerances is ensured, the spring members 1 1 both compensating for tolerances and compensating for vibrations by elastically engaging around the respective contacts 101 and 13b. Furthermore, the spring members 1 1 in the respective contact receptacles 10a, 10b and 13a introduce the contact forces in sprung manner into the battery contact receptacles 10a, 10b by connecting contacts 14a, 14b of the contact element 9a or of the mating contact element 9b.

Consequently, the spring elements 1 1 not only fulfil a mechanical supporting and sliding function but furthermore form part of a current transmission route which extends between the battery contact 101 via the spring element 1 1 in the battery contact receptacle 10a via the contact element 9a, the spring element 1 1 in the connection contact receptacle 13 a, the connection plug contact 13b, the electrical conductor 5, the spring member 1 1 arranged in the battery contact receptacle 10b to the battery contact 101 received therein.

Furthermore, the contact element 9a and the mating contact element 9b are each received in a casing body 15a or 15b respectively. The casing body 15a forms the plug receptacle 6a. The casing body 15b forms the plug section 6b. In the assembled state B and in the mounting state C of the connection device, the plug receptacle 6a and the plug section 6b form a region of overlap 16 in which the casing bodies 15a and 15b overlap each other displaceably in the connection direction Z. Thus the casing bodies 15a and 15b ensure firstly compensation of tolerances in the spacing direction X and secondly protection against contact by encasing all the live parts, namely both the battery contacts 101 and the contact element 9a and the mating contact element 9b.

Further, it is made clear in Fig. 5 that the securing elements 8a, 8b are in each case held displaceably in the spacing direction X in a guide 17a or 17b formed in an aperture in the casing bodies 15a and 15b respectively. The securing elements 8a, 8b are provided in each case with bolting elements 18a and 18b. The bolting elements 18a, 18b are designed to engage in a bolting receptacle 106 of the battery contacts 101 which is formed between the plate-shaped securing aid 105 and the end face 103 of the battery contacts 101.

The securing element 8a is in an unbolted position U, in which it is moved out of engagement with the bolting receptacle 106. An engagement contour 19a on the bolting element 10a of the securing element 8a is designed to be complementary to a cylindrical shank 107 of the battery contact 101 which holds the securing aid 105.

The bolting element 8b is in a bolted position L, in which it engages in the bolting receptacle 106. Thus the non- visible engagement contour 19b, on a bolting element 18b of the securing element 8b, at least partially encompasses the shank 107 between the end face 103 and the securing aid 105 of the battery contact 101 and thus ensures that the securing element 8b and the securing aid 105 in a projection counter to the connection direction Z, or the securing aid 8b and the end face 103 in a projection in the connection direction Z, overlap in the largest possible region. This guarantees secure holding of the connection device 1 on the battery contacts 101, and holds the connection device 1 undetachably on the battery contacts 101, although the bolting receptacle 106, in a height measured parallel to the connection direction Z, is calculated such that its height exceeds a height, measured in the connection direction Z, of the bolting elements 18a, 18b and thus permits a certain play, which promotes compensation of tolerances in the connection direction Z.

Deviations from the embodiments described above are possible within the inventive concept. Thus the connection sections 4a, 4b do not inevitably have to be provided with a plug receptacle 6a or a plug section 6b, although it is advantageous simply to be able to fit the connecting parts 2a, 2b together. The electrical conductor 5 does not compulsorily have to be formed in one piece with the mating contact element 9b. Alternatively, it is for example possible for a pin or stud to be used as electrical conductor 5, which pin or stud is held displaceably in two connection contact receptacles 13a which open to each other, the connection contact receptacles 13a being provided in each case by a contact element 9a. The displaceable receiving of the conductor 5 may also be realised other than by a plugging mechanism.

The connecting contacts 14a, 14b do not inevitably have to be provided with a battery contact receptacle 10a or 10b respectively, but may for example be designed as pin contacts which can be designed to be able to be plugged into battery contacts 101 which are correspondingly designed as pin contact receptacles. Also further alternative forms of the battery contacts 101 and the battery contact receptacles 10a, 10b are possible, as long as they are designed to be complementary to each other and permit compensation of tolerances and also displaceable mounting in the connection direction Z of the connecting parts 2a and 2b. Instead of bolting with the aid of the bolting elements 18a, 18b, latching or screwing of the connecting parts 2a, 2b to the battery contacts 101 is also conceivable.

The casing bodies 15 a, 15b do not inevitably have to be designed to surround the contact element 9a or mating contact element 9b in one piece in each case, but may consist of a plurality of parts. Thus it is for example conceivable for a protection against contact to be realised by at least partial encapsulation of the contact elements 9a, 9b.

Claims

1. A connection device (1) for the electrical connection of at least two battery cells (100), with at least two connecting parts (2a, 2b), which each have a contact section (3 a, 3b) which is designed to be able to be connected to a battery contact (101) of the battery cells (100), with, at least in a mounting state (C) of the connection device (1), the connecting parts (2a, 2b) being connected together by an electrical conductor (5) which at least partially bridges the spacing (xioi) between the battery contacts (101), characterised in that the electrical conductor (5), at least in the mounting state (C), is held displaceably in the direction of the spacing (xioi) by at least one connecting part (2a, 2b).

2. A connection device (1) according to Claim 1, characterised in that the electrical conductor (5) and at least one of the connecting parts (2a, 2b) form a plug-in connection.

3. A connection device (1) according to one of Claims 1 or 2, characterised in that at least one of the connecting parts (2a, 2b) forms a socket contact (13a) in which the electrical conductor (5) is displaceably received.

4. A connection device (1) according to one of Claims 1 to 3, characterised in that at least one of the connecting parts (2a, 2b) is provided with a securing element (8a, 8b) by means of which it can be locked on one of the battery contacts (101).

5. A connection device (1) according to one of Claims 1 to 4, characterised in that, at least in the mounting state (C), the electrical conductor (5) is held in resilient ly movable manner.

6. A connection device (1) according to one of Claims 1 to 5, characterised in that at least one spring member (11) is arranged between the electrical conductor (5) and at least one connection section (4a, 4b) and/or between at least one of the connecting parts (2a, 2b) and the respective battery contact (101), and holds the electrical conductor (5) in resiliently movable manner relative to the at least one connection section (4a, 4b) or the at least one connecting part (2a, 2b) relative to the respective battery contact (101).

7. A connection device (1) according to one of Claims 1 to 6, characterised in that in each case at least one casing body (15a, 15b) surrounds at least one connection contact (12a, 12b) of the connecting parts (2a, 2b), at least in sections, and in that the casing bodies (15a, 15b) overlap at least in the mounting state (C).

8. A connecting part (2a, 2b) of a connection device (1) which can be connected to a battery contact (101), with a contact section (3a, 3b) designed to be able to be connected to the battery contact (101) and a connection section (4a, 4b) which holds an electrical conductor (5), characterised in that the electrical conductor (5) is designed as a pin contact (13b).

9. A connecting part (2a, 2b) according to Claim 8, characterised in that a connection direction (Z) of the connecting part (2a, 2b) which is prescribed by the contact section (3a, 3b) extends substantially perpendicular to a bridging direction (Χ') of the connecting part (2a, 2b) which is prescribed by the connection section (4a, 4b).

10. A battery cell (100) with at least one battery contact (101), characterised in that the at least one battery contact (101) is designed to be complementary to at least one connecting part (2a, 2b) of a connection device (1) according to one of Claims 1 to 9.

11. Use of a contact element (9a) for conductor bars or backplanes as a socket contact in a connecting part (2a, 2b) for the displaceable receiving of an electrical conductor (5), designed as a pin contact (13b), in a connection device (1) for the electrical connection of two battery contacts (101).