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EP4635020A1 - Unité de stockage d'énergie pour un consommateur électrique - Google Patents

Unité de stockage d'énergie pour un consommateur électrique

Info

Publication number
EP4635020A1
EP4635020A1 EP23810363.4A EP23810363A EP4635020A1 EP 4635020 A1 EP4635020 A1 EP 4635020A1 EP 23810363 A EP23810363 A EP 23810363A EP 4635020 A1 EP4635020 A1 EP 4635020A1
Authority
EP
European Patent Office
Prior art keywords
energy storage
storage unit
cell
electrical
battery pack
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP23810363.4A
Other languages
German (de)
English (en)
Inventor
Jan Breitenbach
Florian Kneer
Josef Baumgartner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Robert Bosch GmbH
Original Assignee
Robert Bosch GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Robert Bosch GmbH filed Critical Robert Bosch GmbH
Publication of EP4635020A1 publication Critical patent/EP4635020A1/fr
Pending legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
    • H01M50/107—Primary casings; Jackets or wrappings characterised by their shape or physical structure having curved cross-section, e.g. round or elliptic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/262—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders with fastening means, e.g. locks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/291—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/293—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by the material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/30—Batteries in portable systems, e.g. mobile phone, laptop
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/247—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers

Definitions

  • the invention relates to an energy storage unit for an electrical consumer according to the preamble of the independent claim.
  • energy storage units also known as rechargeable batteries, battery packs or interchangeable battery packs
  • these are discharged by the electrical consumer and can be recharged using a charger.
  • the energy storage units have a suitably sealed housing (e.g. for IP58).
  • the energy storage units usually consist of a plurality of energy storage cells connected in series and/or parallel to achieve a required battery voltage or capacity. If the energy storage cells are designed as lithium-ion cells (Li-ion), for example, a high power and energy density can be achieved with particular advantage.
  • the electrical cell poles of at least two energy storage cells of the energy storage unit can be electrically connected to one another via at least one cell connector in a series or parallel circuit as a so-called cell cluster or submodule.
  • Such cell clusters allow for easier assembly and scaling of the energy storage units.
  • the electrical connection of the cell connectors to the electrical cell poles is made by means of a material connection, for example by soldering, cold welding or the like.
  • the cell connectors are often designed as flat stamped sheets or tabs, which in turn are electrically connected to a printed circuit board (PCB) of the energy storage unit for monitoring the energy storage cells via electrical connection points on the circuit board.
  • PCB printed circuit board
  • cables and ribbon cables can better decouple mechanical influences such as vibrations and shocks, particularly at their electrical connection points, but often have a limited current-carrying capacity.
  • busbars and stamped grids enable a compact design of the energy storage unit while at the same time having a high current-carrying capacity and are used in particular when punching and bending processes are necessary for shaping and for a special connection geometry. At higher currents, however, they require thicker cross-sections, which result in low flexibility, so that with corresponding mechanical influences there is a risk that the welding points or soldering points will come loose.
  • the invention relates to an energy storage unit for an electrical consumer, with a plurality of energy storage cells, each energy storage cell having two electrical cell poles and the electrical cell poles of at least two energy storage cells being electrically connected to one another in a series or parallel circuit as a cell cluster via at least one cell connector.
  • the energy storage unit has at least two cell clusters which are connected to one another by means of a Two-component (2K) or three-component injection molding (3K) processes are used to connect the cell clusters to one another. This particularly advantageously means that additional assembly devices that hold the individual cell clusters in position during assembly of the energy storage unit can be dispensed with.
  • the cell clusters and the insulating plate connecting them thus form a structural unit that can be used for subsequent assembly steps of the energy storage unit and which, by eliminating additional connecting elements such as screws, adhesives or the like, enables the assembly of the energy storage unit to be made significantly easier and less expensive.
  • a structural unit formed in this way results in additional mechanical stabilization of the cell clusters against vibrations, blows and impacts or the like during use of the energy storage unit. It is particularly advantageous for an outer contour of the insulating plate to essentially correspond to an envelope of the cell clusters in cross-section through a longitudinal axis of the structural unit.
  • the invention further relates to an electrical consumer with an energy storage unit according to the invention and to a system consisting of an electrical consumer designed as a handheld power tool and at least one energy storage unit designed as a removable battery pack.
  • an electrical consumer should be understood as all devices with an electrical load that can be supplied by means of an energy storage unit.
  • the electrical load can be designed as a predominantly inductive load in the form of an electric motor drive. Predominantly ohmic or capacitive loads are also conceivable.
  • Electrically commutated electric motors (so-called EC or BLDC motors) in particular can be considered as electric motor drives, the individual phases of which are controlled via at least one power transistor by pulse width modulation to control or regulate their speed and/or torque.
  • the invention is applicable to battery-operated machine tools for machining workpieces using an electrically driven insert tool.
  • the electrical processing device can be designed both as a portable handheld power tool and as a stationary machine tool.
  • Typical machine tools in this context are hand or pillar drills, screwdrivers, impact drivers, etc. drills, planers, angle grinders, orbital sanders, cell polishing machines or the like.
  • Garden and construction equipment such as lawn mowers, grass trimmers, branch saws, motor and trench cutters, blowers, robot breakers and excavators or the like, as well as measuring devices such as laser rangefinders, wall scanners, etc., can also be considered as electrical consumers.
  • the invention is also applicable to household appliances such as vacuum cleaners, mixers, etc., and electrically powered road and rail vehicles such as e-bikes, e-scooters, pedelecs, electric and hybrid vehicles, etc., as well as aircraft and ships with an energy storage unit according to the invention.
  • An energy storage cell is typically designed as a galvanic cell that has a structure in which a cell pole is located at one end and another cell pole at an opposite end. In particular, the energy storage cell has a positive cell pole at one end and a negative cell pole at an opposite end.
  • the energy storage cells are preferably designed as lithium-based battery cells, e.g. Li-ion, Li-cell polymer, Li-metal or the like. However, the invention is also applicable to energy storage units with Ni-Cd, Ni-Mh cells or other suitable cell types.
  • An energy storage cell is preferably designed as an at least essentially cylindrical round cell, with the cell poles arranged at the ends of the cylinder shape.
  • the invention is not dependent on the type and design of the energy storage cells used, but can be applied to any energy storage units and cells, e.g. in addition to round cells, prismatic cells, pouch cells or the like.
  • the DC voltage values are primarily based on the typical cell voltages of the energy storage cells used.
  • the energy storage unit is designed as a removable battery pack, it can be connected to a corresponding complementary electromechanical interface of the electrical consumer or the charger in a force-locking and/or form-locking manner via the electromechanical interface of the removable battery pack.
  • a "detachable connection" is to be understood in particular as a connection that can be released and established without tools - i.e. by hand.
  • the design of the electromechanical interfaces and their receptacles for the force-locking and/or form-locking releasable connection are not the subject of this invention.
  • a first of the at least two components of the insulating plate is designed as a hard component and a second of the at least two components is designed as a soft component.
  • the hard component essentially serves to stiffen the insulating plate, while the soft component functions as mechanical damping or fixation and tolerance compensation.
  • the soft component has a hardness of 0 to 100 Shore A, preferably 30 to 70 Shore A.
  • the soft component can be used to seal dedicated areas of the energy storage unit or the cell cluster, for example in the form of a sealing lip.
  • a third component of the insulating plate can be designed as a hard or soft component with different material properties than the first and second components.
  • the hard component has a plurality of locking hooks for fastening to the at least two cell clusters.
  • the locking hooks tabs, mushroom heads or corresponding projections and/or recesses, for example in the form of a tongue and groove principle, can alternatively be used for mounting on the cell clusters. In this way, good mechanical stabilization can be achieved on the one hand and very simple and quick assembly of the structural units consisting of the cell clusters and the insulation plate on the other.
  • disassembly and simplified replacement are possible.
  • a further embodiment provides that the locking hooks and/or a plurality of mechanical links are arranged on the insulating plate in such a way that the cell clusters can only be connected to the insulating plate in the sense of a poka-yoke principle. This allows increased process reliability during assembly to be achieved in order to avoid any assembly errors that may also lead to damage to the cell clusters or the energy storage cells.
  • the soft component is preferably designed as a plurality of elastic lamellae and/or domes that are arranged within the hard component and that are connected to one another in particular via webs made of the same material.
  • the plurality of lamellae and/or domes preferably corresponds to the number of energy storage cells of at least one of the cell clusters connected to the insulating plate. In this way, the individual energy storage cells or their cell poles and/or the cell connectors connecting them can be effectively protected from mechanical vibrations, impacts and shocks or the like during use of the energy storage unit.
  • the lamellae and/or domes are circular in shape and that their position corresponds to the electrical cell poles of the cell clusters connected to the insulating plate.
  • the circular lamellae or domes have the advantage that they can be easily pressed together and thus stabilize the assembly. In addition, they can take on an additional sealing function within the structural unit or the energy storage unit.
  • the slats and/or caps are pressed together when the insulation plate is mounted. In addition, this allows the heat generated when the electrical consumer is operating or when charging the energy storage unit to be dissipated or distributed.
  • a further object of the invention may be to provide a high-performance energy storage unit which, compared to the prior art, has the most compact design possible and is also cost-effective to manufacture.
  • the invention relates to an energy storage unit for an electrical consumer, with an electromechanical interface for connecting the energy storage unit to the electrical consumer, with a plurality of energy storage cells, each energy storage cell having two electrical cell poles and the electrical cell poles of at least two energy storage cells being electrically connected to one another in a series or parallel circuit as a cell cluster via at least one cell connector, and with a circuit board that electrically connects the at least one cell connector of the cell cluster to a power supply contact of the electromechanical interface, the power supply contact being electrically connected to a busbar or being designed as a busbar.
  • the busbar is arranged directly on a surface of the circuit board.
  • the busbar can thus be installed cost-effectively by the manufacturer of the circuit board, which improves the robustness of the construction.
  • Rigid busbars in particular with larger cross-sections, can also be installed in a much more customized manner and relieve the load on the connection points.
  • hybrid components e.g. a busbar with a “copper mesh” cable
  • further manufacturing costs can be saved.
  • the circuit board for the busbar has at least one recess into which the busbar dips with at least one section.
  • Dipping should be understood in particular to mean that the corresponding section of the busbar penetrates with a first end into the at least one recess below the surface of the circuit board and emerges with a second end from the at least one recess or another recess above the surface.
  • the corresponding section of the busbar is therefore located at least partially, in particular completely, below the surface of the circuit board.
  • the at least one section of the busbar is inserted into the circuit board in such a way that it protrudes from the surface on the opposite side of the circuit board. This makes it possible to increase the spring effect of the busbar and thus the protection of the electrical connection points or to adapt it to any specifications.
  • the at least one section is wave-shaped, in particular U-, V-, W- or meander-shaped.
  • the at least one section of the busbar can be made of a different, electrically conductive material than the busbar.
  • the at least one section of the busbar has a cross section and/or a thickness that deviates from the cross section and/or the thickness of the busbar.
  • the at least one section of the busbar has a depth that is at least as large as its length along the busbar.
  • a further object of the invention may be to provide a high-performance energy storage unit which, compared to the prior art, has a design which is as compact as possible and protected against environmental influences, in particular dirt, liquids or the like, and which is also cost-effective to produce.
  • a sub-housing of the energy storage unit is formed from an electrically non-conductive material that is open at least on one end face and surrounds the cell cluster with its other sides, and that the busbar is overmolded by the electrically non-conductive material at least on one side of the sub-housing.
  • a sub-housing is to be understood in particular as a housing that is at least partially surrounded by another outer housing and thus cannot be reached in its entirety from the outside.
  • the sub-housing thus forms a sub-housing that is separate or separable from the outer housing, which is partially partially or completely surrounded by the outer casing and is not connected to it by a material fit, but only by a force and/or form fit
  • the electrically non-conductive material of the sub-housing is additionally thermally conductive. This enables increased heat spreading or dissipation and thus improved cooling in the contact area by directly coupling the busbars to an outer housing of the energy storage unit and/or the electrical consumer.
  • the sub-housing has a recess through which the busbar is electrically connected to the power supply contact or a signal or data contact, or through which the busbar is designed as a power supply contact or as a signal or data contact. This allows for reduced assembly effort and a lower susceptibility to errors as a result of a corresponding improvement in quality.
  • the busbar is accessible from both sides at the corresponding contact point.
  • the outer housing of the energy storage unit has at least one removable end cap, whereby the end cap and the at least one open front side of the sub-housing are sealed by means of a sealing lip when assembled.
  • the end cap enables easy maintenance or repair of the energy storage unit because defective components can be replaced by removing the end cap.
  • the sealing lip also ensures a high level of protection against environmental influences in conjunction with the replaceable end cap.
  • the sealing lip engages in a groove that runs around at least one open front side of the sub-housing and/or the end cap.
  • the sealing lip is pressed into the groove of the sub-housing and the area is sealed accordingly.
  • the sub-housing has a pressure equalization opening on one side, through which pressure equalization between the sealed sub-housing and the environment can take place with particular advantage. This prevents damage to the sensitive components of the energy storage unit, such as the electronics or the energy storage cells, due to any unfavorable pressure conditions inside the sub-housing compared to the environment.
  • the pressure equalization opening is sealed by a pressure equalization membrane. This allows gas and moisture to exchange between the sub-housing of the energy storage unit and the environment, but the special material properties of the pressure equalization membrane prevent water and dirt from entering the interior of the energy storage unit.
  • a further object of the invention may be to provide a high-performance energy storage unit which, compared to the prior art, has a design which is as compact as possible and protected against environmental influences, in particular dirt, liquids or the like, and which is also cost-effective to produce.
  • the invention relates to an energy storage unit for an electrical consumer, with an outer housing that serves to accommodate a plurality of energy storage cells, wherein the outer housing has an electromechanical interface on a first side wall or a top side for a tool-free detachable connection to an electromechanical interface of the electrical consumer.
  • a housing part is arranged on or in the outer housing, which consists of at least three different injection-molded components.
  • the housing part is therefore manufactured in a three-component injection molding process.
  • the variety of the individual components of the energy storage unit can be reduced compared to a housing part manufactured in a two-component injection molding process by a corresponding functional integration into existing components by means of a further injection-molded component. On the one hand, this helps to reduce manufacturing costs and, on the other hand, to improve the quality of the energy storage unit due to reduced assembly effort and a resulting reduced susceptibility to errors.
  • the at least three injection-molded components of the housing part are formed by a hard component, a soft component and at least a third injection-molded component, wherein the third injection-molded component differs from the hard component and the soft component in its material properties.
  • the hard component can be made of a thermoplastic plastic, for example PC/ABS or PA/GF, and the soft component can be made of a thermoplastic elastomer (TPE).
  • TPE thermoplastic elastomer
  • the hard component thus essentially serves to stiffen and shock-resistant the energy storage unit, while the soft component in conjunction with the hard component enables improved handling of the energy storage unit as well as mechanical damping or fixation, improved sealing and/or tolerance compensation of the energy storage cells or the cell clusters.
  • the soft component has a hardness of 0 to 100 Shore A, preferably 30 to 70 Shore A.
  • a third injection molding component could be, for example, a harder or softer TPE, but also a metal insert or a hard plastic in order to adapt the energy storage unit or its energy storage cells to special requirements with regard to impact and vibration resistance, tightness and/or operability.
  • the housing part can be designed as an end cap that can be detachably attached to a front side of the outer housing of the energy storage unit or the electrical consumer.
  • a base body of the end cap is formed from the hard component and at least a first side of the end cap is overmolded, in particular almost completely, by the soft component. This results in improved handling for an operator, for example in that there is more grip, especially with wet hands.
  • overmolded hard components with the soft component results in increased robustness against impacts, for example if the energy storage unit or the electrical consumer falls down.
  • the soft component forms a sealing lip injected into a groove in the hard component on a second side of the end cap.
  • this improves the sealing of the energy storage unit or the electrical consumer against moisture, liquids, dust and other forms of dirt, and on the other hand, it makes the end cap much easier to install, as the sealing lip does not have to be inserted separately into the groove.
  • the soft component forms a plurality of damping elements sprayed onto projections of the hard component on a second side of the end cap, which serve to axially and/or radially dampen the energy storage cells.
  • the energy storage unit is more robust against any shocks and impacts as well as vibrations that can occur when working with the electrical consumer.
  • the damping elements serve to better fix the energy storage cells or the cell clusters within the energy storage unit.
  • the usability of the energy storage unit can be increased by the third injection-molded component being another soft component made of a transparent or translucent, in particular thermoplastic, elastomer.
  • the third injection-molded component can thus serve, for example, as a charge level indicator for the energy storage unit, with the light from individual LEDs mounted on a circuit board of the energy storage unit being guided outwards by the third injection-molded component designed as a light guide.
  • the third injection-molded component is injected into a recess in the hard component, which is preferably not overmolded by the soft component. This particularly advantageously increases the robustness of the energy storage unit through additional sealing in the area of the charge level indicator.
  • the usability of the energy storage unit can be improved while still maintaining a high level of robustness by injecting at least one actuating element and/or at least one optical separating element into the third injection-molded component, which is formed in particular from the hard component or a comparable thermoplastic.
  • the charge level indicator can be activated for a defined time window by briefly pressing the actuating element. It would also be conceivable to start a quick charging process or something similar.
  • Using at least one optical separating element it is possible to distinguish different charge levels of the energy storage unit more clearly from one another, because this avoids scattered light between the individual LEDs that display the charge levels.
  • Fig. 1 a system consisting of at least one electrical energy storage device designed as a removable battery pack and at least one electrical device that can be connected to the removable battery pack for charging or discharging the removable battery pack in a schematic representation,
  • Fig. 2 a perspective view of the interior of the removable battery pack in a reassembled state
  • Fig. 3 a perspective view of a structural unit consisting of two cell clusters according to Figure 2 in a disassembled state
  • Fig. 4 a perspective view of an insulating plate of the cell
  • Cluster according to Figure 3 formed housing part of the removable battery pack in a first embodiment (Figure 4a) and in a second embodiment as a detail enlargement (Figure 4b),
  • Fig. 5 a section through the assembled unit according to
  • Fig. 6 a perspective view of the assembled interior of the removable battery pack according to Figure 2,
  • Fig. 7 a section along the longitudinal axis through the fully assembled removable battery pack (Figure 7a) and an enlarged detail of a sealing lip for sealing the removable battery pack (Figure 7b),
  • Fig. 8 a section along the longitudinal axis to illustrate pressure equalization of the removable battery pack or the sub-housing
  • Fig. 9 a perspective view of a circuit board of the removable battery pack with busbars arranged on it
  • Fig. 10 a busbar of the removable battery pack in a side view in an undeformed and in a deformed state
  • Fig. 11 a perspective view of a housing part of the interchangeable battery pack designed as an end cap in an internal view ( Figure 11 a) and in an external view ( Figure 11 b).
  • Figure 1 shows a system comprising an energy storage unit 12 designed as a removable battery pack 10 with an electromechanical interface 16 having a plurality of electrical contacts 14 and various electrical devices 18, each with an electromechanical interface 20 corresponding to the electromechanical interface 16 of the removable battery pack 10.
  • Figure 1 is intended illustrate that the system is suitable for various electrical devices 18 operated with interchangeable battery packs 10 without limiting the invention.
  • a charger 22 and several electrical consumers 30 designed as a cordless vacuum cleaner 24, a cordless impact wrench 26 and a cordless light 28 are shown as examples. In the context of the invention, however, a wide variety of power tools, garden tools and household appliances can be considered as electrical consumers 30.
  • the number of interchangeable battery packs 10 within the system is also variable.
  • the system can therefore also comprise several interchangeable battery packs 10.
  • the invention is also applicable to electrical consumers 30 which have purely ohmic and/or capacitive electrical loads, so that the power tools shown here are to be understood merely as examples.
  • the removable battery pack 10 has an outer housing 32, which has the electromechanical interface 16 on a first side wall or its top side 34 for the connection to the electromechanical interface 20 of the electrical device 18 that can be released without tools - i.e. by hand.
  • the electromechanical interface 16 of the removable battery pack 10 has two guide rails 36, which, when inserted, are guided into corresponding guide grooves (not shown) of the electromechanical interface 20 of the electrical consumer 30 or the charger 22.
  • the electromechanical interfaces 16, 20 primarily serve to discharge the removable battery pack 10, while in connection with the charger 22 they can be used to charge the removable battery pack 10.
  • the precise design of the electromechanical interfaces 16, 20 depends on various factors, such as the voltage class of the removable battery pack 10 or the electrical device 18 and various manufacturer specifications. For example, three or more electrical contacts 14 can be provided for energy and/or data transmission between the removable battery pack 10 and the electrical device 18.
  • Mechanical coding is also conceivable, so that the removable battery pack 10 can only be operated with certain electrical devices 18. Since the mechanical design of the electromechanical interfaces 16, 20 of the removable battery pack 10 and the electrical device 18 is irrelevant to the invention, this will not be discussed in further detail here. Both a Both a specialist and an operator of the removable battery pack 10 and the electrical device 18 will make the appropriate selection in this regard.
  • the removable battery pack 10 has a sub-housing 38, which preferably consists of a thermally conductive material (e.g. a thermoplastic polyethylene such as PH-HD) and is partially surrounded by the outer housing 32.
  • the sub-housing 38 forms a housing that is separate or separable from the outer housing 32 and is connected to the outer housing 32 in a force-fitting and/or form-fitting manner.
  • additional housing parts in the form of detachable end caps 40 are provided by screw connections, which fix the sub-housing 38 in the outer housing 32.
  • the removable battery pack 10 and the charger 22 or the electrical consumer 30 have mutually corresponding electromechanical interfaces 16 and 20 with a plurality of electrical contacts 14, wherein a first of the electrical contacts 14 of the electromechanical interfaces 16, 20 serves as a power supply contact 42 to which a first reference potential Vi, preferably a supply potential V+, is applied, and a second of the electrical contacts 14 of the interfaces 16, 20 serves as a power supply contact 44 to which a second reference potential V2, preferably a ground potential GND, is applied (see Figure 2).
  • the removable battery pack 10 can be charged by the charger 22 via the first and second power supply contacts 42, 44.
  • the removable battery pack 10 can also be discharged via this in the event that the electrical device 18 is designed as an electrical consumer 30.
  • loadable is intended to clarify that the potentials V+ and GND are not permanently present at the power supply contacts 42, 44, particularly in the case of an electrical device 18 designed as an electrical consumer 30, but only after the electromechanical interfaces 16, 20 have been connected. The same applies to a discharged removable battery pack 10 after connection to the charger 22.
  • the electromechanical interfaces 16, 20 can also have further electrical contacts 14, which are designed in particular as signal or data contacts 46.
  • Information on various operating parameters of the removable battery pack 10, such as the battery voltage Ußatt, the cell voltages Uceii, a temperature T measured in the removable battery pack 10, a charging or discharging current I, a coding or the like, can be transmitted to the electrical consumer 30 or the charger 22 via the signal or data contacts 46 for evaluation there.
  • the electronics of the electrical consumer 30 or the charger 22 can control or regulate the discharging or charging process using these operating parameters.
  • FIG 2 shows the interior of the removable battery pack 10 shown in Figure 1 before it is fully assembled.
  • the sub-housing 38 of the removable battery pack 10 is designed such that it can accommodate two so-called cell clusters 48.
  • the battery voltage of the removable battery pack 10 is generally a multiple of the cell voltages of the energy storage cells depending on their connection (parallel or series).
  • the energy storage cells are preferably designed as lithium-based battery cells, e.g. Li-Ion, Li-Po, Li-metal or the like.
  • the invention can also be used for removable battery packs with Ni-Cd, Ni-MH cells or other suitable cell types.
  • the ten energy storage cells 50 of a cell cluster 48 are laterally offset from one another and divided into four layers arranged one above the other, with two layers each having two energy storage cells 50 and two further layers each having three energy storage cells 50.
  • Each energy storage cell 50 has a positive and a negative cell pole 54 on both of its front sides.
  • the individual cell poles 54 of the energy storage cells 50 of a cell cluster 48 are electrically connected to one another via cell connectors 56 in such a way that a series and parallel connection of the energy storage cells 50 results in a resulting cluster voltage Uci of 18 V with a capacity of at least 6 Ah.
  • Both cell clusters 48 are connected in series so that a battery voltage Ußatt of 36 V is achieved.
  • the cell connectors 56 are designed as flat stamped sheets which are connected on the one hand via contact timing points 58 with the cell poles 54 and on the other hand at an open end 60 with an electrical connection point of a circuit board 62 in a material-locking manner, for example by means of soldering, resistance welding, cold welding or the like.
  • At least one of the cell connectors 56 has an SCM tap (not shown in detail) for single cell monitoring, which is integrally connected to the cell connector 56 and is preferably arranged between the open end 60 for electrical contact with the circuit board 62 and the contact points 58 for electrical contact with the cell poles 54 of the energy storage cells 50.
  • the SCM tap is connected in a materially bonded manner, for example by soldering, to a cable, which in turn establishes an electrical connection to an SCM pre-stage of a corresponding electronics of the removable battery pack 10 (not shown).
  • the SCM pre-stage switches sequentially between the individual SCM taps of the cell connectors 56, for example via integrated transistors, in such a way that it is connected to a positive and a negative cell pole 54 of the energy storage cell 50 or the cell cluster 48 to be measured.
  • the electronics of the removable battery pack 10 can have an integrated circuit in the form of a microprocessor, ASIC, DSP or the like for controlling or regulating the charging or discharging process. It is also conceivable that the control or regulation takes place by means of several microprocessors or at least partially by means of discrete components with corresponding transistor logic.
  • the electronics can have a memory for storing the operating parameters. Since such electronics are known to the person skilled in the art, this will not be discussed further here.
  • the cell connector 54 of one of the two cell clusters 48 which is supplied with the first reference voltage Vi, is electrically connected to the power supply contact 42 of the electromechanical interface 16 (see also Figures 7a and 8). Accordingly, the cell connector 54 of the other cell cluster 48, which is supplied with the second reference voltage V2, is also electrically connected to the power supply contact 44 of the electromechanical interface 16. Interface 16 is connected via a further busbar 64, which is arranged directly on the surface of the circuit board 62.
  • the opposing cell connectors 56 of the two cell clusters 48 must be electrically insulated from one another in order to prevent any short circuits during later operation.
  • These tasks are performed by a housing part that is designed as an insulating plate 66 arranged between the cell clusters 48 and manufactured using a two-component (2K) or three-component (3K) injection molding process. This means that additional assembly devices that hold the individual cell clusters 48 in position during assembly of the removable battery pack 10 can be dispensed with.
  • Figure 3 illustrates the assembly according to Figure 2 consisting of the two cell clusters 48 and the insulating plate 66 in a disassembled structure, wherein an outer contour of the insulating plate 66 essentially corresponds to an envelope 68 of the cell clusters 48 in cross section through a longitudinal axis 70 of the assembly.
  • the assembly facilitates the subsequent assembly steps of the removable battery pack 10. By eliminating additional connecting elements such as screws, adhesives or the like, this enables a significant simplification and cost reduction in the assembly of the removable battery pack 10.
  • the at least two injection-molded components of the insulating plate 66 are formed by a hard component 72 (for example a thermoplastic or duroplastic or duromer) and a soft component 74 (for example an elastomer such as rubber, silicone or the like).
  • the hard component 72 essentially serves to stiffen the insulating plate 66, while the soft component 74 acts as mechanical damping or fixation and tolerance compensation.
  • the soft component 74 has a hardness of 0 to 100 Shore A, preferably 30 to 70 Shore A.
  • the soft component 74 can be used to seal dedicated areas of the removable battery pack 10 or the cell clusters 48.
  • Figure 4a shows the insulating plate 66 consisting of the hard component 72 and the soft component 74 in a perspective detailed view.
  • the hard component 74 has three locking hooks 76 on each side (see also Figure 3).
  • the locking hooks 76 tabs, mushroom heads or corresponding projections and/or recesses, for example in the form of a tongue and groove principle, can alternatively be used for fastening to the cell clusters 48.
  • the number of fastening elements can vary depending on the design of the cell clusters 48, for example depending on the number N of energy storage cells 50.
  • the locking hooks 76 can be used on the one hand to achieve good mechanical stabilization and on the other hand to achieve very simple and quick assembly of the structural units consisting of the cell clusters 48 and the insulating plate 66.
  • the locking hooks 76 and/or a plurality of mechanical guides 78 are arranged on the insulating plate 66 in such a way that the cell clusters 48 can only be connected to the insulating plate 66 in accordance with a poka-yoke principle. This allows increased process reliability during assembly to be achieved in order to avoid any assembly errors that may also lead to damage to the cell clusters 48 or the energy storage cells 50.
  • the soft component 74 is designed as a plurality M of elastic lamellae 80, which are arranged within the hard component 72 and are connected to one another via webs 82 of the same material.
  • the plurality M of lamellae 80 preferably corresponds to the number N of energy storage cells 50 of at least one of the cell clusters 48 connected to the insulating plate 66.
  • the individual energy storage cells 50 or their cell poles 54 and/or the cell connectors 56 connecting them or their contact points 58 can be effectively protected from mechanical vibrations, blows and impacts or the like during use of the removable battery pack 10.
  • the heat generated during operation of the electrical consumer 22 or during charging of the removable battery pack 10 can be dissipated or distributed.
  • the lamellae 80 circular in shape. Their position corresponds to the cell poles 54 of the cell clusters 48 connected to the insulating plate 66.
  • the pressing takes place in the assembled state of the insulating plate 66, so that the energy storage cells 50 and/or the cell connectors 56 can be held in position and the robustness of the removable battery pack 10 can be further improved.
  • the domes 83 shown in Figure 4b can also be used as part of the soft component 74.
  • Figure 6 shows the assembly of the removable battery pack 10 according to Figure 2 inserted into the sub-housing 38.
  • the sub-housing 38 is designed to be open at least on one end face 84, while it surrounds the assembly consisting of the cell clusters 42 and the insulating plate 66 with its other sides.
  • the sub-housing 38 also carries the electrical contacts 14 designed as the first and second power supply contacts 42, 44 and as the signal or data contact 46.
  • the electrical contacts 14 are designed as contact tulips, each of which is electrically connected to the busbars 64 in a material-locking manner through a recess 86 in the sub-housing 38.
  • the busbars 64 In order to enable the contact tulips to be welded on, the busbars 64 must be accessible on both sides at the corresponding contact points.
  • the busbars 64 are in turn overmolded with the material of the sub-housing 38 on a side adjacent to the circuit board 62 of the assembly. For this reason, the material of the sub-housing 38 must not be electrically conductive. If the exchangeable battery pack 10 with its electromechanical interface 16 is inserted into the corresponding counter-interface 20 of the electrical device 18 (cf. Figure 1), the contacts 14 of the electromechanical interfaces 20 of the electrical device 18, which are designed as flat metal webs, engage in the contact tulips to create an electrical connection.
  • busbars 64 By overmolding the busbars 64, the area around them is sealed accordingly and prevents liquid and dirt from entering the interior of the removable battery pack 10. This also increases the protection of sensitive components of the removable battery pack 10, such as the electronics or the energy storage cells 50, by appropriately isolating them from the environment. In addition, increased heat spreading or dissipation and thus improved cooling in the contact area is possible through the direct coupling of the busbars 64 to the outer housing 32 of the removable battery pack 10 and/or the electrical consumer 22.
  • busbars 64 injected into the sub-housing 38 facilitate the assembly of the removable battery pack 10 because the assembly consisting of the cell clusters 48 and the insulating plate 66 can very easily be inserted laterally into the sub-housing 38 through the opening on its front side 84.
  • Figure 7 shows a section through the fully assembled removable battery pack 10 along the longitudinal axis 70.
  • the two end caps 40 seal the sub-housing 38 at its open end faces 84 by means of a sealing lip 88.
  • the sealing lip 88 is preferably made of an elastomer such as rubber, silicone or the like and engages in a groove 90 running around the open end faces 84 of the sub-housing 38 and the end caps 40.
  • Figure 7b illustrates this using an enlarged detail of the area marked in Figure 7a.
  • Figure 6 also shows the groove 90 running around the end face 84 of the sub-housing 38 in a perspective view.
  • the sealing lip 90 is preferably injected or inserted into the groove 90 of the end caps 90 before the end caps 90 are mounted.
  • the sealing lip 90 is pressed into the groove 90 of the sub-casing 38 and seals the area surrounding it accordingly.
  • the end caps 40 are particularly advantageous in that they enable easy maintenance or repair of the removable battery pack 10, because defective components can be easily replaced by removing at least one of the end caps 40, by pulling the assembly consisting of the cell clusters 48 and the insulating plate 66 out of the open front side 84 of the Sub-housing 38 can be pulled out.
  • the sealing lip 88 in conjunction with the exchangeable end caps 40 ensures a high level of protection against environmental influences.
  • the sub-housing 38 has a pressure equalization opening 92 on one side, in particular on a side facing the circuit board 62, via which pressure equalization can take place between the sub-housing 38 sealed by the end caps 40 and the environment.
  • the pressure equalization opening 92 is sealed by a pressure equalization membrane 94. On the one hand, this enables gas and moisture to be exchanged between the sub-housing 38 and the environment, but on the other hand, the special material properties of the pressure equalization membrane 94 can prevent water and dirt from entering the interior of the removable battery pack 10.
  • Air-permeable, fine-pored membranes made of PTFE (polytetrafluoroethylene) are particularly suitable as the pressure equalization membrane 94.
  • these membranes can be coated oleophobically on at least one side, so that certain liquids roll off their outside.
  • Figure 8 shows a temperature measurement concept of the removable battery pack 10 using a flexible film 100 with two integrated temperature sensors 102 designed as NTCs, whereby the flexible film 100 is guided through two recesses 96 of the circuit board 62 on its upper side for electrical contact.
  • the temperature sensors 102 of the flexible film 100 are each pressed onto the outer surface of the energy storage cells 50 to be measured by a foam element 104 that is supported on the circuit board 62.
  • the flexible film 100 is electrically connected via the circuit board 62 to the electronics of the removable battery pack 10, which evaluates the measured temperature of the energy storage cells 50 and controls the charging or discharging process depending on this.
  • the circuit board 62 has recesses 96 for the busbars 64, into which the busbars 64 can be inserted with at least one a wave-shaped, in particular U-shaped, section 98.
  • the at least one section 98 is located below the surface of the circuit board 62. This makes it very efficient and easy to accommodate a tension and/or impact relief for the busbars 64 in the installation space of the circuit board 62, which enables a particularly compact design of the removable battery pack 10. In addition, a greater mobility of the busbars 64 is achieved.
  • the busbar 64 can deform elastically in the area of the at least one recess 96 of the circuit board 62 in order to reduce the introduced force as deformation energy. This leads to a relief of the electrical connection point 106 and the busbar 64. Corresponding connection points on the circuit board can also be relieved.
  • Figure 10 shows a section of the busbar 64 in the area of the U-shaped section 98 according to Figure 9 in the undeformed and deformed state, with the deformation shown being clearly exaggerated for better understanding. It is particularly advantageous for the U-shaped section 98 of the busbar 64 to have a depth extension T that is at least as large as its length extension L along the busbar 64. This makes it possible to increase the spring effect of the busbar 64 and thus the protection of the electrical connection point 106 or to adapt it to any specifications.
  • a wave shape in this context should also be understood as a shape with steep rectangular flanks.
  • the entire section 98 is below the Surface of the circuit board 62.
  • the at least one section 98 again partially protrudes from the surface of the side on which the busbar 64 is located.
  • the at least one section 98 of the busbar 64 can be made of a different, electrically conductive material than the rest of the busbar 64.
  • the busbar 64 is made of copper and the section 98 is made of aluminum, tungsten, silver, gold or the like. Additionally or alternatively, it can be provided that the at least one section 98 of the busbar 64 has a cross section and/or a thickness that differs from the cross section and/or the thickness of the rest of the busbar 64. For example, a smaller cross section and/or a smaller thickness of the section 98 offers greater flexibility and spring action, while a larger cross section and/or a greater thickness can be used, in particular in conjunction with a copper mesh as an additional material.
  • Figure 11 a shows a perspective view of the housing part of the removable battery pack 10 according to Figure 1, designed as an end cap 40, in an internal view.
  • Figure 11 b shows the end cap 40 in an external view.
  • the end cap 40 is manufactured in a three-component injection molding process and thus consists of three different injection molding components.
  • a base body 108 of the end cap 40 is formed from the hard component 74 and is molded, in particular almost completely, by the soft component 74 on at least a first side, in particular an outer side, of the end cap 40. This results in improved handling for an operator, for example in that there is more grip, especially with wet hands.
  • this improves the sealing of the removable battery pack 10 or the electrical consumer 30 against moisture, liquids, dust and other forms of dirt, and on the other hand, it makes the assembly of the end cap 40 much easier, since the sealing lip 88 does not have to be inserted separately into the groove 90.
  • a further improvement in the usability of the removable battery pack 10 can be achieved by injecting at least one actuating element 124 and/or at least one optical separating element 126 into the third injection-molded component 116, which is formed in particular from the hard component 72 or a comparable thermoplastic.
  • the charge level indicator 118 can be activated for a defined time window by briefly pressing the actuating element 124.
  • the at least one optical separating element 126 makes it possible to distinguish different charge levels of the removable battery pack 10 more clearly from one another, because this avoids scattered light between the individual LEDs that display the charge levels.
  • the embodiments shown are not limited to Figures 1 to 11 or to the shape, number and size of the energy storage cells 50 and the busbars 64 shown therein.
  • the number and shape of the cell clusters 48 of the removable battery pack 10 can also vary accordingly. This also applies in particular to the sub-housing 38, the end caps 40, the insulating plate 66 and the circuit board 62 of the removable battery pack 10.
  • several insulating plates 66, circuit boards 62 and sub-housings 38 can also be used within the outer housing 32 of the removable battery pack 10.
  • the design and number of the end caps 40 are also not limited to the embodiments shown.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

L'invention concerne une unité de stockage d'énergie (12) pour un consommateur électrique (20), comportant une pluralité (N) de cellules de stockage d'énergie (50). Chaque cellule de stockage d'énergie (50) présente deux pôles de cellule électrique (54) et les pôles de cellule électrique (54) d'au moins deux cellules de stockage d'énergie (50) sont connectés de manière électriquement conductrice les uns avec les autres en série ou en parallèle en tant que groupe de cellules (48) au moyen d'au moins un connecteur de cellule (56). Selon l'invention, l'unité de stockage d'énergie (12) comprend au moins deux groupes de cellules (48) qui sont reliés l'un à l'autre au moyen d'une plaque isolante (66) produite dans un procédé de moulage par injection à deux composants ou à trois composants. L'invention concerne également un consommateur électrique (30) comprenant l'unité de stockage d'énergie (12) selon l'invention et un système constitué d'un consommateur électrique (30) réalisé sous la forme d'une machine-outil portative (24, 26, 28) et d'au moins une unité de stockage d'énergie (12) selon l'invention conçue sous la forme d'un bloc-batterie rechargeable échangeable (10).
EP23810363.4A 2022-12-14 2023-11-23 Unité de stockage d'énergie pour un consommateur électrique Pending EP4635020A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102022213649.7A DE102022213649A1 (de) 2022-12-14 2022-12-14 Energiespeichereinheit für einen elektrischen Verbraucher
PCT/EP2023/082856 WO2024125997A1 (fr) 2022-12-14 2023-11-23 Unité de stockage d'énergie pour un consommateur électrique

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EP4635020A1 true EP4635020A1 (fr) 2025-10-22

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CN (1) CN120380647A (fr)
DE (1) DE102022213649A1 (fr)
WO (1) WO2024125997A1 (fr)

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CN118841690B (zh) * 2024-09-13 2024-12-03 思极星能科技(四川)有限公司 一种模块化管理的储能设备

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Publication number Priority date Publication date Assignee Title
KR101934399B1 (ko) * 2011-11-14 2019-01-02 삼성에스디아이 주식회사 보호회로모듈과 접속 단자부를 포함하는 배터리 팩 및 이를 구비한 전기 바이크
KR101255250B1 (ko) * 2012-03-23 2013-04-16 삼성에스디아이 주식회사 전지 모듈
DE102016203424A1 (de) * 2015-03-06 2016-09-08 Robert Bosch Gmbh Akkupack für eine Handwerkzeugmaschine
KR102394690B1 (ko) * 2015-07-20 2022-05-06 삼성에스디아이 주식회사 배터리 셀 홀더 부재
CN110710026A (zh) * 2017-05-29 2020-01-17 三洋电机株式会社 电池组
DE102017213474A1 (de) * 2017-08-03 2019-02-07 Bayerische Motoren Werke Aktiengesellschaft Batteriemodul und Batteriemodulstapel für ein Kraftfahrzeug
WO2019208217A1 (fr) * 2018-04-25 2019-10-31 三洋電機株式会社 Bloc batterie
US12300842B2 (en) * 2019-07-29 2025-05-13 Panasonic Energy Co., Ltd. Battery pack
CN110416458B (zh) * 2019-08-05 2021-11-12 安徽相源新能源有限公司 一种加强散热的防爆锂电芯电池组及其制造方法
DE102021206828A1 (de) * 2021-06-30 2023-01-05 Robert Bosch Gesellschaft mit beschränkter Haftung Akkupack

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CN120380647A (zh) 2025-07-25
DE102022213649A1 (de) 2024-06-20

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