DE102009050319A1 - Electro-chemical device i.e. lithium iron phosphate accumulator, for drive of motor vehicle, has terminals comprising contact surfaces, where contact region of connector is connected with one of surfaces by soldering process or adhesion - Google Patents

Abstract

The device (100) has a cell connector (132) for connecting two cell terminals (134, 136) in an electrically conductive manner. The two cell terminals comprise contact surfaces that are made first and second materials, respectively, where the second material is different from the first material. The cell connector comprises a base body and a contact region that is made of third material. The contact region of the cell connector is connected with one of the contact surfaces of one of the terminals by a soldering process or adhesion. The second and third materials comprise nickel as a main part.

Description

The present invention relates to an electrochemical device comprising at least a first electrochemical cell having a first cell terminal, a second electrochemical cell having a second cell terminal, and a cell connector for electrically connecting the first cell terminal and the second cell terminal, wherein the first cell terminal comprises a contact surface a first material and the second cell terminal comprises a contact surface of a second material different from the first material.

Such electrochemical devices can be designed, in particular, as electric accumulators, for example as lithium-ion accumulators.

In a lithium-ion battery, the voltage difference between the two cell terminals (poles) of a single battery cell is about 3.6 V. In order to obtain a higher voltage level of, for example, about 360 V required for many applications, for example in automotive propulsion technology, For example, many such accumulator cells (for example, about 100) must be electrically connected in series.

The accumulator cells or generally electrochemical cells can be combined into modules, each of which contains a plurality of such electrochemical cells, wherein the installation direction of juxtaposed cells alternates, so that positive and negative cell terminals are adjacent to each other.

These mutually adjacent cell terminals of opposite polarity are connected directly to each other for the series connection of the cells by means of a respective cell connector.

The present invention has for its object to provide an electrochemical device of the type mentioned, in which a reliable, reliable, corrosion-resistant and a low contact resistance having connection of the cell connector is achieved with the cell terminals.

This object is achieved according to the invention in an electrochemical device having the features of the preamble of claim 1 in that the cell connector has a main body made of the first material and a contact region made of a third material connected to the main body and connected to the contact surface of the second cell terminal. and that the contact region of the cell connector is connected to the contact surface of the second cell terminal by soldering or by gluing.

In the concept according to the invention, therefore, a contact region of a third material is arranged between the main body of the first material, which coincides with the material of the contact surface of the first cell terminal, and the contact surface of the second cell terminal of the second material, which contact area of the contact surface of the second cell terminals can be soldered and / or glued.

In this way, a cohesive connection between the cell connector and the second cell terminal can be produced without the cell connector and the second cell terminal having to be welded together.

As a result, in particular, a corrosion protection layer made of the second material which is present on the second cell terminal and which is arranged above a base material of the second cell terminal susceptible to corrosion, can remain undamaged.

It is therefore a gentle and stable type of connection between the cell connector and the second cell terminal.

By contrast, the basic body of the cell connector can be welded to the first cell terminal in a manner which allows a particularly simple connection process and a low contact resistance at the transition between the first cell terminal and the cell connector.

In a preferred embodiment of the invention it is provided that the second material and the third material are substantially equal. As a result, a pure soldering between the contact region of the cell connector and the contact surface of the second cell terminal is possible, resulting in a simple to produce compound with high long-term stability and low contact resistance. Furthermore, in this case, a particularly large number of suitable solder materials are available for soldering the contact region of the cell connector to the contact surface of the second cell terminal.

In a preferred embodiment of the invention, it is provided that the first material and the second material are not directly soldered together. The solderability of the cell connector with the contact surface of the second cell terminal is made in this case only by the arranged between the main body of the cell connector and the contact surface of the second cell terminal contact area of the cell connector.

The contact region of the cell connector can be connected in particular by means of a soft solder to the contact surface of the second cell terminal, preferably by means of a soft solder with a soldering temperature of less than about 250 ° C. This offers the advantage that in the soldering of the cell connector to the second cell terminal thermally sensitive components of the electrochemical device, in particular insulating parts made of a plastic material, are not damaged.

For example, a solder containing tin and silver, for example the solder having the composition SnAg _3.5 , can be used as soft solder.

As an alternative to using a soft solder, a brazing alloy, such as a silver-based brazing alloy, may also be used. In this case, the brazing solder is preferably melted by means of a short-time laser to prevent damage to thermally sensitive components of the electrochemical device.

As an alternative to soldering the contact region of the cell connector to the contact surface of the second cell terminal, these elements can also be glued together by means of an electrically conductive adhesive.

In particular, an epoxy resin adhesive with an electrically conductive filler can be used for the bonding.

The electrically conductive filler may in particular comprise silver.

The electrically conductive adhesive can be applied to one of the elements to be bonded together or to both elements, whereupon both elements are brought into contact with the adhesive layer and the adhesive layer is cured.

The curing of the adhesive layer can in particular by heat, at room temperature relative to elevated temperature, take place.

The two elements to be bonded together are preferably pressed against each other under a contact pressure until these elements are connected to one another in a material-locking manner by the adhesive.

• – der silberhaltige Epoxidharz-Kleber, der unter der Bezeichnung LOCTITE^® 3880 von der Firma Henkel Technologies, Heydastraße 10, 58093 Hagen, Deutschland, vertrieben wird. Hinsichtlich der chemischen und physikalischen Eigenschaften und der Arbeitsschritte zur Verarbeitung dieses Klebers wird auf das technische Datenblatt zum Kleber LOCTITE^® 3880 vom Juni 2005 Bezug genommen, und das genannte Datenblatt wird diesbezüglich zum Bestandteil der vorliegenden Beschreibung gemacht.
• – der silberhaltige Epoxidhard-Kleber, der von der Firma Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA, unter der Bezeichnung Master Bond Supreme 10 HT/S vertrieben wird. Hinsichtlich der physikalischen und chemischen Eigenschaften und der Arbeitsschritte zum Verarbeiten dieses Klebers wird auf das technische Datenblatt zum Kleber Master Bond Supreme 10 HT/S Bezug genommen, und dieses Datenblatt wird diesbezüglich zum Bestandteil der vorliegenden Beschreibung gemacht.
• – der silberhaltige Epoxidharz-Kleber, der von der Firma Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA, unter der Bezeichnung Master Bond FL901S vertrieben wird. Hinsichtlich der physikalischen und chemischen Eigenschaften und der Arbeitsschritte zum Verarbeiten dieses Klebers wird auf das technische Datenblatt zu dem Kleber Master Bond FL9015 Bezug genommen, und dieses Datenblatt wird diesbezüglich zum Bestandteil der vorliegenden Beschreibung gemacht.

Suitable electrically conductive adhesives are in particular the following:

• - The silver-containing epoxy resin adhesive, which is sold under the name LOCTITE ^® 3880 by Henkel Technologies, Heydastrasse 10, 58093 Hagen, Germany. With regard to the chemical and physical properties and the procedures for processing of this adhesive, reference is made to the technical data sheet 2005 for adhesive LOCTITE ^® 3880 June, and said sheet is in this respect made a part of this specification.
• The silver-containing epoxy hard adhesive marketed by Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA under the name Master Bond Supreme 10 HT / S. With regard to the physical and chemical properties and the steps for processing this adhesive, reference is made to the technical data sheet for the Master Bond Supreme 10 HT / S adhesive, and this data sheet is hereby made part of the present description.
• The silver-containing epoxy resin adhesive sold by Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA under the name Master Bond FL901S. With regard to the physical and chemical properties and the steps for processing this adhesive, reference is made to the technical data sheet for the adhesive Master Bond FL9015, and this data sheet is hereby made part of the present description.

In a preferred embodiment of the invention, it is provided that the main body of the cell connector comprises aluminum as the main component. The proportion of aluminum in the material of the main body is preferably more than 90 percent by weight, in particular more than 99 percent by weight. Aluminum has a low electrical volume resistance (bulk resistance) and is thus particularly suitable for a lossless electrical connection in series connected electrochemical cells.

The basic body of the cell connector can be connected by welding, preferably by laser welding, to the contact surface of the first cell terminal.

If the electrochemical device comprises a receiving device with at least one first receptacle for the first electrochemical cell and a second receptacle for the second electrochemical cell, it is for reducing mechanical stresses occurring during operation of the electrochemical device, by different thermal expansions of the cell connector on the one hand and the receiving device for the electrochemical cells can arise on the other hand, advantageous if the first material from which the base body is formed, has a thermal expansion coefficient α, the less than Deviates 10% from the coefficient of thermal expansion of the material of the recording device.

When the thermal expansion coefficients of these materials vary widely from the ambient temperature to the operating temperature of the electrochemical device, this indication refers to the respective average coefficient of thermal expansion when heated from the ambient temperature (20 ° C) to the operating temperature of the electrochemical device (e.g. 60 ° C).

To avoid such mechanical stresses, it is particularly favorable if the first material and the material of the receiving device are essentially the same.

In particular, it can be provided that the first material and the material of the receiving device comprise aluminum as the main component.

The second material preferably comprises nickel as the main constituent and, in particular, may be substantially completely formed from nickel.

Likewise, the third material preferably also comprises nickel as its main component; In particular, the third material may be formed substantially entirely of nickel.

The contact region of the cell connector may comprise a coating arranged on the base body.

Preferably, such a coating is created on the body of the cell connector before the cell connector is connected to the cell terminals.

In particular, it can be provided that the contact region of the cell connector comprises a coating applied galvanically to the base body.

Alternatively or additionally, it can be provided that the contact region of the cell connector comprises a contact body, which is materially connected to the base body.

This contact body is made separately from the body as a separate part and then fixed to the body.

In particular, it can be provided that the contact body of the cell connector is connected by welding, in particular by laser welding or ultrasonic welding, with the main body of the cell connector.

If the electrochemical device is designed as an accumulator, the first cell terminal preferably forms a positive pole of the first electrochemical cell and the second cell terminal preferably forms a negative pole of the second electrochemical cell.

The cell connector of the electrochemical device of the invention utilizes the synergies of different materials and reduces or overcomes the disadvantages characteristic of known types of connection of such cell connectors.

The cell connector has a low volume electrical resistance and low contact resistance at the junctions between the cell terminals and the cell connector.

Furthermore, the cell connector has a low mass and a good handling and can be produced at low cost.

The cell connector can be manufactured using established manufacturing processes and reliably connected to the cell terminals using process-safe procedures.

The type of connection of the cell connector with the cell terminals ensures good corrosion protection of all components involved.

Particular embodiments of the cell connector and the electrochemical device according to the invention offer the advantages that a length compensation for the compensation of relative movements of the cell terminals relative to each other and / or a compensation of differences in the positions of the cell terminals caused by manufacturing tolerances or by different thermal length changes of the electrochemical cells along the axial direction the cells are integrated into the cell connector.

If a length compensation field is integrated in the cell connector, the cells interconnected by the cell connector are spared and their longevity promoted.

Furthermore, at least one voltage tap for single cell monitoring can be integrated into the cell connector. As a result, a voltage measuring device can be coupled in a simple manner to each cell connector.

Multiple cell connectors may be fabricated together in a contiguous connector assembly, such as stamped and bent parts and then handled together until they are committed to the respective associated cell terminals. This significantly speeds up the assembly of the electrochemical device since the cell connectors no longer need to be individually supplied to the cell terminals to be connected. As a result, the handling costs are significantly reduced.

Due to a modular structure of the cell connectors, a process improvement is achieved.

The present invention enables the fabrication of cost-effective, fail-safe connectors for connecting single electrochemical cells with high power density and short charge and discharge cycles.

Through the cell connector as short as possible and low-loss direct connection between two electrochemical cells is produced.

The conductivity of the cell connector meets high standards, especially when a pure-grade welding or soldering of the cell terminals is done with the cell connector.

If the electrochemical device according to the invention is designed as an accumulator, it is particularly suitable as a heavy-duty energy source, for example for the propulsion of motor vehicles.

Further features and advantages of the invention are the subject of the following description and the drawings of exemplary embodiments.

In the drawings show:

1 a schematic perspective view of a module of an electrochemical device, which several, for example eight, electrochemical cells, a receiving device for receiving the cells, a plurality of cell connectors for electrically connecting cell terminals of two electrochemical cells, a circuit board for the voltage tap of the cell connectors and electrical connections for electrically conductive connection of the module with other modules, with a charging device or with a consumer comprises;

2 a plan view of a front of the module 1 ;

3 one of the 1 corresponding schematic perspective view of the module without the receiving device;

4 a schematic side view of the module without the recording device 3 ;

5 a schematic plan view of the circuit board of the module from the 1 to 4 ;

6 a schematic plan view of the front cell terminals of the electrochemical cells of the module;

7 one of the 6 corresponding plan view of the front cell terminals of the electrochemical cells and a holder frame in which the electrochemical cells are held;

8th a schematic plan view of a group of cell connectors, which are separated together from a starting material and connected to each other via connecting webs;

9 a schematic plan view of the front cell terminals of the module with the cell terminators fixed cell connectors of the cell connector group 8th wherein the connecting webs between the cell connectors are still present;

10 a schematic plan view of the front cell terminals of the module and the cell connectors fixed thereto after the connecting webs have been removed between the cell connectors of the cell connector group;

11 a schematic section through two electrochemical cells and a cell connector with a base body which is directly welded to a first cell terminal and is welded to a second cell terminal indirectly via a contact area, wherein the contact area is connected by ultrasonic welding to the base body;

12 a schematic section through two electrochemical cells and a cell connector which is directly welded to a first cell terminal and is welded to a second cell terminal indirectly via a contact region, wherein the contact region is connected by laser welding along a weld with the main body;

13 a schematic section through two electrochemical cells and a cell connector, which is connected to a first cell terminal by welding and with a second cell terminal by soldering;

14 a schematic plan view of a cell connector having a deformable compensation area with a wave structure, wherein the wave structure has an amplitude directed parallel to the axial direction of the electrochemical cells and a plurality of wave crests extending transversely to the axial direction of the electrochemical cells, for example, and a plurality of wave troughs extending transversely to the axial direction of the electrochemical cells, for example; and wherein the cell connector further comprises retaining webs for connecting the electrochemical cells Cell connector having the circuit board of the module;

15 a schematic side view of the cell connector 14 ;

16 a schematic side view of the cell connector 14 and the two electrochemical cells connected together by the cell connector;

17 a schematic plan view of an alternative embodiment of a cell connector having a deformable compensation region comprising a wave structure, wherein the wave structure has an amplitude in the axial direction of the electrochemical cells and a plurality, for example, three transverse to the axial direction of the electrochemical cells wave crests and several, for example two, transverse to the axial direction of the electrochemical cells extending troughs and further wherein the cell connector has no holding webs;

18 a schematic side view of the cell connector 17 ;

19 a schematic plan view of an alternative embodiment of a cell connector with a deformable compensation area with a half-bead structure, which merges with creases in contact areas of the cell connector;

20 a schematic side view of the cell connector 19 ;

21 a schematic plan view of an alternative embodiment of a cell connector with a deformable compensation region having a wave structure, wherein the wave structure has an amplitude in the axial direction of the electrochemical cells and a transversely to the axial direction of the electrochemical cells extending wave crest and transverse to the axial direction of the comprising corrugations extending over electrochemical cells;

22 a schematic side view of the cell connector 21 ;

23 a schematic plan view of an alternative embodiment of a cell connector with deformable compensation area, which has a wave structure, wherein the wave structure has an amplitude in the axial direction of the electrochemical cells and a plurality, for example, two, transverse to the axial direction of the electrochemical cells extending wave peaks and transverse to Axial direction of the electrochemical cells extending wave trough comprises;

24 a schematic side view of the cell connector 23 ;

25 a schematic plan view of an alternative embodiment of a cell connector with deformable compensation area, which has a zigzag structure, wherein the zigzag structure has a plurality, for example five, extending transversely to the axial direction of the electrochemical cells bending lines;

26 a schematic side view of the cell connector 25 ;

27 a schematic plan view of an alternative embodiment of a cell connector deformable Kompensationsbereich having a wave structure, wherein the wave structure having an amplitude in the axial direction of the electrochemical cells and a plurality, for example three, transverse to the axial direction of the electrochemical cells extending wave peaks and a plurality, for example two comprising troughs extending transversely to the axial direction of the electrochemical cells;

28 a schematic side view of the cell connector 27 ;

29 a schematic plan view of an alternative embodiment of a cell connector having a deformable compensation region, which has a wave structure, wherein the wave structure has an amplitude in the axial direction of the electrochemical cells and a plurality, for example, four transverse to the axial direction of the electrochemical cells extending wave peaks and a plurality, for example three, comprising troughs extending transversely to the axial direction of the electrochemical cells;

30 a schematic side view of the cell connector 29 ;

31 a schematic plan view of an alternative embodiment of a cell connector with deformable compensation area, which has a wave structure, the wave structure having an amplitude in the axial direction of the electrochemical cells and a plurality, for example, three, transverse to the axial direction of the electrochemical cells extending wave peaks and a plurality, for example, two, extending transversely to the axial direction of the electrochemical cells troughs, wherein a main body of the cell connector is formed as a laminate of a plurality, for example, three, superimposed layers or layers of material;

32 a schematic side view of the cell connector 31 ;

33 an enlarged view of the area A from 32 ;

34 a schematic plan view of an alternative embodiment of a cell connector deformable Kompensationsbereich having a wave structure, wherein the wave structure having an amplitude in the axial direction of the electrochemical cells and a plurality, for example three, transverse to the axial direction of the electrochemical cells extending wave peaks and a plurality, for example two , wherein the compensating region is subdivided by a plurality of, for example three, wave-shaped slots into a plurality of, for example four, wavy webs, which are arranged next to one another in a direction transverse to the axial direction of the electrochemical cells the waveform of the slots and the waveform of the lands have an amplitude transverse to the axial direction of the electrochemical cells;

35 a schematic side view of the cell connector 34 ;

36 a schematic plan view of an alternative embodiment of a cell connector with deformable compensation area, which is substantially planar, but is divided by a plurality, for example, three, wave-shaped slots in a plurality, for example four, wavy bars, wherein the waveform of the slots and the waveform of the webs have an amplitude transverse to the axial direction of the electrochemical cells;

37 a schematic side view of the cell connector 36 ;

38 a schematic plan view of a plurality of cell connectors, which are each formed integrally with in each case a conductor for a voltage tapping of the cell connectors;

39 a schematic side view of the cell connector assembly from

38 wherein the cell connectors are disposed at the cell terminals of the electrochemical cells of the module;

40 a schematic perspective view of two modules of the electrochemical device, wherein an electrical terminal of a first module is connected to an electrical terminal of a second module via a module connector;

41 a schematic side view of the two modules with module connector 40 , overlooking a narrow side of the modules;

42 a schematic longitudinal section through the two modules and the module connector 41 , along the line 42-42 in 41 ;

43 a schematic perspective view of the module connector of the 40 to 42 , seen from the electrical connections of the modules side facing;

44 a schematic perspective view of the module connector of the 40 to 42 , seen from the side facing away from the electrical connections of the modules;

45 a schematic side view of the module connector of the 43 and 44 ;

46 a schematic plan view of the module connector from the

43 to 45 , with a view to the side facing away from the electrical connections of the modules module connector;

47 a schematic plan view of a specimen for determining the corrosion resistance of a weld between a cell terminal and a cell connector;

48 a schematic side view of the sample body 47 ;

49 a schematic longitudinal section through the sample body of the 47 and 48 ;

50 a schematic plan view of a subframe for holding cell connectors; and

51 a schematic plan view of a holder frame of the module with a connector assembly held thereon.

Identical or functionally equivalent elements are denoted by the same reference numerals in all figures.

One as a whole 100 referred to electrochemical device comprises a plurality of electrochemical modules 102 , one of which is exemplified in the

1 to 4 as a whole is shown. Each of the modules 102 comprises several, for example eight, electrochemical cells 104 , each in a recording 106 a recording device 108 of the module 102 are included.

This cradle 108 especially as a heat sink 110 be formed, with the recorded therein electrochemical cells 104 is in heat conductive contact to during operation of the electrochemical device 100 Heat from the electrochemical cells 104 dissipate.

The cradle 108 is preferably formed of a good heat conducting material, for example of aluminum or an aluminum alloy.

How best of the 3 and 4 to see which is the module 102 without the cradle 108 represent are the electrochemical cells 104 in the cradle surrounding it 108 arranged and aligned so that the axial directions 112 the electrochemical cells 104 which are parallel to the central longitudinal axes 114 the electrochemical cells 104 run, are aligned substantially parallel to each other.

How best 4 As can be seen, each of the electrochemical cells extends 104 from one (in 4 shown above) front cell terminal 116 in the respective axial direction 112 up to one (in 4 shown below) rear cell terminal 118 wherein each cell terminal each has a positive pole or a negative pole of the electrochemical cell 104 forms.

The central longitudinal axes 114 the electrochemical cells 104 are at the same time central longitudinal axes of the cell terminals 116 . 118 the respective electrochemical cells 104 ,

In the module 102 are adjacent electrochemical cells 104 each aligned so that arranged on the same side of the module cell terminals of two adjacent cells have opposite polarity.

This will be explained below on the basis of 6 illustrates the polarities of, for example, eight, front cell terminals 116 of the eight electrochemical cells 104 a module 102 shows.

Here, the front cell terminal forms 116 the electrochemical cell 104a a positive pole of the relevant electrochemical cell 104a while the front cell terminal 116 in a first transverse direction 120 of the module 102 the electrochemical cell 104a adjacent electrochemical cell 104 b a negative pole of the electrochemical cell 104 b forms.

Accordingly, the front cell terminal forms 116 in the first transverse direction 120 on the electrochemical cell 104 b following electrochemical cell 104c a positive pole of the electrochemical cell 104c and the front cell terminal 116 in the first transverse direction 120 on the electrochemical cell 104c following electrochemical cell 104d a negative pole of the electrochemical cell 104d ,

The front cell terminal 116 of the module 102 the electrochemical cell 104e , which in a second transverse direction 122 perpendicular to the first transverse direction 120 of the module 102 and perpendicular to the axial directions 112 the electrochemical cells 104 aligned to the electrochemical cell 104d follows, forms a positive pole of the electrochemical cell 104e , The front cell terminal 116 in the first transverse direction 120 on the electrochemical cell 104e following electrochemical cell 104f forms a negative pole of the electrochemical cell 104f while the front cell terminal 116 in the first transverse direction 120 on the electrochemical cell 104f following electrochemical cell 104g a positive pole of the electrochemical cell 104g and the front cell terminal 116 in the first transverse direction 120 on the electrochemical cell 104g following electrochemical cell 104h finally again a negative pole of the electrochemical cell 104h forms.

If the front cell terminal 116 an electrochemical cell 104 a positive pole of the relevant electrochemical cell 104 forms, so forms the back cell terminal 118 a negative pole of the same cell 104 , If the front cell terminal 116 an electrochemical cell 104 a negative pole of the relevant electrochemical cell 104 forms, so forms the back cell terminal 118 the same electrochemical cell 104 a positive pole of the same electrochemical cell 104 ,

The electrochemical device 100 can be designed in particular as an accumulator, in particular as a lithium-ion accumulator, for example of the type LiFePO ₄ .

The electrochemical cells 104 the electrochemical modules 102 can be used as accumulator cells, in particular as lithium-ion batteries. Accumulator, for example, the type LiFePO ₄ , be formed.

As in particular from the 3 and 4 As can be seen, the front ends of the electrochemical cells extend 104 with the front cell terminals 116 through a front holder frame 124 , which for each electrochemical cell 104 in each case one passage opening 126 and the rear ends of the electrochemical cells 104 with the rear cell terminals 118 through a rear holder frame 128 , which for each electrochemical cell 104 likewise in each case one passage opening 130 having.

The holder frame 124 and 128 thus serve to position the electrochemical cells 104 ,

The holder frame 124 and 128 may be formed of an electrically insulating material, for example of a plastic material.

As in particular from the top view of 2 can be seen, includes the electrochemical module 102 furthermore several cell connectors 132 , by means of which the cell terminals of adjacent electrochemical cells 104 are electrically conductively connected to each other with different polarity, in order in this way all the electrochemical cells 104 of the electrochemical module 102 to connect electrically in series.

Each cell connector connects 132 a first cell terminal 134 positive polarity with a second cell terminal 136 negative polarity of an adjacent electrochemical cell 104 ,

How out 2 can be seen are, in particular, the first cell terminal 134c the electrochemical cell 104c and the second cell terminal 136b the electrochemical cell 104 b through a cell connector 132c interconnected, the first cell terminal 134e the electrochemical cell 104e and the second cell terminal 136d the electrochemical cell 104d through a cell connector 132e connected to each other and the first cell terminal 134g the electrochemical cell 104g and the second cell terminal 136f the electrochemical cell 104f through a cell connector 132g connected with each other.

To all electrochemical cells 104 of the module 102 In addition, the rear cell terminals are also connected electrically in series 118 adjacent electrochemical cells 104 by cell connectors (not shown) 132 interconnected, namely the (negative) rear cell terminal 118 the electrochemical cell 104a with the (positive) posterior cell terminal 118 the electrochemical cell 104 b , the (negative) posterior cell terminal 118 the electrochemical cell 104c with the (positive) posterior cell terminal 118 the electrochemical cell 104d , the (negative) posterior cell terminal 118 the electrochemical cell 104e with the (positive) posterior cell terminal 118 the electrochemical cell 104f and the (negative) rear cell terminal 118 the electrochemical cell 104g with the (positive) posterior cell terminal 118 the electrochemical cell 104h ,

The front cell terminal 116 the beginning of the cell series connection of the electrochemical module 102 forming electrochemical cell 104a and the front cell terminal 116 the end of the cell series connection forming electrochemical cell 104h are each electrically conductive with an electrically conductive connection 138 of the electrochemical module 102 connected.

Each of the electrical connections 138 comprises a trained example as stamped bent part contact element 140 with a contact section 142 , which is fixed to the respective associated cell terminal, with an example sword-shaped connector portion 144 , which, for example, in the first transverse direction 120 of the electrochemical module 102 and preferably perpendicular to the axial direction 112 the electrochemical cells 104 from the contact section 142 extends away, and with a compared to the contact portion 142 and the connector portion 144 narrow trained, for example, angular holding web 146 which is the contact element 140 with one at the front of the electrochemical module 102 arranged bracket 148 in the form of a printed circuit board 150 combines.

A contact section 142 and the connector portion 144 of the contact element 140 opposite end of the retaining bridge 146 is electrically conductive to a (not shown) trace on the electrochemical cells 104 facing the back of the circuit board 150 connected.

The jetty 146 thus serves not only as a mechanical holding element, but at the same time as a voltage tap 151 ,

Each of the cell connectors 132 , which each have a first cell terminal 134 and a second cell terminal 136 connect electrically conductive with each other, comprises a main body 152 with a first contact section 154 in the assembled state of the cell connector 132 with the (positive) first cell terminal 134 an electrochemical cell 104 is connected, and a second contact portion 156 in the assembled state of the cell connector 132 with a (negative) second cell terminal 136 another electrochemical cell 104 connected is.

The main body 132 of the cell connector 132 is preferably produced as a stamped and bent part.

In the in the 2 and 8th to 10 illustrated embodiment of a cell connector 132 includes the main body 152 of the cell connector 132 Furthermore, a first holding bridge 158 with which the cell connector 132 on the bracket 148 is fixed and which the first contact section 154 with an associated trace of the circuit board 150 electrically conductively connects, and a second holding bridge 160 over which the cell connector 132 also on the bracket 148 is fixed and which the second contact portion 156 with an associated trace of the circuit board 150 electrically conductive connects.

Every cell connector 132 of the electrochemical module 102 is each a separate trace on the circuit board 150 and these tracks are connected to a control unit (not shown) of the electrochemical device 100 connected, so that on the respectively associated conductor track and the electrically conductive holding webs 158 or 160 the electrical potential of the respective cell connector 132 and the cell terminal associated therewith 116 can be tapped from the control unit.

The first jetty 158 and the second jetty 160 thus serve as voltage taps 162 , about which the electrical potential of the cell connector 132 by the control unit of the electrochemical device 100 can be tapped and evaluated.

Furthermore, it is possible by means of the control unit of the electrochemical device 100 over the voltage taps 162 a charge balance between different electrochemical cells 104 perform.

Since the first contact section 154 and the second contact portion 156 of the cell connector 132 are at the same electrical potential, it is sufficient if one of the holding webs 158 . 160 with an associated trace of the circuit board 150 connected is.

A particularly simple and time-saving installation of multiple cell connectors 132 and optionally also the electrical connections 138 in the form of the contact elements 140 at the cell terminals 116 of the electrochemical module 102 is achieved when the main body 152 several cell connectors 132 and preferably also the contact elements of the electrical connections 138 of the module 102 are cut together from a starting material, in particular punched out, and then a connector assembly 164 form (see 8th ), in which the cell connectors 132 through connecting bridges 166 are integrally connected to each other and thus can be handled as a unit.

In particular, it can be provided that the connector assembly 164 , which as a punched grid 168 may be formed, a cell connector 132 and optionally also the contact elements 140 surrounding frame bridge 170 at which the cell connectors 132 and the contact elements 140 through individual connecting bridge sections 172 are held.

This connector assembly 164 is used during assembly of the electrochemical module 102 in the desired assignment to the electrochemical cells 104 of the module 102 which the front holder frame 124 enforce (see 7 ), whereupon the contact sections 154 and 156 the cell connector 132 as well as the contact elements 140 the electrical connections 138 , preferably cohesively, with the respective associated cell terminal 116 be connected so that the in 9 shown assembly state is reached, in which the cell connectors 132 and contact elements 140 the connector assembly 164 still over the connecting bridges 166 are integrally connected to each other.

Subsequently, the connecting webs 166 So the frame bridge 170 and the individual connecting bridge sections 172 , from the cell connectors 132 and the contact elements 140 separated, so that in 10 shown assembly state is achieved, in which the individual cell connectors 132 and contact elements 140 no longer electrically connected to each other.

To complete the electrochemical module 102 then becomes the bracket 148 in the form of the printed circuit board 150 at the front of the electrochemical module 102 arranged and with the retaining bars 158 . 160 respectively. 146 connected (preferably by soldering), so that in 2 illustrated assembly final state of the electrochemical module 102 is reached.

In a variant of the method described above for mounting the cell connectors 132 and the contact elements 140 at the cell terminals 116 of the electrochemical module 102 becomes the connector assembly 164 as a whole with the bracket 148 in the form of the printed circuit board 150 connected before the cell connectors 132 and the contact elements 140 in the desired assignment to the electrochemical cells 104 of the module 102 be arranged and set to the same.

For this purpose, the holding webs 158 . 160 and 146 the cell connector 132 or the contact elements 140 with the tracks of the holder 148 , preferably by soldering.

Subsequently, the connecting webs 166 So the frame bridge 170 and the individual connecting bridge sections 172 , from the cell connectors 132 and the contact elements 140 separated so that the individual cell connectors 132 and contact elements 140 no longer electrically connected to each other.

To complete the electrochemical module 102 then becomes the bracket 148 in the form of the printed circuit board 150 with the cell connectors held thereon 132 and contact elements 140 so on the front of the electrochemical module 102 arranged that the cell connectors 132 and the contact elements 140 in the desired assignment to the electrochemical cells 104 of the module 102 which the front holder frame 124 enforce, are positioned, where the contact sections 154 and 156 the cell connector 132 as well as the contact elements 140 the electrical connections 138 , preferably cohesively, with the respective associated cell terminal 116 be joined, so that finally also in 2 illustrated assembly final state of the electrochemical module 102 is reached.

In a further variant of the above-described method for assembling the cell connectors 132 and the electrical connections 138 in the form of the contact elements 140 at the cell terminals 116 of the electrochemical module 102 becomes the connector assembly 164 as a whole not with the bracket 148 in the form of the printed circuit board 150 but with the front holder frame 124 of the electrochemical module 102 connected, as in 51 is shown.

This will be the cell connectors 132 and the contact elements 140 the connector assembly 164 each separately on the front holder frame 124 determined, for example, by clamping or locking by means of suitable clamping elements or latching elements.

Subsequently, the connecting webs 166 So the frame bridge 170 and the individual connecting bridge sections 172 , from the cell connectors 132 and the contact elements 140 separated.

In a further step, the front holder frame 124 with the cell connectors held thereon 132 and the contact elements held thereon 140 so on the electrochemical cells 104 of the module 102 Put on the front ends of the electrochemical cells 104 the respective associated passage openings 126 in the front holder frame 124 prevail and the cell connectors 132 as well as the contact elements 140 in the desired assignment to the electrochemical cells 104 of the module 102 are positioned.

Then the contact sections become 154 and 156 the cell connector 132 as well as the contact elements 140 the electrical connections 138 , preferably cohesively, with the respective associated cell terminal 116 connected.

To complete the electrochemical module 102 then becomes the bracket 148 in the form of the printed circuit board 150 at the front of the electrochemical module 102 arranged and with the retaining bars 158 . 160 respectively. 146 connected (preferably by soldering), so that finally the in 2 illustrated assembly final state of the electrochemical module 102 is reached.

In this variant for mounting the cell connector 132 and the contact elements 140 at the cell terminals 116 thus serves the front holder frame 124 as a holder to which the cell connectors 132 and the contact elements 140 each be set separately before the connecting webs 166 the connector assembly 164 be separated.

Various possibilities for materially connecting a cell connector 132 with the associated first cell terminal 134 and the associated second cell terminal 136 are described below with reference to the 11 to 13 described:
Like, for example 11 can be seen, includes the (positive) first cell terminal 134 an electrochemical cell 104g a base body 174 of an electrically conductive, preferably metallic, first material, for example aluminum or an aluminum alloy, wherein the first base body 174 a cell connector 132 associated first contact surface 176 comprising the first material.

That with the first cell terminal 134 through the cell connector 132 to be connected second cell terminal 136 the electrochemical cell 104f comprises a second base body 178 from an electrically conductive, preferably metallic, material susceptible to corrosion, for example from a low-alloyed steel material, wherein the second base body 178 with a corrosion protection layer 180 from a second material, for example nickel or a nickel alloy, which at the same time forms a first corrosion protection material is provided.

The corrosion protection layer 180 has a cell connector 132 facing second contact area 182 from the second material or first anti-corrosion material.

The main body 152 of the cell connector 132 is preferably of the first material, ie of the same material as the first base body 174 the first cell terminal 134 , educated.

Furthermore, the cell connector comprises 132 in this embodiment one with the main body 152 connected contact area 184 from a third material, which also forms a second corrosion protection material.

The contact area 184 of the cell connector 132 is preferably as a separate from the main body 152 produced contact body 186 formed and in the region of the second contact portion 156 of the basic body 152 , preferably cohesively, at the cell terminals 134 . 136 facing side of the body 152 established.

At the in 11 illustrated embodiment is particularly provided that the contact area 184 by ultrasonic welding to the body 152 is fixed.

The third material or the second corrosion protection material, from which the contact area 184 is formed, in particular with the second material or the first corrosion protection material from which the corrosion protection layer 180 of the second cell terminal 136 is formed, essentially match.

For example, it can be provided that the third material or the second corrosion protection material is nickel or a nickel alloy.

Alternatively, it can also be provided that the third material or the second corrosion protection material is a chromium alloy.

During assembly of the electrochemical module 102 becomes the basic body 152 of the cell connector 132 by welding, preferably by laser welding, with the first cell terminal 134 connected after the cell connector 132 in the desired manner relative to the two cell terminals 134 . 136 has been positioned.

The contact area 184 of the cell connector 132 is made by a weld that is in 11 through the broken line 188 is indicated with the second cell terminal 136 welded, with the weld 188 is preferably produced by laser welding.

During this welding process, although the corrosion protection layer 180 of the second cell terminal 136 melted and thereby at least partially broken; from the contact area containing the second corrosion protection material 184 However, during the welding process, so much of the second anticorrosive material enters the microstructure and, in particular, the free surface of the weld 188 in that after the completion of the welding process, the weld 188 at least on its free surface, but preferably in its entire structure, is formed of a corrosion-protected material.

This corrosion-protected material consists predominantly of the corrosion-endangered material of the second base body 178 and from the contact area 184 of the cell connector 132 originating second corrosion protection material, by which the corrosion-prone material is alloyed to a corrosion-resistant material.

The anticorrosion effect of the first anticorrosive material and / or of the second anticorrosive material may be based, in particular, on the first anticorrosive material and / or the second anticorrosive material containing at least one corrosion protection metal in a proportion of at least 50 percent by weight.

In particular, it can be provided that the first corrosion protection material and / or the second corrosion protection metal contains nickel as a corrosion protection metal.

Alternatively or additionally, it can be provided that the first corrosion protection material and / or the second corrosion protection material contains chromium as a corrosion protection metal.

The first corrosion protection material and / or the second corrosion protection material may also contain both nickel and chromium as anticorrosive metal, it being sufficient if the total proportion of both anticorrosive metals to the first anticorrosive material and to the second anticorrosive material is at least 50 percent by weight.

The corrosion resistance of the corrosion-protected material on the free surface of the weld formed 188 is preferably determined by a neutral salt spray test (NSS test) according to the Standard DIN EN ISO 9227 (as of July 2006) checked. With respect to the performance of such a neutral salt spray test, reference is made to said standard, and said standard is incorporated herein by reference.

To perform the salt spray test, a specimen is used 190 in the 47 to 49 produced type produced.

The specimen 190 includes a cuboid base 192 with a square face 194 which has an edge length b of, for example, 12 mm.

The base 192 consists of the corrosion-prone material of the second base body 178 of the second cell terminal 136 Thus, for example, from the low-alloy steel material, which is provided on its surface with the corrosion protection layer of the first corrosion protection material, for example nickel or a nickel alloy.

On the face 194 becomes a cuboidal support 196 hung up, which one of the base 192 facing, square face 198 having an edge length a of, for example, 15 mm and a thickness d of, for example, 0.5 mm, and by welding along an annularly closed weld 188 ' , in particular by means of a laser weld, under the same conditions as in the welding of the cell connector 132 with the second cell terminal 136 connected.

The sample thus prepared 190 is subjected to the neutral salt spray test (NSS test) in a spray chamber during a test period of 96 hours according to the DIN EN ISO 9227 (as of July 2006) subjected.

Upon completion of the neutral salt spray test, a visual assessment of the surface of the sample is made 190 , in particular the weld 188 ' , and a visual evaluation of a cut along one in the axial direction of the sample body 190 through the weld 188 ' extending cutting plane 199 (please refer 49 ).

• – Rating 1: keine Veränderung, keine Verfärbung, keine Korrosion;
• – Rating 2: Verfärbung oder Farbumschlag, aber keine Korrosion;
• – Rating 3: Spuren von Korrosion, nur wenige kleine punktförmige Flächen;
• – Rating 4: leichte Korrosion mit einer Vielzahl von kleinen punktförmigen Flächen, aber ohne zusammenhängende korrodierte Bereiche;
• – Rating 5: mäßige Korrosion, zusammenhängende korrodierte Bereiche;
• – Rating 6: starke Korrosion, Muster total korrodiert.

In the visual assessment, the material of the tested weld 188 ' assigned a rating number ("Rating") according to the following rating scheme:

• - Rating 1: no change, no discoloration, no corrosion;
• - Rating 2: discoloration or color change, but no corrosion;
• - Rating 3: traces of corrosion, only a few small punctate areas;
• - Rating 4: slight corrosion with a multitude of small punctiform areas, but without contiguous corroded areas;
• - Rating 5: moderate corrosion, contiguous corroded areas;
• - Rating 6: severe corrosion, patterns totally corroded.

In order to be considered corrosion-protected, the material of the specimen, in particular the weld, may be used 188 ' of the specimen 190 , after the neutral salt spray test (NSS test) maximum rated with the rating 3.

The neutral salt spray test at the weld seam 188 ' of the specimen 190 certain rating is the material of the weld 188 between the second cell terminal 136 and the contact area 184 of the cell connector 132 assigned.

Alternatively to using a separate from the main body 152 of the cell connector 132 produced and then cohesively with the body 152 connected contact body 186 can also be a contact area 184 be used, the one on the main body 152 produced coating, in particular a galvanically applied coating, from the second corrosion protection material.

The main body 152 of the cell connector 132 is preferably formed of aluminum or an aluminum alloy. Preferably, the aluminum content of the material of the body is 152 at least 99.5 weight percent.

In order to operate the electrochemical device 100 mechanical stresses caused by differential thermal expansion of the cell connectors 132 on the one hand and the receiving device 108 for the electrochemical cells 104 On the other hand can arise to reduce as much as possible, it is advantageous if the material of the body 152 of the cell connector 132 a thermal expansion coefficient α, which is less than 10% of the thermal expansion coefficient α of the material of the receiving device 108 differs.

When the thermal expansion coefficients of these materials from the ambient temperature to the operating temperature of the electrochemical device 100 vary greatly, this statement refers to the respective average coefficient of thermal expansion when heated from the ambient temperature (20 ° C) to the operating temperature of the electrochemical device 100 ,

It is therefore particularly advantageous if the main body 152 and the cradle 108 are formed of substantially the same material, so for example both of aluminum or an aluminum alloy.

At an in 12 schematically illustrated alternative possibility for cohesive Connecting the cell connector 132 with the first cell terminal 134 and the second cell terminal 136 is considered as separate from the main body 152 of the cell connector 132 produced contact body 186 trained contact area 184 not by ultrasonic welding, but by laser welding along an in 12 through the line 200 indicated weld on the body 152 established.

Incidentally, the in 12 shown possibility for cohesive connection of the cell connector 132 with the cell terminals 134 and 136 in terms of structure, functionality and method of manufacture with the in 11 The possibility described above, to the above description to which reference is made.

An in 13 schematically illustrated alternative way of materially connecting the cell connector 132 with the cell terminals 134 and 136 is different from the ones in the 11 and 12 illustrated possibilities in that the cell connector 132 not with the second cell terminal 136 but instead by soldering to the second cell terminal 136 is connected.

Further, in this embodiment, the contact area 184 from the third material or the second corrosion protection material not by a separately from the body 152 produced and then cohesively with the body 152 connected contact body 186 but by one on the main body 152 arranged coating 202 , for example, made of nickel or a nickel alloy.

In this case, the coating extends 202 at least over the assembled state of the electrochemical module 102 the second cell terminal 136 facing side of the second contact portion 156 of the basic body 152 ,

How out 13 can be seen, the coating can be 202 but also on the same side of the first contact section 154 and / or about the cell terminals in the mounted state 134 and 136 opposite side of the body 152 extend.

The soldering of the contact area 184 in the form of the coating 202 with the second cell terminal 136 For example, by means of a solder foil 204 from a soft solder, in particular from a lead-free solder, for example, from the solder with the composition SnAg _3.5 , take place.

Soldering using a solder with a low soldering temperature (less than about 250 ° C) offers the advantage that during assembly of the cell connector 132 thermally sensitive components of the electrochemical module 102 , in particular insulation parts made of plastic material, are not damaged.

As an alternative to using a soft solder, a brazing filler metal, for example a silver-based brazing alloy, may also be used, wherein the brazing solder is preferably melted by means of a short-time laser to damage thermally sensitive components of the electrochemical module 102 to avoid.

The coating 202 which the contact area 184 of the cell connector 132 forms, may in particular be a galvanically applied coating.

Alternatively to a soldering of the contact area 184 of the cell connector 132 with the cell terminal 136 These elements can also be glued together by means of an electrically conductive adhesive.

In particular, an epoxy resin adhesive with an electrically conductive filler can be used for the bonding.

The electrically conductive filler may in particular comprise silver.

The electrically conductive adhesive can be applied to one of the elements to be bonded together or to both elements, whereupon both elements are brought into contact with the adhesive layer and the adhesive layer is cured.

The curing of the adhesive layer can in particular by heat, at room temperature relative to elevated temperature, take place.

The two elements to be bonded together are preferably pressed against each other under a contact pressure until these elements are connected to one another in a material-locking manner by the adhesive.

• – der silberhaltige Epoxidharz-Kleber, der unter der Bezeichnung LOCTITE^® 3880 von der Firma Henkel Technologies, Heydastraße 10, 58093 Hagen, Deutschland, vertrieben wird. Hinsichtlich der chemischen und physikalischen Eigenschaften und der Arbeitsschritte zur Verarbeitung dieses Klebers wird auf das technische Datenblatt zum Kleber LOCTITE^® 3880 vom Juni 2005 Bezug genommen, und das genannte Datenblatt wird diesbezüglich zum Bestandteil der vorliegenden Beschreibung gemacht.
• – der silberhaltige Epoxidhard-Kleber, der von der Firma Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA, unter der Bezeichnung Master Bond Supreme 10 HT/S vertrieben wird. Hinsichtlich der physikalischen und chemischen Eigenschaften und der Arbeitsschritte zum Verarbeiten dieses Klebers wird auf das technische Datenblatt zum Kleber Master Bond Supreme 10 HT/S Bezug genommen, und dieses Datenblatt wird diesbezüglich zum Bestandteil der vorliegenden Beschreibung gemacht.
• – der silberhaltige Epoxidharz-Kleber, der von der Firma Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA, unter der Bezeichnung Master Bond FL901S vertrieben wird. Hinsichtlich der physikalischen und chemischen Eigenschaften und der Arbeitsschritte zum Verarbeiten dieses Klebers wird auf das technische Datenblatt zu dem Kleber Master Bond FL901S Bezug genommen, und dieses Datenblatt wird diesbezüglich zum Bestandteil der vorliegenden Beschreibung gemacht.

Suitable electrically conductive adhesives are in particular the following:

• - The silver-containing epoxy adhesive, under the name LOCTITE ^® 3880 by Henkel Technologies, Heydastraße 10 , 58093 Hagen, Germany. With regard to the chemical and physical properties and the procedures for processing of this adhesive, reference is made to the technical data sheet 2005 for adhesive LOCTITE ^® 3880 June, and said sheet is in this regard made part of the present description.
• The silver-containing epoxy hard adhesive marketed by Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA under the name Master Bond Supreme 10 HT / S. With regard to the physical and chemical properties and the steps for processing this adhesive, reference is made to the technical data sheet for the Master Bond Supreme 10 HT / S adhesive, and this data sheet is hereby made part of the present description.
• The silver-containing epoxy resin adhesive sold by Master Bond Inc., 154 Hobart Street, Hackensack, NJ 07601-3922, USA under the name Master Bond FL901S. With regard to the physical and chemical properties and the steps for processing this adhesive, reference is made to the technical data sheet for the adhesive Master Bond FL901S, and this data sheet is made part of the present description in this regard.

In operation of the electrochemical device 100 It may be due to different temperatures and / or due to different thermal expansion coefficients of the cell connectors 132 on the one hand and the receiving device 108 for the electrochemical cells 104 on the other hand, a difference between a longitudinal expansion of the cell connectors 132 on the one hand and a change in the distance between the longitudinal axes 114 through the cell connectors 132 interconnected cell terminals 134 . 136 come on the other hand. By a temperature change, the relative positions of the cell connector 132 interconnected cell terminals 134 . 136 in the direction perpendicular to the axial direction 112 the electrochemical cells 104 aligned transverse directions 120 or 122 of the module 102 changed.

Furthermore, due to different longitudinal expansions, they may be interconnected by a cell connector 132 connected electrochemical cells 104 to a change in the relative positions between the interconnected cell terminals 134 and 136 along the axial direction 112 the interconnected electrochemical cells 104 come.

To such differences between a longitudinal strain of the cell connector 132 on the one hand and a change in the distance between the longitudinal axes 114 the through the cell connector 132 interconnected cell terminals 134 and 136 on the other hand and / or such differences between a longitudinal expansion of a first electrochemical cell (for example 104g ) and a second electrochemical cell (for example 104f ) passing through the cell connector 132 to be able to compensate, is in the in the 14 to 37 illustrated alternative embodiments of cell connectors 132 provided that the respective cell connector 132 an elastically and / or plastically deformable compensation area 206 comprising, which between the first contact portion 154 and the second contact portion 156 of the cell connector 132 is arranged and the two contact sections 154 and 156 connects with each other.

Preferably, the main body 152 of the cell connector 132 with such a compensation range 206 Mistake.

In the in the 14 and 15 illustrated embodiment of a cell connector 132 indicates the deformable compensation area 206 a wave structure, wherein the wave structure has a plurality of waves with a direction parallel to the axial direction 112 the through the cell connector 132 to be connected cells 104 and substantially perpendicular to the contact surfaces 208 and 210 with which the cell connector 132 in the assembled state at the first cell terminal 134 or at the second cell terminal 136 applied, directed amplitude includes. These waves have a plurality, for example four, transversely, preferably substantially perpendicular, to the axial direction of the electrochemical cells 104 and transversely, preferably substantially perpendicular, to a longitudinal direction 212 of the cell connector 132 as well as substantially parallel to a transverse direction 214 of the cell connector 132 which is perpendicular to the longitudinal direction 212 of the cell connector 132 and perpendicular to the axial direction 112 the electrochemical cells 104 aligned, running wave mountains and several, between the wave mountains 216 arranged and transversely, preferably substantially perpendicular, to the axial direction 112 the electrochemical cells 104 , and transversely, preferably substantially perpendicular, to the longitudinal direction 212 of the cell connector 132 and substantially parallel to the transverse direction 214 of the cell connector 132 running wave troughs 218 on.

The wave mountains 216 stand in one to the contact surfaces 208 and 210 of the cell connector 132 vertical contact direction 217 of the cell connector 132 in the assembled state of the cell connector 132 with the axial direction 112 the cells 104 coincides, upwards, while the troughs 218 in the contact direction 217 down (to the cells to be connected 104 out).

As with the in the 1 to 4 illustrated embodiment of a cell connector 132 which is in the area between the contact sections 154 and 156 is substantially planar, has in the 14 and 15 illustrated embodiment of a cell connector 132 , which has a deformable compensation area 206 between the two contact sections 154 and 156 includes, two holding webs 158 and 160 on, through which the cell connector 132 with the bracket 148 is connectable and which for electrically conductive connection of the cell connector 132 with a to the control unit of the electrochemical device 100 leading conductor can serve, so that the holding webs 158 and 160 especially as voltage taps 162 are usable.

Each of the retaining bars 158 and 160 can in each case with a bend 220 Be provided for a height difference between the position of the cell connector 132 and the position of the bracket 148 in the axial direction 112 the electrochemical cells 104 to bridge.

Due to the undulating structure of the deformable compensation area 206 of the cell connector 132 is achieved that the compensation range 206 in a simple manner is elastically and / or plastically deformable such that the second contact portion 156 relative to the first contact section 154 both in the axial direction 112 the electrochemical cells 104 as well as in the longitudinal direction 212 of the cell connector 132 can be shifted to the above-described differences in the relative positions of the cell connector 132 cell terminals to be interconnected 134 and 136 compensate. This can cause the occurrence of excessive mechanical stresses at the joints between the cell connector 132 on the one hand and the first cell terminal 134 as well as the second cell terminal 136 on the other hand be avoided.

In particular, by flattening or splitting up the wave crests 216 and the troughs 218 the extent of the compensation range 206 in the longitudinal direction 212 of the cell connector 132 changed and thus the distance between the first contact section 154 and the second contact portion 156 be increased or decreased.

By an asymmetrical change in the slopes of the wave crests 216 and the troughs 218 may be the first contact section 154 and the second contact portion 156 in the axial direction 112 the electrochemical cells to be interconnected are shifted relative to each other.

The operation of the electrochemical device 100 At these joints occurring mechanical stresses can be further reduced if the deformable compensation area 206 of the cell connector 132 is formed of a material with a relatively low yield strength R of at most 60 N / mm ² , preferably of at most 40 N / mm ² , in particular of at most 20 N / mm ² .

Furthermore, to reduce the at the joints between the cell connector 132 and the cell terminals to be interconnected 134 and 136 occurring mechanical stresses be provided that the cell connector 132 already before connecting to the first cell terminal 134 and / or before connecting to the second cell terminal 136 thus, preferably plastically, is deformed, that with the first cell terminal 134 to be connected first contact section 154 of the cell connector 132 and the one with the second cell terminal 136 to be connected second contact section 156 of the cell connector 132 be shifted relative to each other, that differences in the positions of the first cell terminal 134 and the second cell terminal 136 in the axial direction 112 the electrochemical cells to be joined together 104 , which may be caused for example by manufacturing tolerances, at least partially, preferably substantially completely, be balanced.

It is particularly advantageous if, before the corresponding deformation of the cell connector 132 the relative positions of the first cell terminal 134 and the second cell terminal 136 passing through the cell connector 132 be connected with each other, be measured.

Furthermore, the yield strength of the material of the cell connector 132 in the compensation area 206 and / or in the first contact section 154 and / or in the second contact section 156 by a heat treatment before and / or during the cohesive connection of the cell connector 132 with the first cell terminal 134 and / or with the second cell terminal 136 be reduced. By such a reduction of the yield strength of the material by a heat treatment, the mechanical stresses at the junction during and / or after the cohesive connection of the cell connector 132 with the first cell terminal 134 or with the second cell terminal 136 be reduced.

Incidentally, the right in the 14 to 16 illustrated embodiment of a cell connector 132 in terms of structure, function and method of manufacture with the previously described embodiments of cell connectors 132 without deformable compensation range 206 to the above description of which reference is made.

One in the 17 and 18 illustrated alternative embodiment of a cell connector 132 is different from the one in the 14 to 16 illustrated embodiment in that the wave structure of the deformable compensation area 206 instead of four only three in the transverse direction 214 of the cell connector 132 running wave mountains 216 and instead of three only two along the transverse direction 214 running wave troughs 218 having.

Furthermore, this embodiment has a cell connector 132 no tie-bars 158 . 160 for connecting the cell connector 132 with the bracket 148 on.

Such a cell connector 132 is thus only by the cohesive connection with the cell terminals 134 and 136 on the electrochemical module 102 held.

Also, this embodiment of a cell connector 132 and all cell connector embodiments described below 132 , which without holding bars 158 . 160 are shown, but can in principle also with one or more holding webs 158 or 160 be provided, in particular as voltage taps 162 can serve.

Incidentally, the right in the 17 and 18 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 14 to 16 illustrated embodiment, reference is made to the above description in this regard.

One in the 19 and 20 illustrated alternative embodiment of a cell connector 132 is different from the one in the 14 to 16 illustrated embodiment in that the deformable compensation area 206 instead of a wave structure has a half-bead structure, which two in the transverse direction 214 of the cell connector 132 running beading 222 and at a first bend line 224 in the first contact section 154 and at a second crease line 226 in the second contact section 154 of the cell connector 132 passes.

Incidentally, the right in the 19 and 20 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 14 to 16 illustrated embodiment, reference is made to the above description in this regard.

One in the 21 and 22 illustrated alternative embodiment of a cell connector 132 is different from the one in the 14 to 16 illustrated embodiment in that the deformable compensation area 206 has a wave structure that is only one in the transverse direction 214 of the cell connector 132 extending wave mountain 216 and only one in the transverse direction 214 of the cell connector 132 extending trough 218 includes.

Incidentally, the right in the 21 and 22 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 14 to 16 illustrated embodiment, reference is made to the above description in this regard.

One in the 23 and 24 illustrated alternative embodiment of a cell connector 132 is different from the one in the 14 to 16 illustrated embodiment in that the deformable compensation area 206 has a wave structure, which two in the transverse direction 214 of the cell connector 132 running wave mountains 216 and one between the waves 216 in the transverse direction 214 of the cell connector 132 running wave trough 218 includes.

Incidentally, the right in the 23 and 24 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 14 to 16 illustrated embodiment, reference is made to the above description in this regard.

One in the 25 and 26 illustrated alternative embodiment of a cell connector 132 is different from the one in the 14 to 16 illustrated embodiment in that the deformable compensation area 206 a zigzag structure having a plurality, for example five, transversely, preferably substantially perpendicular, to the axial direction 112 the electrochemical cells to be joined together 104 and substantially along the transverse direction 214 of the cell connector 132 running crease lines 228 having.

Incidentally, the right in the 25 and 26 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 14 to 16 illustrated embodiment, reference is made to the above description in this regard.

One in the 27 and 28 illustrated alternative embodiment of a cell connector 132 is different from the one in the 17 and 18 illustrated embodiment in that the cell connector 132 none at the second contact section 156 arranged contact area 184 comprising the third material or the second corrosion protection material.

In principle, however, any of these in this specification and the accompanying drawings without such a contact area 184 illustrated embodiment of a cell connector 132 with such a contact area 184 be provided.

Incidentally, the right in the 27 and 28 illustrated embodiment of a cell connector 132 with the in the 17 and 18 illustrated embodiment, reference is made to the above description in this regard.

One in the 29 and 30 illustrated alternative embodiment of a cell connector 132 is different from the one in the 14 to 16 illustrated embodiment in that the cell connector 132 no tie-bars 158 . 160 for connecting the cell connector 132 with a holder 148 having.

This cell connector 132 is thus in the assembled state only by the cohesive connection with the first cell terminal 134 and the second cell terminal 136 on the electrochemical module 102 held.

Incidentally, the right in the 29 and 30 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 14 to 16 illustrated embodiment, reference is made to the above description in this regard.

One in the 31 to 33 illustrated alternative embodiment of a cell connector 132 is different from the one in the 27 and 28 illustrated embodiment in that the basic body 152 of the cell connector 132 is not formed in one piece, but as a laminate of several, for example, three, superimposed material layers 230 is trained.

The elastic and / or plastic deformation of the compensation area 206 permitting structure, in particular its wave structure remains intact.

Also in all other embodiments of cell connectors disclosed in this specification and in the accompanying drawings 132 can the basic body 152 include such a laminate.

Incidentally, the right in the 31 to 33 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 27 and 28 illustrated embodiment, reference is made to the above description in this regard.

One in the 34 and 35 illustrated alternative embodiment of a cell connector 132 is different from the one in the 27 and 28 illustrated embodiment in that the deformable compensation area 206 by several, for example three, wave-shaped slots 232 in several, for example, four, wavy ridges 234 is divided, which in the transverse direction 214 of the cell connector 132 are arranged side by side.

This shows the waveform of the slots 232 and the bridges 234 an amplitude in the transverse direction 214 of the cell connector 132 on.

Furthermore, the cell connector 132 at the lateral edges of the deformable compensation area 206 each with a plurality, for example, three or four, for example, approximately circular section-shaped, recesses 236 Be provided to achieve that even the outside bars 234 have an approximately constant width over their longitudinal extent and also have an approximate waveform on their outer side.

Through the slots 232 and the subdivision of the compensation range 206 in several bars 234 becomes the deformability of the compensation range 206 increases and the generation of an offset between the contact sections 154 and 156 of the cell connector 132 facilitated.

Incidentally, the right in the 34 and 35 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 27 and 28 illustrated embodiment, reference is made to the above description in this regard.

One in the 36 and 37 illustrated alternative embodiment of a cell connector 132 is different from the one in the 34 and 35 illustrated embodiment in that the deformable compensation area 206 is substantially planar and thus no wave structure with an amplitude in the axial direction of the electrochemical cells to be joined together 104 having.

In this embodiment of a cell connector 132 becomes the elastic and / or plastic deformability of the compensation area 206 exclusively through the undulating slits 323 which caused the compensation area 206 in several wavy bars 234 divide that in the transverse direction 214 of the cell connector 132 are arranged side by side.

Incidentally, the right in the 36 and 37 illustrated embodiment of a cell connector 132 in terms of structure, function and method of production with in the 34 and 35 illustrated embodiment, reference is made to the above description in this regard.

All described embodiments of cell connectors 132 can in the first contact section 154 and / or in the second contact section 156 and optionally in the contact area 184 of the cell connector 132 be provided in each case with at least one passage opening in order for measuring purposes, an electrical contact with the cell connector 132 cohesively connected first cell terminals 134 or the cohesive with the cell connector 132 connected second cell terminals 136 to allow for determining the electrical contact resistance of the connection between the cell connector 132 and the respective cell terminal 134 . 136 can be used.

In the above, in particular with reference to 2 described embodiment of an electrochemical device 100 are the cell connectors 132 and the electrical connections 138 of the electrochemical module 102 over retaining bars 158 . 160 respectively. 146 with the tracks of a printed circuit board 150 connected, the cell connectors 132 and the contact elements 140 the electrical connections 138 separately from the tracks of the circuit board 150 produced and only during assembly of the electrochemical module 102 electrically conductive with the conductor tracks of the printed circuit board 150 have been connected.

In the in the 38 and 39 illustrated alternative embodiment of an electrochemical device 100 is, on the other hand, every cell connector 132 integral with a respective associated conductor track 238 educated.

The tracks 238 are not fixed to a circuit board, but self-supporting trained.

Also the contact elements 140 the electrical connections 138 of the electrochemical module 102 are in this embodiment preferably integral with a respective associated conductor track 238 educated.

The cell connectors 132 remote free ends of the tracks 238 are electrically conductive with a connecting web 240 which is replaceable by a plug of a corresponding multicore cable connection to the control unit of the electrochemical device 100 leads, so that in this way the electrical potentials of the cell connectors 132 can be tapped by the control unit.

In this embodiment, the cell connectors 132 on a subframe 241 held, which is formed of an electrically insulating material, such as a plastic material, and in 50 is shown separately.

The subframe 241 points for each cell connector 132 each an associated recess 243 on which the passage of the respective cell connector 132 to those through the cell connector 132 cell terminals to be interconnected 134 and 136 and / or the passage of the through the cell connector 132 cell terminals to be interconnected 134 and 136 to the respective cell connector 132 allows.

Further, the subframe has 241 a lead 245 on, on both sides of the contact elements 140 are arranged (see 38 ).

The tracks 238 can get attached to the subframe 241 support.

The cell connectors 132 and / or the contact elements 140 For example, by clamping or latching by means of suitable clamping elements or latching elements on which as a holder for the cell connectors 132 and the contact elements 140 serving subframe 241 be set.

The subframe 241 allows the assembly from the cell connectors 132 , the contact elements 140 and the associated conductor tracks 238 an electrochemical module 102 during assembly of the module 102 as a unit, thus facilitating the assembly of the electrochemical module 102 ,

In the in the 38 and 39 illustrated embodiment of the electrochemical device 100 is provided that the cell connectors 132 and the contact elements 140 with the tracks 238 and the connecting bridge 240 First, a one-piece connector assembly 164 form, in which the cell connectors 132 and the contact elements 140 through the tracks 238 and the connecting bridge 240 are integrally connected to each other, wherein the connecting web 240 then removed when the cell connectors 132 and the contact elements 140 cohesively with the respective associated cell terminals 116 have been connected and / or with the subframe 241 have been connected.

Incidentally, the right in the 38 and 39 illustrated embodiment of an electrochemical device 100 in terms of structure, function and method of production with in the 1 to 4 illustrated embodiment, reference is made to the above description in this regard.

Any of the above-described embodiments of an electrochemical device 100 can have several electrochemical modules 102 include, which are preferably electrically connected in series.

Such a series connection can in particular be produced by an electrical connection 138 a first electrochemical module 102 by means of a module connector 242 electrically conductive with an electrical connection 138 (opposite polarity) of a second electrochemical module 102b is connected, as in the 40 to 42 is shown.

Details of the module connector 242 are from the 43 to 46 to see in which the module connector 242 is shown separately.

The module connector 242 includes two connector units 244 for connecting the module connector 242 to the electrical connections to be connected 138 the electrochemical modules 102 and 102b , where the plug units 244 in each case an approximately cuboid plug housing, for example 246 comprise, which is formed for example of a metallic material, in particular of a stainless steel material.

Each connector housing 246 encloses a recording 248 , which are in a connecting direction 250 of the module connector 242 extends and in each of which a connector portion 144 a contact element 140 of the electrical connection 138 an electrochemical module 102 is insertable.

How out 46 can be seen are in the recording 248 Furthermore, two mutually opposite contact tongues 252 arranged, between which the respective connector portion 144 clamped under elastic bias when the module connector 242 on the relevant electrochemical module 102 is arranged.

Further, each connector housing 246 on its outside with locking elements 254 for locking the plug housing 246 with an electrical insulation body (not shown) and with projections 256 provided, which in the connection of the respective connector housing 246 can serve with the relevant insulating body as a guide element and / or as a stop.

The tongues 252 each plug unit 244 are electrically conductive with an angled connection lug 258 connected, which from the module to be connected 102 opposite end of the connector housing 246 protrudes and their free thighs 260 in a transverse, preferably substantially perpendicular, to the direction of connection 250 extending longitudinal direction 262 of the module connector 242 from the respective connector housing 246 extends away.

Here are the free thighs 260 the connection flags 258 the two plug units 244 along this longitudinal direction 262 directed in opposite directions.

The connection flags 258 the two plug units 244 are through a flexible conductor 264 electrically connected to each other, which, preferably in one piece, from a woven from electrically conductive wires fabric tape 266 , in particular of a flat strand, is formed and a plurality, for example four, convolutions 268 having.

The electrically conductive wires of the fabric tape 266 are preferably formed of copper as an electrically conductive component.

A first end section 270a of the leader 264 is at a connected state of the module connector 242 the to be connected electrochemical module 102 facing side of the terminal lug 258 the first connector unit 244a determined, for example by welding, in particular by ultrasonic welding.

The first end section 270a extends in the longitudinal direction 262 of the module connector 242 from the terminal lug 258 the first connector unit 244a away, in the second plug unit 244b opposite direction, and can with a bend 271 Be provided by which of the first plug unit 244a remote part of the first end portion 270a along the connecting direction 250 to the module to be connected 102 is offset.

The connecting flag 258 opposite end of the first end portion 270a goes to a first fold line 272a , which at an angle, preferably at an angle of approximately 45 °, to the longitudinal direction 262 of the module connector 242 and to the local longitudinal direction of the fabric tape 266 in the first end section 270a runs, in an approximately trapezoidal first connecting portion 274a above, in which the local longitudinal direction of the conductor 264 parallel to a transverse direction 276 the module connector runs perpendicular to the longitudinal direction 262 and perpendicular to the direction of connection 250 of the module connector 242 is aligned.

The folding takes place 268a at the first fold line 272a preferably such that the first connection section 274a at the modules to be connected 102 opposite side of the first end portion 270a is arranged.

The first connection section 274a goes through a folding 268b at a second fold line 272b , which obliquely, preferably at an angle of approximately 45 °, to the transverse direction 276 of the module connector 242 and to the local longitudinal direction 278 of the leader 264 in the first connection section 274a runs, in a compensation section 280 over which is parallel to the longitudinal direction of the module connector 242 on the side of the plug units 244a and 244b extends past, wherein the compensating section 280 in the transverse direction 276 of the module connector 242 opposite the plug units 244a . 244b and opposite the first end portion 270a of the leader 264 is offset.

The balancing section 280 of the leader 264 can with an electrically insulating sheath 282 which may be formed, for example, from an elastomeric plastic material, in particular from a PVC material.

The broadsides 284 . 284 ' the band-shaped compensation section 280 of the leader 264 are substantially perpendicular to the direction of connection 250 of the module connector 242 aligned.

At its the first connecting section 274a the opposite end is the compensation section 280 through a convolution 268c at a third fold line 272c , which obliquely, preferably at an angle of approximately 45 °, to the longitudinal direction 262 of the module connector 242 and to the local longitudinal direction 278 of the leader 264 in the balancing section 280 runs, in a second connecting portion 274b about, which is substantially trapezoidal and extending from the balancing section 280 starting in the transverse direction 276 of the module connector 242 to the side of the balancing section 280 extends on which the plug units 244a and 244b are arranged.

The folding takes place at the second fold line 272b and at the third fold line 272c such that the compensation section 280 on the modules to be connected 102 . 102b facing side of the first connecting portion 274a and the second connection portion 274b is arranged.

As in particular from 45 can be seen, is the compensation section 280 therefore in the connection direction 250 not over the connection flags 258 the plug units 244 out onto the modules to be connected 102 . 102b opposite side of the plug units 244 over, leaving the module connector 242 a particularly small extent in the connection direction 250 having.

The second connection section 274b goes through a folding 268d at an angle, preferably at an angle of approximately 45 °, to the transverse direction 276 of the module connector 242 and to the local longitudinal direction 278 of the leader 264 in the second connection section 274b extending fourth fold line 272d in a second end section 270b over, extending from the second connecting section 274a up to the connecting lug 258 the second plug unit 244b extends and at the modules to be connected 102 . 102b facing side of this connection lug 258 is determined, for example by welding, in particular by ultrasonic welding.

Also the second end section 270b can with a bend 271 Be provided by which of the second plug unit 244b remote part of the second end portion 270b along the connecting direction 250 to the module to be connected 102 is offset.

The folding 268d along the fourth fold line 272d takes place such that the second end portion 270b of the leader 264 on the modules to be connected 102 . 102b facing side of the second connecting portion 274b is arranged.

As in particular from 46 can be seen, the compensation section 280 of the leader 264 a length L in the longitudinal direction 262 of the module connector 242 which is greater than the distance D of the opposite ends of the terminal lugs 258 the plug units 244a . 244b from each other.

Because of this large distance available for compensation of tolerances and due to the folds 268 increased flexibility of the geometric shape of the conductor 264 allows the module connector described 242 a particularly slight change in the relative positions of the plug units 244a and 244b to each other, so that by manufacturing tolerances or by changes during operation of the electrochemical device 100 generated deviations in the relative position of the plug into the units 244a . 244b to be inserted plug sections 144 the electrical connections 138 the electrochemical modules to be joined together 102 . 102b be easily and effectively compensated.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited non-patent literature

• Standard DIN EN ISO 9227 (as of July 2006) [0177]
• DIN EN ISO 9227 (as of July 2006) [0182]

Claims (15)

Electrochemical device comprising at least one first electrochemical cell ( 104 ) with a first cell terminal ( 134 ), a second electrochemical cell ( 104 ) with a second cell terminal ( 136 ) and a cell connector ( 132 ) for the electrically conductive connection of the first cell terminal ( 134 ) and the second cell terminal ( 136 ), the first cell terminal ( 134 ) a contact surface ( 176 ) of a first material and the second cell terminal ( 136 ) a contact surface ( 182 ) of a second material different from the first material, characterized in that the cell connector ( 132 ) a basic body ( 152 ) of the first material and one with the main body ( 152 ) connected contact area ( 184 ) of a third material which is in contact with the 182 ) of the second cell terminal ( 136 ) and that the contact area ( 184 ) of the cell connector ( 132 ) with the contact surface ( 182 ) of the second cell terminal ( 136 ) is connected by soldering or by gluing. An electrochemical device according to claim 1, characterized in that the second material and the third material are substantially equal. Electrochemical device according to one of claims 1 or 2, characterized in that the first material and the second material are not directly solderable to each other. Electrochemical device according to one of Claims 1 to 3, characterized in that the contact region ( 184 ) of the cell connector ( 132 ) with the contact surface ( 182 ) of the second cell terminal ( 136 ) is connected by means of a soft solder. Electrochemical device according to one of Claims 1 to 4, characterized in that the basic body ( 152 ) of the cell connector ( 132 ) by welding to the contact surface ( 176 ) of the first cell terminal ( 134 ) connected is. Electrochemical device according to one of claims 1 to 5, characterized in that the basic body ( 152 ) of the cell connector ( 132 ) comprises as the main component aluminum. Electrochemical device according to one of Claims 1 to 6, characterized in that the electrochemical device has a receiving device ( 108 ) with at least one first recording ( 106 ) for the first electrochemical cell ( 104 ) and a second recording ( 106 ) for the second electrochemical cell ( 104 ), wherein the first material has a thermal expansion coefficient (α) which is less than 10% of the thermal expansion coefficient (α) of the material of the receiving device ( 108 ) deviates. Electrochemical device according to claim 7, characterized in that the first material and the material of the receiving device are substantially equal. Electrochemical device according to one of Claims 1 to 8, characterized in that the second material comprises nickel as the main constituent. Electrochemical device according to one of Claims 1 to 9, characterized in that the third material comprises nickel as the main constituent. Electrochemical device according to one of Claims 1 to 10, characterized in that the contact region ( 184 ) of the cell connector ( 132 ) one on the main body ( 152 ) arranged coating ( 202 ). Electrochemical device according to claim 11, characterized in that the contact region ( 184 ) of the cell connector ( 132 ) one on the main body ( 152 ) electroplated coating ( 202 ). Electrochemical device according to one of Claims 1 to 12, characterized in that the contact region ( 184 ) of the cell connector ( 132 ) a contact body ( 186 ), which cohesively with the base body ( 152 ) connected is. Electrochemical device according to claim 13, characterized in that the contact body ( 186 ) by welding to the base body ( 152 ) connected is. Electrochemical device according to one of Claims 1 to 14, characterized in that the electrochemical device ( 100 ) is formed as an accumulator and the first cell terminal ( 134 ) a positive pole of the first electrochemical cell ( 104 ).

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