DE102014217526A1 - Conductor module and electrochemical energy storage having such a conductor module - Google Patents

Abstract

The present invention relates to a conductor module (10) comprising at least two electrical conductor sections (12, 14), characterized in that the conductor module (10) further comprises a ferrite core (16) for suppressing common mode noise, wherein the ferrite core (16) with the at least two electrical conductor sections (12, 14) are mechanically connected to form a component, and wherein the at least two electrical conductor sections (12, 14) are selected such that, in the case of trouble-free operation of the conductor module (10) by the electrical conductor sections (12, 14 ) passes through the ferrite core (16) passing a summation current of zero. A previously described conductor module (10) provides an advantageous solution for easily and cost-effectively integrating such a magnetic field-reducing component into electronic systems, such as electrochemical energy stores. The present invention further provides an electrochemical energy store (30, 30 ').

Description

The present invention relates to a conductor module and an electrochemical energy store, comprising such a conductor module.

State of the art

Areas of use for lithium-based energy storage devices include, in addition to fully electrically powered vehicles or hybrid vehicles, electrical tools, electrical entertainment electronics, computers, cell phones, and other applications. Such, in particular, electrochemical energy stores usually comprise one or a multiplicity of battery cells.

Often, a battery system is composed of a plurality of battery cells, which are combined to form a module. Here, the individual battery cells are interconnected by electrically conductive connections, for example, connected in series. For example, because the module provides the power to a clocked inverter for high power requirements, high peak currents can occur. This can lead to magnetic fields with high field strengths. As a result, disturbances can be induced in the battery system, which can disturb the battery management system (BMS) of the battery. In addition, these disturbances by radiation or irradiation may affect other electronic devices, such as radios. This is particularly true for vehicle traction batteries that have a plastic housing that does not provide shielding.

From the document US 2010/0210318 A1 For example, a mobile communication device is known which has a rechargeable battery system. Such a battery system may include a filter, such as a ferrite core, which may be disposed on an output line.

The document US 5,471,658 A describes a communication system having a battery. Outside the battery ferrite cores are also arranged.

From the document DE 201 08 259 U1 a battery charging system is known, which serves for recharging a battery. In this case, a battery charging line is provided with a ferrite core.

Disclosure of the invention

The present invention is a conductor module comprising at least two electrical conductor sections, wherein the conductor module further comprises a ferrite core at least partially surrounding the at least partially conductor sections for suppressing common mode noise, wherein the ferrite core is mechanically connected to the at least two electrical conductor sections to form a component, and wherein the at least two electrical conductor sections are selected such that when the conductor module is operated and in the absence of common-mode interference through the electrical conductor sections, the zero-crossing current flows through the ferrite core.

A previously described conductor module makes it possible in a particularly advantageous manner to significantly reduce interference, in particular common-mode interference, for example due to conductor-bound or field-bound electromagnetic interference, from electronic components, such as battery modules, by electromagnetic fields, and it also provides a particularly advantageous implementation in electronic systems , such as battery systems allowed.

In this case, such a conductor module can be used in particular in any application in which high currents, in particular clocked by inverters or DC-DC converters, run via discrete conductors, such as busbars or busbars. For example, the conductor module can serve to connect various components in a battery system, such as cell modules, BDU (Battery Disconnect Unit, also called Junction Box), fuses, current sensors, etc., or about battery cells with the corresponding contacts or electrical consumers or to connect with other battery cells. In particular, such a conductor module can be used in vehicle traction batteries.

The above-described conductor module comprises at least two electrical conductor sections wherein the conductor module is not limited to the provision of two electrical conductor sections. Rather, a plurality of greater than two can be provided on electrical conductor sections, such as four conductors, which in turn together have the total current zero.

External disturbances, for example from a high-frequency clocked inverter or DC-DC converter, can be connected to the conductor or as an electromagnetic field in the conductor module or in a battery comprising the conductor module. This can cause a common mode noise that can negatively affect the signal processing units of the energy storage or adjacent components. For example, measurement errors can occur in the battery by disturbing the cell voltage detection of the battery management system (BMS). This can be, for example adversely affect state-of-charge (SoC) and state-of-health (SoH) determinations. In addition, the permissible limit values relating to magnetic fields, for example in vehicles, may possibly be exceeded. Among other things, to comply with this limit measures such as the conductor module advantage. Under common mode noise disturbances or influences are to be understood in a conventional manner, which act with the same phase and the same amplitude on the at least two conductor sections.

In order to effectively reduce the above-described effects, a ferrite core at least partially bridging the at least two conductor portions is provided for suppressing common-mode noise. A ferrite core or ferrite filter may in particular be understood as meaning a component which comprises or consists of ferrite and thereby can concentrate electromagnetic fields in itself and thus escape the environment, as is generally known to the person skilled in the art. As a result, a particularly effective shielding of electromagnetic fields can be realized. A ferrite core that at least partially surrounds the at least two conductor sections can also be understood as meaning a ferrite core that surrounds the two conductor sections, but it is encompassed by the scope of the invention that the ferrite core or the strain can have interruptions, such as smaller air gaps.

By providing a ferrite core, the aforementioned common mode noise caused by magnetic fields can be damped. Thus, provision of a ferrite core serves as an effective measure to prevent adverse influence on electronic components such as a battery system ,

In this case, shielding in the case of a previously-described conductor module is particularly advantageous, since the ferrite core is positioned or the at least two electrical conductor sections are selected such that the ferrite core passes when the conductor module operates without the common-mode interference passing through the electrical conductor sections Sum flow of zero flows, that is, that the currents enclosed by the ferrite sum in total to zero, since in two conductors, the currents are equal in magnitude but flow in the opposite direction. This applies, for example, if the two conductor sections are designed as a forward conductor and as a return conductor to a consumer. Furthermore, then there is a summation current of zero through the conductor sections when there is no common-mode noise. A common mode noise then causes the total current to deviate from zero in the short term, which in turn leads to a magnetic field in the ferrite core, which counteracts the cause of the magnetic field, so that in turn the common mode noise can be counteracted.

In this case, the at least two conductor sections are to be electrically completely isolated from each other due to their potential difference. In addition, the electrical conductors should have an electrical conductivity which, depending on the field of application, is sufficient to be able to serve as a forward conductor or return conductor within a battery module, for example. Such electrical conductor sections designed, for example, as busbars are designed in particular from a metal. By way of example, such conductor sections comprise copper or aluminum or consist of one of these materials or may, for example, have a corresponding electrical conductivity.

Thus, the at least two electrical conductor sections can in particular be connectable to one or a plurality of battery cells. It may be provided, for example, that the electrical conductor sections with the same battery cell or with the same battery cells can be connected such that an electrical conductor section in an operating state of the conductor module or the battery is used as an electrical forward or can form part of this and that Another electrical conductor section is usable in an operating state of the conductor module or the battery as an electrical return conductor or forms part of this. However, it is not excluded in principle but included in the scope of the invention that the electrical conductor sections contact different battery cells and / or are equally designed as forward or as return conductors, as far as they pass the ferrite core, the summation current of zero.

In a previously described conductor module, it is further provided that the ferrite core with the at least two electrical conductor sections is mechanically connected to a component, in particular with one, several or or all of the present conductor sections is fixed. As a result, the disadvantage can be encountered that a ferrite filter is often unfavorable to install, since it is possibly brittle and thus could be damaged without protective measures under mechanical load, such as vibration or shock. By the arrangement described above, however, these disadvantages of the prior art can be circumvented, so that the Longevity and reliability of a conductor module, as described above, in particular can be particularly high compared to the arrangements known from the prior art.

The above-described arrangement of the ferrite core, which is mechanically connected to the at least two conductor sections to form a component, may in particular mean that the ferrite core is attached or fixed directly to the first and / or the second electrical conductor section, or indirectly, ie with the aid of a or several other components, so that a separate component is formed, which comprises the conductors and the ferrite core and as such is buildable.

The above-described solution thus makes it possible to integrate two or more electrical conductor sections with a ferrite core into a continuous component, which offers significant advantages due to the method. Thus, such a component is often particularly advantageous for a favorable production of electrical components, since it allows a particularly simple and inexpensive assembly of electrical systems. This is especially true in contrast to the use of items that need to be assembled into a common electrical system.

Busbars are highly insulated against each other and also outwardly with a material having an electrical insulation resistance, for example in the gig-ohm range. For example, can be used as an electrically insulating material, a plastic, as it is known for the isolation of electrical lines, such as cables, the skilled person. In particular, this embodiment may allow a particularly simple manufacturing method with known method steps. For example, in this embodiment, industrially known methods of plastics technology can be resorted to, such as injection molding, extrusion or shrink-fitting of a hose in order to coat the electrical conductor sections and the ferrite filter in an advantageous manner with only one operation with a plastic material. The composite thus produced can then be easily installed in an electrical system such as in a battery assembly.

Furthermore, only a small space is required for such integration of the ferrite filter, so that this measure can be used easily even in confined spaces. Furthermore, it is possible to integrate the filter between the individual battery cells without additional elaborate work steps, so that the assembly of the battery or of a battery module can be simplified.

In summary, a prescribed conductor module provides a cost-effective solution to effectively prevent interference caused by magnetic fields, such as in a battery or an influence of the energy storage components.

Within the scope of an embodiment, the ferrite core can be connected to at least one electrical conductor section in a form-fitting or cohesive manner. For example, the ferrite core can be connected to a first electrical conductor section and a second electrical conductor section in a form-fitting or cohesive manner. It is particularly advantageous that in this embodiment, a particularly simple and inexpensive manufacturing process and also a particularly stable arrangement can be realized, the latter may be particularly advantageous for mobile applications.

A cohesive connection can be designed, for example, by the ferrite filter and the corresponding conductor section or the corresponding conductor sections are connected to each other by an adhesive. With regard to the positive connection, for example, known fastening means can be used. The above examples are in no way limiting.

In principle, for example, the ferrite core and one or both of the electrical conductor sections, formed approximately as a busbar, are each encapsulated in plastic, so that the plastic on the one hand causes isolation and further ensures a positive connection between the ferrite core and conductor section.

Alternatively, the ferrite core, for example, in its interior have a plastic part with two, for example, slot-shaped recesses into which the conductor sections such as in particular the busbars uninsulated or insulated can be inserted directly positive fit.

In a further embodiment, the ferrite core can completely span the at least two conductor sections. In particular, in the presence of more than two electrical conductor sections, through which the summation current of zero flows through the ferrite core, the ferrite core can completely surround all of the aforementioned conductor sections. For example, the ferrite core can be designed as a ring core, which completely spans the electrical conductor sections. Such a configuration, for example, with a design of the ferrite core as a toroidal core, may have the advantage that the ferrite core, the electrical conductor sections in a particularly simple Fully encompassing way, and so a particularly effective reduction of disturbing influences can be made possible. In addition, in particular in a ring core arranged between the battery cells, the production method can be particularly simple, so that this embodiment can provide a particularly cost-effective solution. A toroidal core can be a ring-shaped ferrite core in a manner known per se.

This refinement can furthermore be advantageous, since such a configuration of the ferrite core and the associated particularly effective protective effect can already be sufficient for a comparatively small ferrite core, so that an electronic system such as, for example, an electrochemical energy store can be produced in a particularly cost-effective manner.

In the context of a further embodiment, at least one spacer can be arranged between the electrical conductor sections. By a spacer can be ensured that, on the one hand, the electrical conductor sections do not contact electrically, causing short circuits can be reliably prevented. In addition, one or more spacers may be advantageous, in particular for the production method, since a particularly defined structure can be produced in a particularly simple manner, since the spacers can fix the conductor sections to one another. Such a defined structure can help in that the ferrite core can dampen or prevent the common mode noise particularly effectively.

For example, at least one spacer can be designed as a cross strut, which is mechanically integrated into the overall component, ie, in particular, is mechanically connected to at least one of the electrical conductor sections. In particular, when using a cross member as a spacer, a particularly cost-effective manufacturing process can be made possible. Because struts are inexpensive to produce and can be integrated into the system in a particularly simple manner. In the context of the invention, a transverse strut may be understood to mean, in particular, a component of this type which runs essentially at right angles to the longitudinal extent of the electrical line and in each case contacts one of the lines or an insulation surrounding the lines at its two ends.

In the context of a further embodiment, the ferrite core can be designed in several parts. In this case, the ferrite core, for example, have two half rings or two half shells. For example, depending on a conductor portion with a portion of the ferrite core, about a half, for example a half-shell, be connected or fixed, so that the two ferrite parts can be joined magnetically conclusive and so again enclosing the two conductors by the assembled ferrite core can be realized. It may be important in mounting the at least two parts of the ferrite core, which only a negligible air gap exists between them.

With regard to further technical features and advantages of the conductor module according to the invention, reference is hereby explicitly made to the explanations in connection with the energy store according to the invention, the figures and the description of the figures.

The present invention furthermore relates to an electrochemical energy store, comprising at least one battery cell, which is electrically connected to a conductor module designed as described in detail above.

In the context of the present invention, an electrochemical energy store may, in particular, be understood to mean an electrochemical component which can store energy, in particular electrical energy, and deliver it in the desired manner. In particular, an electrochemical energy store may be a battery or an accumulator. For example, the energy store may be a lithium-based energy store. Lithium-based energy storage includes lithium batteries as well as lithium-ion batteries. Basically, batteries may comprise, in a manner known per se, for example nickel-metal hydride, Li-ion, Li-air, Li-sulfur, the invention not being limited to the aforementioned examples in a manner which is obvious to the person skilled in the art.

In one embodiment, the electrochemical energy store comprises one or a plurality of battery cells, which are electrically connected to the conductor module. The conductor module can thus likewise be part of the energy store and integrated into the line structure thereof. There may be various configurations which may be particularly advantageous on their own or in combination.

For example, it can be provided that an electrical conductor section can be used as a forward conductor to an external consumer supplied by the energy store and that a further electrical conductor section can be used as a return conductor from the external consumer. In this embodiment, it may thus be provided that the ferrite core shields a forward conductor and a return conductor to an external consumer powered by the energy store. By the Hinleiter flows while discharging the energy storage power to the consumer or in the consumer, whereas current flows from the consumer to the battery cell or the stack of battery cells through the return conductor in a discharge of the energy storage.

Thus, it can be provided that the conductor sections are connected between a cell stack and an electrical connection of the energy store. In this case, the ferrite core can be arranged, for example, with respect to the return conductor before the single or first battery cell of the cell stack and with respect to the forward conductor to the single or last battery cell of the stack. It may further be provided that no further cell stacks or other components are arranged between the ferrite core and the single or first battery cell and the single or last battery cell, so that the ferrite core with respect to the Hinleiter and the return conductor immediately before or arranged behind the cell stack is.

The conductor module may further be arranged such that the conductor sections are electrically connected between two cell stacks or between two battery cells. In other words, the current flows both in the forward conductor and in the return conductor before and after the conductor module through a battery cell, so that the conductor module between two battery cells or between two cell stacks is arranged.

Furthermore, a plurality of conductor modules may also be provided at different positions of the energy store, or one or more of the aforementioned embodiments may be combined with one or more of the aforementioned or different embodiments of the conductor modules, without departing from the scope of the invention. It is only important that, as explained above, the electrical conductor sections are selected such that at a trouble-free operation of the conductor module or the energy storage along the ferrite core through all the ferrite core passing, for example, connected to the ferrite core and framed approximately by the ferrite core Conductor sections the summation current zero flows.

With regard to further technical features and advantages of the energy storage device according to the invention, reference is hereby explicitly made to the explanations in connection with the conductor module according to the invention, the figures and the description of the figures.

Examples and drawings

Further advantages and advantageous embodiments of the subject invention are illustrated by the drawings and explained in the following description. It should be noted that the drawings have only descriptive character and are not intended to limit the invention in any way. Show it

1 a schematic representation of an embodiment of a conductor module according to the invention;

2 , a schematic representation of an embodiment of an energy storage device according to the present invention; and

3 a schematic representation of another embodiment of an energy storage device according to the present invention.

In the 1 is an embodiment of a conductor module 10 shown in accordance with the present invention. Such a conductor module 10 can be used in a variety of applications. For example, such a conductor module 10 be used in an electrochemical energy storage 30 . 30 ' or in a battery system, as in the 2 and 3 shown in detail. For example, such a conductor module 10 or one with such a conductor module 10 equipped energy storage 30 . 30 ' Application find in the at least partially electrically powered vehicles.

The conductor module 10 includes a first electrical conductor section 12 and a second electrical conductor section 14 , In this case, for example, and in no way limiting the first electrical conductor section 12 as a lead to one of the energy storage 30 . 30 ' Serving consumers serve and can the second electrical conductor section 14 as a return conductor of one of the energy storage 30 . 30 ' supplied consumers, as explained below with reference to the 2 and 3 will be described in detail. Furthermore, a ferrite core 16 provided, the first electrical conductor section 12 and the second electrical conductor section 14 is arranged fully encompassing, so that the magnetic flux of the conductor sections 12 . 14 becomes fully relevant to the river. In other words, through the ferrite core 16 the magnetic field is attenuated, which is created by the through the line sections 12 . 14 flowing current or acting on the conductor sections common mode noise can be attenuated. This follows in particular from the Law of Flooding, which in a manner known per se relates the curve integral of the magnetic field around a closed curve to the current flowing through the area enclosed by this curve.

Further, the ferrite core 16 with the first electrical conductor section 12 and the second electrical conductor section 14 mechanically, for example, positively or materially connected. The ferrite core 16 can thus be configured for example as a toroidal core and the two electrical conductor sections 12 . 14 completely span. Further, as the ferrite material, for example, and not by way of limitation, manganese-zinc ferrites (MnZn) in the composition Mn _a Zn _(1-a) Fe ₂ O ₄ or else nickel-zinc ferrites (NiZn) in the composition Ni _a Zn _{(1) a)} Fe ₂ O ₄ are used.

In a non-limiting embodiment, two conductor sections designed as busbars can be used 12 . 14 to integrate with a typical cross-section of 10mm × 3mm and to have space for insulation layers of 1mm, an inner diameter of the toroidal core ferrite core 16 about 15mm. The length or width of the ferrite core is typically at least twice the diameter, ie about 30mm.

It can also be seen that between the first electrical conductor section 12 and the second electrical conductor section 14 two spacers designed as cross struts 18 are provided, which are suitably made of an electrically insulating material, such as a plastic, designed to prevent a short circuit. Here are the electrical conductor sections 12 . 14 as well as the ferrite core 16 and optionally the spacers 18 from an electrical insulation 20 surround. The electrical insulation 20 can be configured for example as a plastic sheath.

The 2 and 3 show each embodiments of one with a prescribed conductor module 10 equipped energy storage 30 . 30 ' , Here is the conductor module 10 in each case arranged or the conductor sections are selected such that the ferrite core 16 two such electrical conductor sections 12 . 14 spanned, passing through the conductor sections 12 . 14 in the absence of common mode noise, the summation current flows from zero.

2 shows an embodiment of the energy storage 30 in which the conductor sections 12 . 14 of the conductor module 10 between a cell stack 36 and an electrical connection 34 of the energy store 30 are interconnected. It can also be seen that an electrical conductor section 12 as a lead to one of the energy storage 30 fed external consumers 37 is usable and that another electrical conductor section 14 as return from the external consumer 37 is usable. Here is the ladder section 12 a forward conductor, as a discharge current to the consumer 37 i ₁ (t) of the in the 2 top battery cell 32 or from the cell stack 36 through the ladder section 12 flows, whereas the discharge current from the consumer 37 i ₂ (t) to the in 2 lowest battery cell 32 or to the cell stack 36 through the conductor section acting as return conductor 14 flows. As a result, the Kirschhoff node rule flows through the conductor module 10 with its ferrite core 16 or through the conductor sections 12 . 14 the total current zero, since the currents i ₁ (t) and i ₂ (t) are equal in magnitude but opposite flow, as far as there are no common mode noise.

3 further shows an embodiment in which the conductor sections 12 . 14 electrically between two cell stacks 36 . 36 '; 36 '' . 36 ''' are interconnected.

A possible manufacturing process for the in 1 shown and designed as a busbar element conductor module 10 can proceed as follows. For the integration of the ferrite core formed approximately as a toroidal core 16 The two busbars are electrical conductor sections 12 . 14 initially in a form-fitting or cohesive with the ferrite filter 16 connected to the conductor sections 12 . 14 do not touch each other. This can be done, for example, by the appropriate spacers 18 , an insulation layer 20 or additional, additional elements can be realized. Subsequently, industrially known methods of plastics technology are used, such as injection molding, extrusion or shrinking of a hose to the two electrical conductor sections 12 . 14 as well as the ferrite filter 16 in at least one operation with a plastic encase.

Now, the composite of the conductor module 10 be installed as a separate element directly in a battery module. Furthermore, it is conceivable that the two electrical conductor sections formed approximately as busbars 12 . 14 as well as the ferrite filter 16 Without additional elements insert directly into a suitable, specially designed, injection molding tool and to fill this with a plastic melt.

During production, care should be taken that the corresponding process does not adversely affect the product to be manufactured. For example, in the case of an encapsulation or application of a plastic, the production method and the plastic used should be adapted to the ferrite material in such a way that its magnetic properties are not lost by too high a processing temperature or are negatively influenced to a disproportionate extent.

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 patent literature

• US 2010/0210318 A1 [0004]
• US 5471658 A [0005]
• DE 20108259 U1 [0006]

Claims (9)

Conductor module ( 10 ), comprising at least two electrical conductor sections ( 12 . 14 ), characterized in that the conductor module ( 10 ) further comprises the at least two conductor sections ( 12 . 14 ) at least partially spanning ferrite core ( 16 ) for suppressing common mode noise, wherein the ferrite core ( 16 ) with the at least two electrical conductor sections ( 12 . 14 ) is mechanically connected to a component, and wherein the at least two electrical conductor sections ( 12 . 14 ) are selected such that during operation of the conductor module ( 10 ) and in the absence of common-mode noise through the electrical conductor sections ( 12 . 14 ) the ferrite core ( 16 ) passing a summation current of zero flows. Conductor module ( 10 ) according to claim 1, characterized in that the ferrite core ( 16 ) with at least one electrical conductor section ( 12 . 14 ) is positively connected or materially connected. Conductor module ( 10 ) according to claim 1 or 2, characterized in that the ferrite core ( 16 ) the at least two conductor sections ( 12 . 14 ) completely spanned. Conductor module ( 10 ) according to one of claims 1 to 3, characterized in that between the at least two electrical conductor sections ( 12 . 14 ) at least one spacer ( 18 ) is arranged. Conductor module ( 10 ) according to one of claims 1 to 4, characterized in that the ferrite core ( 16 ) is designed in several parts. Electrochemical energy store ( 30 . 30 ' ), comprising at least one battery cell ( 32 . 32 ' . 32 '' . 32 ''' ) connected to a conductor module ( 10 ) is electrically connected according to one of claims 1 to 5. Electrochemical energy store ( 30 . 30 ' ) according to claim 6, characterized in that an electrical conductor section ( 12 ) as a lead to one of the energy storage ( 30 . 30 ' external consumers ( 37 ) is usable and that another electrical conductor section ( 14 ) as return from the external consumer ( 37 ) is usable. Electrochemical energy store ( 30 . 30 ' ) according to one of claims 6 or 7, characterized in that the at least two conductor sections ( 12 . 14 ) electrically between two battery cells ( 32 . 32 ' . 32 '' . 32 ''' ), or that the at least two conductor sections ( 12 . 14 ) between a battery cell ( 32 . 32 ' . 32 '' . 32 ''' ) and an electrical connection ( 34 ) of the energy store ( 30 . 30 ' ) are interconnected. Electrochemical energy store ( 30 . 30 ' ) according to one of claims 6 to 8, characterized in that the energy store ( 30 . 30 ' ) is arranged in an at least partially electrically driven vehicle.

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