DE102019216256A1 - Electro-mechanical connection of battery modules in motor vehicles - Google Patents

Abstract

The invention relates to an electrical energy store (10) for a motor vehicle (1), having: • a plurality of modules (12) arranged next to one another, each comprising a module housing (14) and at least one battery cell (13) accommodated therein and each with structural components (7) of the motor vehicle (1) can be connected; and • at least one connecting element (16) which releasably connects two adjacent modules (12) to one another; wherein the connecting element (16) is elastically deformable and is set up to generate a connecting force (F) which urges the connected modules (12) towards one another as a result of an elastic deformation. The connecting element (16) also connects the modules (12) to one another in an electrically conductive manner. The invention also relates to a motor vehicle (1) having an electrical energy store (10), a connecting element (16) and a method for producing an electrical energy store (10). for a motor vehicle (1).

Description

The invention relates to an electrical energy storage device (i.e. an electrical energy storage device, e.g. a battery and in particular a traction battery). The energy store is intended for motor vehicles and has at least one connecting element for modules of the energy store. The invention also relates to a motor vehicle and a method for producing an electrical energy store for a motor vehicle. The motor vehicle can be, for example, a passenger car or a truck. In general, the motor vehicle can be driven at least partially or completely by means of electrical energy, i. H. the traction energy can be generated by converting electrical energy, for example by means of at least one electric traction motor.

The use of modular electrical energy storage devices is known for motor vehicles and in particular electrically driven motor vehicles. For example, the modules of the energy store can each include a plurality of battery cells. In order to be able to replace defective or insufficiently powerful battery cells, due to production requirements or also for cost reasons, several modules, which are small compared to the entire energy storage device, are provided, each of which includes battery cells and a module housing surrounding the battery cells. The modules are attached to one another and / or to support structures within the energy store.

For this it is, for example, from the DE 10 2017 202 354 A1 known to connect adjacent modules via form-fitting profiles (eg in the form of a dovetail guide) with one another. The DE 10 2017 201 710 A1 teaches a multi-part housing structure in which individual housing plates are connected to one another and accommodate battery cells between them. The DE 10 2016 209 853 A1 discloses a lower shell that is used to accommodate a plurality of battery cells.

One of the findings of the inventors is that the known solutions do not always allow a high battery cell density and thus energy density of the energy storage device, since e.g. connection or support structures take up an undesirably large amount of space. In addition, the previous solutions cannot always enable low-cost assembly and disassembly (e.g. for repair purposes) of the battery cells or modules. Furthermore, the previous solutions can be characterized by insufficient collision behavior, e.g. because the connection structures of the modules or battery cells can be pressed into them in the event of a collision.

One object of the invention is therefore to improve electrical energy storage devices for motor vehicles in order to avoid at least some of these disadvantages

This object is achieved by the subject matter of the attached independent claims. Advantageous further developments are given in the attached dependent claims. It goes without saying that, unless otherwise stated or evident, all of the above remarks and features also apply to the present solution or can be provided for it.

The invention generally proposes that individual modules of an electrical energy store be fastened to one another with connecting elements (and at least one to be precise). These can be the only connecting elements with which the modules are directly attached to one another. Furthermore, these connecting elements are preferably elastically deformable and, in the event of elastic deformation, can press the modules against one another or generate a restoring force which presses the modules towards one another and thus holds them together.

As will be explained in more detail below, these connecting elements are also electrically conductive. They enable an electrically conductive connection between the modules attached to one another. For example, (high-voltage) connections of the neighboring modules can be electrically connected to one another via the connecting element.

The electrical connection enables functional integration. More precisely, the connection element can also provide the function of an electrical connection in addition to the mechanical connection. This creates the possibility of omitting or at least simplifying additional electrical connections between adjacent ones. This can be accompanied by a cost saving, but above all also a saving of space. The space that is freed up, previously occupied by a high-voltage connection between neighboring modules, can then be filled with battery cells. In addition to a reduced number of parts, there is also the possibility of increasing the energy density of the energy store, since according to the invention fewer and / or smaller components are used for the electrical-mechanical connection of the modules.

Since previous high-voltage connections are often positioned on an upper side of the energy storage device facing the underbody of the vehicle, the vertical height of the energy storage device is also reduced accordingly (ie the so-called Z dimensional chain, with the Z axis being the vehicle height axis and / or generally corresponds to a vertical spatial axis).

The electrical-mechanical functional integration by means of the disclosed connecting elements also enables individual modules to be removed more easily, for example for repair purposes. According to the invention, only one component (connecting element) has to be released and not a separately provided electrical connection.

In general, the electrical connection of the modules enables them to be electrically interconnected according to principles already known in the prior art. In contrast to the previous solution, however, this electrical connection is provided via mechanically connecting and preferably significantly resilient connecting elements.

The elastic deformation can be generated when the connecting elements are installed and essentially permanently maintained during the operating life of the energy storage device (for example if no unexpected external forces act on the modules, which press them together and / or at least partially cancel the elastic deformation of the connecting elements). In this way, a connection force that is preferably permanently applied can be generated which, for example, can also vary depending on the relative movements of the modules. Alternatively, the connecting elements can, for example, be essentially elastically undeformed in normal operation in which there are no significant external forces acting on the modules. The elastic deformation, which causes the desired forces of the connecting elements on the modules, can only occur, for example, when the modules are moved away from one another due to external loads. In this case too, the connecting elements can be elastically deformed in accordance with this relative movement and generate corresponding counterforces.

As will be explained in more detail below, the connecting elements are preferably designed in the form of a clip or clip, for example because they comprise two clip sections that preferably extend in parallel and / or are positioned opposite one another. The connecting elements and in particular their possible clip sections can, for example, be elastically deformed at least temporarily during assembly or during insertion into the electrical energy store and, as explained above, this deformation can then be permanently maintained (or additionally deformed in accordance with the relative movement of the connected modules ). Alternatively or additionally, they can initially be undeformed after assembly and only be elastically deformed as a result of relative movements of the modules.

According to a further aspect of the invention, it is proposed that the connecting element comprises a displaceable component for generating connecting forces. In this case, the connecting element can also be elastically deformable, but this is not mandatory. Instead, the displaceable component can preferably be displaced (for example rotated or displaced) into a recess after it has been inserted. In this way, when the connection element is preferably already attached or inserted, the desired connection force can be generated, for example, by clamping the modules by means of the displaceable component.

• • einer Mehrzahl (bevorzugt parallel) nebeneinander angeordneter Module, die jeweils ein Modulgehäuse und wenigstens eine darin aufgenommene Batteriezelle umfassen und die jeweils mit Strukturbauteilen des Kraftfahrzeugs verbindbar sind; und
• • wenigstens einem Verbindungselement, das zwei (unmittelbar bzw. direkt) benachbarte der Module lösbar miteinander verbindet;

wobei das Verbindungselement (zumindest temporär, zum Beispiel vorübergehend bei der Montage oder infolge von Relativbewegungen der Module, oder aber dauerhaft zum Beispiel durch Aufweiten während der Montage) elastisch deformierbar ist und dazu eingerichtet ist, in Folge einer elastischen Deformation eine die verbundenen Module zueinander (oder, anders ausgedrückt, aufeinander zu und/oder aneinander) drängende Kraft zu erzeugen,
und wobei das Verbildungselement ferner dazu eingerichtet ist, die Module elektrisch leitend miteinander zu verbinden.In detail, the invention proposes an electrical energy store for a motor vehicle, with:

• A plurality of modules arranged next to one another (preferably in parallel), each of which comprises a module housing and at least one battery cell accommodated therein and which can each be connected to structural components of the motor vehicle; and
• • at least one connecting element that releasably connects two (directly or directly) adjacent modules to one another;

wherein the connecting element (at least temporarily, for example temporarily during assembly or as a result of relative movements of the modules, or permanently, for example by expanding during assembly) is elastically deformable and is set up to move the connected modules to one another as a result of elastic deformation ( or, in other words, to generate force pushing towards and / or towards one another,
and wherein the adjustment element is further configured to connect the modules to one another in an electrically conductive manner.

The electrically conductive connection can be provided, for example, in that the connection element provides or forms an electrically conductive connection path between the modules, in particular by providing an electrically conductive connection between sections (contact sections) of the connection element that can be brought into contact with the modules.

The connecting element can therefore be electrically conductive at least in sections. As explained below, however, it is preferably electrically isolated from the environment and / or the module housings. Instead, it can protrude into the modules and, more precisely, into the module housing and there contact points of the modules electrically conductively contact (for example by means of contact sections of the connecting element explained below).

According to one embodiment, the connecting element forms an electrically conductive plug connection with contact points in the interior of the modules or module housings.

On the other hand, the connecting element is preferably set up to generate a restoring force as a result of the elastic deformation, which acts against a relative movement of the modules in which a distance between the modules would be increased. The connecting element is therefore generally set up to hold the modules together and / or to limit the increase in the distance between them.

The elastic deformability can be achieved in a manner known per se via a suitable choice of material (in particular a suitable metallic material) and / or via a suitable structure or shape of the connecting element. By means of these parameters, for example, a desired spring constant of the connecting element or, in general, a desired elastic deformation behavior can be set.

The connecting element can interconnect two immediately adjacent modules (i.e. two modules with no other module between them). The connecting element can generally provide a releasable connection of the modules. It can be attached and / or removed without tools. According to one embodiment, however, it has a receiving structure or also an engagement structure (for example a threaded hole) for a tool (for example a threaded rod), in particular to facilitate removal.

The modules can be releasably attached to a body structure separately from one another at both ends. For example, they can be attached to frame-like areas of the body structure and / or connect opposite areas of a body structure to one another. Screw connections, for example, can be provided for fastening. Structural components can be components that are part of the body structure of the motor vehicle. They can thus be set up to accommodate loads and / or to carry additional components. For example, it can be (components) of frame-like components or, in general, supports.

Each of the modules is preferably connected to its directly adjacent module via at least one connecting element of the type described herein. In general, different types of connection elements can also be provided, namely electrically conductive but also non-electrically conductive ones, which, however, preferably have the elastic deformability disclosed herein. Immediately adjacent modules can be connected via at least one electrically conductive connecting element, but also at least one electrically non-conductive (but preferably elastically deformable) connecting element.

The at least one electrically conductive connecting element is preferably positioned centrally and, for example, close to or directly in the area of a vehicle longitudinal axis which runs through a central plane of the vehicle and in its longitudinal direction (i.e. from the rear to the front). In any case, they are preferably attached where connection areas, contact points and, in particular, so-called middle connection blocks are located inside the modules. In contrast, the electrically non-conductive connection elements can be positioned outside the center and / or closer to the outer ends of the modules. In particular, two electrically non-conductive connecting elements can accommodate or enclose an electrically conductive connecting element between them (for example viewed in the transverse direction of the vehicle).

In general terms, connecting elements of any kind can be positioned in an area between the module ends and, in particular, their housing ends. At least one of the connecting elements (then preferably an electrically conductive one) can be positioned essentially centrally between the named ends.

The modules can (when the electrical energy store is installed in a vehicle) run transversely to a vehicle longitudinal axis and / or in a horizontal plane. In contrast, the connecting element can be oriented essentially vertically and / or inserted vertically into, for example, receiving structures or recesses in the modules for attachment. In particular, these recesses can extend predominantly (i.e. with a largest dimension) vertically.

In general, the connecting element (and all possible connecting elements are preferably used) is preferably used on an underside of the energy storage device facing away from the vehicle or facing the road surface. In doing so, however, they can run vertically upwards and protrude into the modules or module housings or be inserted there.

According to a preferred embodiment, the connecting element comprises at least two electrical contact sections which can each be brought into electrically conductive contact with one of the modules. In particular, a first contact section can be brought into electrically conductive contact with a first one of the modules and a second contact section can be brought into contact with a second one of the modules (ie the contact sections can be contacted with different ones of the preferably immediately adjacent modules). The contact sections can also be referred to as contact fingers. It can be elongated and / or cylindrical sections. These can protrude from a base body, the connecting element and in particular any clip sections explained below therefrom. In a state inserted into the energy store, the contact sections preferably run in the vertical direction (that is, they protrude vertically upwards from, for example, the clip sections). Such a configuration enables the simple production of a plug connection and simple manual assembly of the connecting elements.

The contact points and / or connection areas of the modules (preferably in the module housing), with which the contact sections of the connecting elements are brought into contact, can be high-voltage connections. They can comprise recesses, openings, bores or general receiving structures into each of which a contact section can be inserted and / or received. A form fit can therefore be established between the contact points / connection areas and the contact sections of the connecting elements introduced therein, preferably within the modules. In this way, a reliable electrically conductive connection can be established by simply (preferably manual) plugging in.

A further development provides that the connecting element is designed in the form of a clamp and / or comprises at least one clamp section, it being preferred that its orientation can be varied in the event of an elastic deformation of the connecting element. One of the contact sections is preferably arranged on each of the clip sections and, more precisely, extends from a clip section. In particular, two clip sections can be provided, the alignment of which can be varied relative to one another within the scope of the elastic deformation. Consequently, the connecting element could also be referred to as a connecting clip. This advantageously enables the stiffest possible connection between adjacent modules in order to minimize relative movements.

In particular, the connecting element can comprise at least two legs or, in other words, clip sections which, at least in the undeformed state, preferably extend parallel to one another. As a result of an elastic deformation, a distance and in particular an angle between these legs / clip sections can be increased. The connecting element can therefore generally be expanded as a result of the elastic deformation, in particular if it is designed in the form of a clamp.

The legs / clamp sections can be connected to one another via a connecting section. This extends in the attached state of the connecting elements preferably in a substantially horizontal plane. The legs / clamp sections and also the electrical contact sections, on the other hand, can run essentially vertically. Each of the legs / clamp sections can be brought into contact with one of the modules and in particular with a module housing. In particular, it can hereby form a form fit and / or at least partially encompass the module or module housing. The clip sections can have undercuts with which they can encompass edge areas of the recesses described herein or other contours of the module housing.

In principle, however, it is also possible to make one leg / section essentially elastically undeformable or at least to make it less elastically deformable than another leg / section. This further section, which can then form the actual clamp section, can be forced away from the first-mentioned section as a result of the elastic deformation.

The legs / clamp sections and the contact sections preferably arranged thereon can form the inserted sections of the connecting elements explained below, without this being repeated separately in each of the following cases.

The contact sections are advantageously electrically isolated from the module housings. For example, they cannot be connected to the module housings in an electrically conductive manner. Instead, they can protrude from electrically non-conductive areas of the connecting elements, these electrically non-conductive areas being in contact with the module housings or at least being able to be supported thereon. In particular, the contact sections can only extend from the clamp sections in an area within the module housing, so that contacts with the module housings (at least their outside) can be reliably avoided.

According to a variant, a seal is provided, for example as a separately manageable component (for example rubber seal) or as a sealing layer (for example plastic layer) on the module housing and / or Be attached connecting element. Alternatively or additionally, the seal is attached or attachable to an intermediate wall which separates any cavities in the modules from one another as described below, in particular in order to prevent moisture from penetrating into a cavity that accommodates battery cells.

The seal can protect the interior of the module housing and in particular the contact sections preferably positioned there from moisture. Optionally, the seal can also be electrically insulating. According to one variant, an electrical insulation and sealing layer is provided which extends at least in sections between the connecting element and an adjoining module, module cavity and / or module housing. In this way, undesired current transmission from the connecting element or its contact sections to the module housing can be avoided.

Alternatively or additionally, the contact sections can be connected to one another by an electrically conductive conductor section, the conductor section being received in the connecting element, at least in sections, electrically insulated from the surroundings. In particular, the conductor section can comprise an electrical conductor and, furthermore, in particular a wire or a cable. However, it can also be a flat and / or inflexible line, that is to say not necessarily a cable-shaped line. The conductor section can be integrated into a non-conductive base body and / or connection section of the connecting element and / or received therein.

In particular, it can be provided that the connecting element, with the exception of the contact sections and the conductor section, is not electrically conductive and is made of a plastic, for example. This also applies to the clip sections, which, however, can still preferably be elastically deformable. At least those areas of the connecting element which are in contact with the contact sections and / or the conductor section can be non-electrically conductive and preferably made from a plastic.

Overall, this avoids undesirable current transmissions from the contact sections to the connecting element, in particular to areas of the connecting element that are accessible from the outside. It is generally preferred that at least in an inserted state of the connecting elements the contact sections and / or any conductor section (or generally all current-carrying sections) are not accessible from the outside or are shielded by electrically non-conductive areas of the connecting element. This increases safety and avoids undesired current drainage into the environment.

According to a further aspect, the contact sections are detachably received in the connecting element and / or are detachably connected to it. In particular, these can only be inserted subsequently into the connecting element that already connects the modules. For example, the contact sections can be pushed or pushed into bores within the connecting element. In general, the connecting element can have a preferably electrically non-conductive base body which, for example, can comprise the clip sections and / or a connection section connecting the clip sections. The contact sections can be detachably connected to the base body.

The releasable connection can simplify the assembly process, since it is not necessary to simultaneously accommodate the contact sections in connections within the modules and to establish the mechanical connection via the connection elements. Instead, the assembly tasks can be completed one after the other, so to speak.

In particular, it can be provided in this context that the contact sections are formed on (or as) screws that can be inserted into the connecting element. The contact sections can, for example, form pointed or free ends of these screws, which can be pushed through the connecting element and / or the protruding base body thereof (e.g. through electrically conductive and electrically interconnected bores) into the modules and, in particular, module housings. There they can then be received in threaded bores, these threaded bores being electrically conductive and forming connection areas in the sense of this disclosure. This enables a reliable and mechanically resilient electrical connection to be established.

A further development provides that the connecting element (and in particular any base body thereof) has an edge region which protrudes laterally beyond the contact sections. In particular, it can be brought into contact with at least one of the module housings and / or can at least be supported on it. It can provide a stop function and / or a centering function. In particular, it can reduce the risk that the contact sections will inadvertently come into contact with the module housing during assembly or disassembly or that they will hit it.

The edge area can form a base area or an outer contour of the connecting element and / or be included therein. The edge region can protrude laterally in a horizontal spatial plane and / or in a plane running orthogonally to the longitudinal direction of the contact sections. In particular, the edge region can define the largest dimension of the connecting element and / or its outline within such a plane. In other words, the contact sections can be offset inwardly with respect to the edge region or can be positioned closer to a geometric center of the connecting element.

According to a further embodiment, the module housings of the connected modules each comprise (at least) one recess into which at least one section (for example leg / clamp section including the contact section arranged thereon) of the connecting element can be inserted. As mentioned, this enables in particular a vertical insertion or pushing in of the sections. The recesses of adjacent modules can be dimensioned and / or positioned in the same way (for example at the same height). They can be formed on mutually opposite edge areas and / or generally at least partially on the undersides of the respective module housings. They can be put together to form a common and correspondingly larger-sized free space or receiving space for the connecting elements.

It can further be provided in this context that the inserted sections, with the exception of the contact sections of the connecting element, rest against an inside of a respective module housing. For this purpose, the module housings can, for example, provide an inner cavity and / or the inserted sections can be pushed into an inner cavity of the module housing from the outside. In contrast, the contact sections can run within the module housing to the connection areas there and are preferably pushed into them in order to establish an electrically conductive connection.

According to one variant, the module housings have at least two preferably elongated cavities or, in other words, chambers. A first cavity, preferably larger in comparison, serves to accommodate battery cells. A second, in comparison preferably smaller, cavity is preferably largely or completely empty and serves as a deformation zone in the event of a collision (for example when driving up to ground level, such as a bollard). The cavities can adjoin one another or be separated from one another by a common partition. When installing the energy store in a motor vehicle, the second cavity preferably points downwards or forms an underside of the energy store and preferably also of the entire motor vehicle (i.e. faces the road surface).

In this context, the recesses in the module housing can be positioned in such a way that they extend into the second cavity, in which the clip sections can preferably be received. However, the recesses can also extend into the first cavity. The contact sections can then be positioned there and brought into electrically conductive contact with connection areas. In particular, the clip sections of a connecting element can at most be inserted into the second cavity and there, for example, rest against an inside thereof, but not in the first cavity. This offers advantages with regard to the energy density that can be achieved, since the first cavity can, for example, be filled with battery cells as large as possible and / or the connecting elements (at least their clip sections) do not form any interfering contours there. Furthermore, the battery cells are protected from damage by the connecting elements (or at least their clip sections) if they are displaced or displaced in the event of a collision.

In summary, a development of the invention provides that the module housing comprises at least two cavities (according to any of the above variants) separated from one another (for example by an essentially closed or only locally perforated partition), one of the cavities accommodating the at least one battery cell. The clip sections of the connecting element can be positioned near the further cavity (or, in other words, closer to the further cavity than to the cavity receiving the battery cell (s)) and / or at least partially protrude into it (for example via the recesses described) ). On the other hand, they cannot protrude into the first cavity receiving the battery cells, which is preferably reserved for the electrical contact sections at most. The cavities can be adjacent and / or strung together, in particular along a height axis of the vehicle (that is, along a vertical spatial axis). The further cavity is preferably positioned further down or below the first-mentioned cavity.

The cavities are preferably formed at least in sections with a largely or completely closed cross-sectional profile, but can also have individual recesses, such as for example bores, or at least in sections, for example, areas that are open on one side. A separation of the cavities can take place via a (common) partition of the module housing, which preferably at least partially delimits both of the cavities.

It can further be provided that at least one of the inserted sections (of the connecting element) is set up to form a form fit and / or a frictional fit with the module housing, in the recess of which this section is inserted. This can apply in particular to clip sections of the connecting element. In contrast, the contact sections are preferably not in contact with the module housing, but at most with (high-voltage) connection areas within the module housing.

In particular, structures such as projections, recesses or general engagement structures can be provided on the inside of the module or module housing, in which the inserted section (for example clamp section) can engage in order to form the form fit. For the production of a friction shot, on the other hand, a system on, for example, the inside can be sufficient. The section can be suitably profiled in the contact area with the inner wall (for example, have prongs, teeth or points).

These variants improve the hold of the connecting elements and thus increase the reliability of the connection made. In particular, an undesired loosening or moving out of the connecting elements from the recesses can be avoided by the form fit and / or the frictional connection.

Furthermore, according to one embodiment it is provided that a section (connecting section) of the connecting element connecting the inserted sections is accessible from the outside (ie from outside the energy store and preferably without dismantling the energy store) and in particular rests and / or on an outside of at least one of the module housings extends parallel to this at least in sections. This enables the connecting elements to be easily removed, for example to detach individual modules for the purpose of repairs after the energy storage device has been installed in a vehicle. It is therefore also preferred that, when the energy store is installed, the connecting elements are arranged on an underside of the energy store and / or motor vehicle. However, it cannot be ruled out that the motor vehicle has panels (for example an underbody panel) that must first be removed.

A further development provides that the connecting element comprises a recess, in particular a threaded hole, for receiving a tool (for example a threaded rod) that applies a removal force. The recess can in turn be accessible from the outside and in particular be formed on an outside of the connecting element. This can be an outside of a connecting section of the connecting element. Overall, this makes it easier to remove the connecting elements, for example if the modules are to be removed from the energy store for repair.

• • einer Mehrzahl nebeneinander angeordneter Module, die jeweils ein Modulgehäuse und wenigstens eine darin aufgenommene Batteriezelle umfassen und die jeweils mit Strukturbauteilen des Kraftfahrzeugs verbindbar sind; und
• • wenigstens einem Verbindungselement, das zwei benachbarte der Module miteinander verbindet;

wobei das Verbindungselement eine verlagerbare Komponente umfasst, die zum Erzeugen der Verbindungskraft verlagerbar ist. Das Verbindungselement ist erneut bevorzugt dazu eingerichtet, die Module elektrisch leitend miteinander zu verbinden.The invention also relates to an electrical energy store for a motor vehicle, with:

• A plurality of modules arranged next to one another, each of which comprises a module housing and at least one battery cell accommodated therein and which can each be connected to structural components of the motor vehicle; and
• • at least one connecting element that connects two adjacent modules to one another;

wherein the connecting element comprises a displaceable component which can be displaced in order to generate the connecting force. The connecting element is again preferably set up to connect the modules to one another in an electrically conductive manner.

All of the above explanations and developments relating to identical features of the variant with deformable connecting elements also apply to the present (displaceable) variant. In the present case, too, the connecting element can therefore be elastically deformable, but this is not mandatory.

The displaceable component can be rotatable and / or displaceable, for example. For this purpose, it can be fastened to the connecting element in a suitable manner, for example by means of a rotary joint (pin). In particular, as a result of a displacement, the displaceable component can produce a clamping contact or cause the connecting element to jam on the adjacent modules.

For this purpose, the displaceable component can be brought into contact, for example, as a result of a displacement, preferably with an inner wall of one of the module housings and then apply a clamping force to this during a further displacement.

Opposite the displaceable component there is preferably a fixed (or rigid and / or non-displaceable) section of the connecting element which can serve as a type of counter bearing. This can preferably be on the inner wall of the corresponding other module rest (ie on the other of the adjacent modules on which the displaceable component is not directly supported or contacted). As a result of a displacement, a distance or an intermediate space between this fixed area and the displaceable component can be reduced. The adjacent modules and, in particular, side walls thereof can be at least partially accommodated in this intermediate space. Consequently, as a result of its displacement, the displaceable component can increasingly press the modules against one another and thus jam against one another.

The displaceable component can be cam-shaped and / or an eccentrically mounted rotatable component. It can be rotatable and, for example, due to the eccentric mounting as a result of the rotation, then bring about the described reduction in distance or reduction in the space.

The invention also relates to a motor vehicle with an electrical energy store according to one of the preceding aspects, the modules being arranged parallel to one another in a receiving slot of a body structure of the vehicle and the module housings being releasably fastened to the body structure separately at both ends and in one area by means of the at least one connecting element are releasably connected between the ends of the housing.

The invention also relates to a connecting element for the electrically conductive connection of modules of an electrical energy store, wherein the connecting element is elastically deformable and comprises two clip sections, the alignment of which can be changed within the scope of the elastic deformation, and wherein the connecting element comprises at least two electrical contact sections which can be brought into contact with one of the modules to be connected while establishing an electrical connection between the modules. In general, the connecting element can comprise any further feature described herein in connection with connecting elements.

• • lösbares Verbinden von zwei benachbarten der Module mit wenigstens einem Verbindungselement;

wobei das Verbindungselement elektrisch leitend und elastisch deformierbar sowie dazu eingerichtet ist, in Folge einer elastischen Deformation eine die verbundenen Module zueinander drängende Verbindungskraft zu erzeugen.The invention also relates to a method for producing an electrical energy store for a motor vehicle, wherein the electrical energy store comprises a plurality of modules arranged next to one another, each of which comprises a module housing and at least one battery cell accommodated therein and which can each be connected to structural components of the motor vehicle; and wherein the method comprises:

• • releasable connection of two adjacent modules with at least one connecting element;

wherein the connecting element is electrically conductive and elastically deformable and is designed to generate a connecting force that urges the connected modules towards one another as a result of an elastic deformation.

The connection can be made by inserting the connecting element into the recesses described above. In general, all of the above and below variants, developments and explanations, in particular with regard to identical device features, can also apply to the method and its features or be provided for them. For example, the method can enable the production of an electrical energy store in accordance with any embodiment described herein. For this purpose, all further method steps can be provided that are required to produce any energy storage device described herein and / or generally provide any operating state or effect described herein. The method can also include the step of elastically deforming the connecting element as part of the releasable connection.

• 1 zeigt eine schematische Ansicht eines Kraftfahrzeugs gemäß einem Ausführungsbeispiel der Erfindung mit einem elektrischen Energiespeicher gemäß einem ersten Ausführungsbeispiel der Erfindung;
• 2 - 5 zeigen Teilansichten des Energiespeichers aus 1 mit einem Verbindungselement gemäß dem ersten Ausführungsbeispiel und in Fi.g 3 das Verbindungselement als solches;
• 6 - 7 zeigen Teilansichten eines erfindungsgemäßen Energiespeichers mit Verbindungselementen gemäß weiteren Ausführungsbeispielen;
• 8 - 9 zeigen Teilansichten eines erfindungsgemäßen Energiespeichers mit Verbindungselementen gemäß einem weiteren Ausführungsbeispiel.

Embodiments of the invention are explained below with reference to the attached schematic figures. Features that are the same or have the same effect can be provided with the same reference symbols across the figures.

• 1 shows a schematic view of a motor vehicle according to an embodiment of the invention with an electrical energy store according to a first embodiment of the invention;
• 2 - 5 show partial views of the energy storage system 1 with a connecting element according to the first embodiment and in Fi.g 3 the connecting element as such;
• 6th - 7th show partial views of an energy store according to the invention with connecting elements according to further exemplary embodiments;
• 8th - 9 show partial views of an energy store according to the invention with connecting elements according to a further exemplary embodiment.

In 1 is an underside of a motor vehicle 1 according to an embodiment of the invention and with an electrical energy store 10 according to an embodiment of the invention shown, the energy storage 10 was produced by means of a method according to the invention.

The energy storage 10 is a traction battery and stores electrical energy, which by means of traction motors (not shown) is converted into a traction force for the movement of the motor vehicle 1 is immutable. In addition, other electrical consumers of the vehicle can also be used 1 that are not used to generate a traction force with electrical energy from the energy speaker 10 such as air conditioning, an infotainment system or vehicle lighting.

The car 1 is shown in a very simplified way. You can see a front and a rear axle 2 , 3 , on each of the two vehicle wheels 4th are arranged. The axes 2 , 3 are in the usual way along a vehicle longitudinal axis L. objected to each other. A body structure is also shown 5 . This points in an area between the axes 2 , 3 a frame-like area 6th on, the one receiving slot 17th for electrical energy storage 10 limited or defined. On two opposite and essentially parallel to the vehicle's longitudinal axis L. running girders 7th is the energy store 10 attached as by cross-shaped fasteners 11 (for example screws) indicated schematically.

The energy storage 10 includes several and in 1 just an example of four individual modules 12th . These each have a module housing explained in more detail in the further figures 14th on, in which only very schematically indicated battery cells 13th are included (see 3 ). It is also not shown that each of the modules 12th (or at least one) has its own high-voltage connection, so that the battery cells of these modules 12th (or the at least one) electrical energy can be taken but also supplied. For example, this high-voltage connection is provided for connection to a main vehicle line. The high-voltage connection is preferably integrated in the connecting clamps below. In any case, the modules are 12th but electrically connected to each other in the manner explained below by means of connecting clips, whereby these are preferably connected in series ..

The modules 12th extend parallel to one another and essentially transversely to the longitudinal axis of the vehicle L. and are at their two opposite ends via the fastening elements already described 11 on the carriers 7th which are an example of structural members. These are preferably the only fastenings for the modules 12th on the body structure 5 , however, with several individual screw connections to the girders 7th at both ends of the modules 12th can be provided.

The modules 12th are also along the longitudinal axis of the vehicle L. lined up. They therefore each have at least one directly adjacent module 12th on. Adjacent modules 12th are by means of connecting elements explained in more detail below 16 connected with each other. The fasteners 16 are in 1 indicated schematically as simple lines. For reasons of clarity, not all of the connecting elements are 16 provided with their own reference number, but only the connecting elements 16 from a selected adjacent pair of the modules 12th .

It can be seen that one of the connecting elements 16 centrally positioned (and preferably electrically conductive) and preferably on the vehicle's longitudinal axis L. lies. Two more fasteners 16 are on both sides of the central connecting element 16 positioned and preferably halfway between the fasteners 11 and the central connector 16 . These can be electrically conductive or not electrically conductive. All connecting elements 16 are preferably deformable in the manner described herein.

According to the invention and not restricted to the further details of the exemplary embodiments, only one connecting element can also be used 16 per pair of adjacent modules 12th be provided. This is then preferably the centrally positioned connecting element 16 .

It should be emphasized that the fasteners 16 on an underside of the energy store 10 are arranged, which is also an underside of the vehicle 1 forms and the viewer in 1 is facing. Optionally, however, an underbody cladding could also be provided. Next are the modules 12th in 1 only by way of example slightly apart from one another along the longitudinal axis of the vehicle L. objected pictured. It is preferred that the modules 12th rest against each other and in this position by the connecting elements 16 being held.

In 2 is a partial section of two neighboring modules 12th shown in perspective. More precisely, you can see a recess 24 that are in each of the module housings 14th and, more precisely, is formed on their undersides. The recesses 24 the neighboring module housing 14th merge into one another or define a common free space for receiving one of the connecting elements explained below 16 . The recesses are only set as an example 24 in the case shown to an oval recess together. Rectangular or circular shapes would also be possible.

In 4th Figure 3 is a cross-sectional view through two adjacent modules 12th shown. You can first see that the modules 12th and more precisely the module housing 14th are designed as elongated hollow profiles and preferably extruded profiles. They preferably have two cavities or chambers 26th on. These are only exemplified in 3 almost the same size. It is preferred that the upper cavity 26th larger than the lower cavity 26th is.

The lower cavity 26th is closer to the bottom of the electrical energy store 10 positioned or facing the vehicle surface. It serves as a deformation zone in the event of a collision, for example if the vehicle 1 unintentionally hits a raised floor such as a bollard.

The upper cavity 26th serves to accommodate schematically indicated battery cells 13th passing through the deformation zone in the form of the lower cavity 26th are protected against damage in the event of a collision. There are also connection areas 100 (For example, cylindrical bores) are provided, which can be high-voltage connections, for example. The connection area 100 can with contact sections explained below 102 the fasteners 16 form an electrically conductive plug connection. At least parts of the battery cells 13th of the neighboring modules 12th can be connected to one another in an electrically conductive manner in this way.

In 4th you can also see the area of the recesses 24 , which is used to accommodate a connecting element also shown and shown in the inserted state 16 serve. The recesses 24 extend from a bottom of the modules 12th or module housing 14th into the lower cavity 26th into it. Along the same vertical axis (ie concentric or overlapping with the recesses 24 ) is in a partition 104 showing the respective cavities 26th of a module 12th separates from each other in each of the modules 12th an opening (for example a bore) 106 is formed. Through this breakthrough 106 an elongated cylindrical contact section can pass through each 102 of the connecting element 16 into the upper cavity 26th to be introduced. The connecting element 16 protrudes with the exception of these contact sections 102 but not in the upper cavity 26th into it. This reduces the risk of the connecting element 16 especially in the event of a collision on the battery cells 13th supports and introduces significant forces there that could lead to damage.

The connecting element 16 , this in 3 is shown in a detail view, is formed bracket-like. It has a horizontally extending connecting section 32 on and two clip sections (or legs) 30 projecting angled therefrom. The latter extend at least partially vertically and thus protrude into the recesses 24 and especially the lower cavity 26th into it. There they arrive with a respective inner wall of the lower cavity 26th in Appendix.

Starting from the bracket section 30th each extend vertically upwards (ie in the direction of the vehicle 1 ) elongated cylindrical contact sections 102 . These are made of an electrically conductive material. A conductor section is also indicated by dashed lines 108 who made these contact sections 102 electrically connects to each other. Thus, through the connecting element 16 an electrically conductive connection via the contact sections 102 and the ladder section 108 between the connection areas 100 of the neighboring modules 12th provided.

The connecting section 32 and the bracket sections 30th are in the example shown of an electrically non-conductive base body 110 the connecting element 16 includes (made for example from a plastic). The ladder section 108 is in this basic body 110 recorded and electrically isolated from the environment (for example, cast in it). The contact sections 102 lie inside the modules 12th free, which can prevent undesired power transmission to the environment.

Not shown separately that the contact sections 102 in the main body 110 be inserted manually and, for example, guided through them as bolts and into the connection area 100 could be screwed in. Preferably there are then bores in the base body 110 electrically conductive sleeves are used to the contact sections 102 via the connecting element 16 also to be connected to one another electrically conductive.

Alternatively, the contact sections 102 but also the conductor spacing 108 in the main body 110 poured in or overmolded through this.

Various electrically insulating seals or sealing layers 112 can be provided. For example, these can be applied to the inner walls of the openings 106 applied or arranged as sleeve inserts therein to allow current to flow away from the contact sections 102 into the module housing 14th to prevent. If these seals 112 the contact sections 102 tightly enclose, can also transfer moisture into the upper cavity 26th be prevented.

In 4th is also a horizontal distance A of the mutually facing inner sides or ends of the clip sections 30th registered. This is in the unused state of the connecting element 16 smaller than the distance between the inner walls on which the bracket sections 30th should concern. In the case shown, the latter corresponds to twice the wall thickness of the adjacent side walls of the module housing 14th . As a result, the bracket portions 30th when inserting into the recesses 24 and after being brought into contact with the respective inner walls and urged away from each other and the connecting element 16 thus expanded overall. This results in an elastic deformation of the connecting element 16 so that one of the bracket sections 30th elastic restoring force towards each other F. arises. This will make the bracket sections 30th against the inner walls of the module housing 14th pressed and a frictional connection is created, which causes a loosening of the connecting element 16 out of the recess 24 prevented.

The restoring forces act in particular F. but as the connecting forces which the modules 12th huddle together and hold together during operation. This results in relative displacements of the modules 12th limited to each other, especially in the event of a collision, without being affected by the connecting elements 16 there is an increased risk of damage to the battery cells. The latter applies, for example, due to their elastic deformability even if there is no lower cavity 26th provided and the connecting elements 16 would be arranged adjacent to battery cells. The fasteners 16 In the event of a collision, for example, they can be further elastically deformed at least partially and / or at least slightly evade the battery cells and thus not or only to a limited extent pressed into them.

As explained in the introduction, significant restoring or connecting forces can F. can also only be generated during operation when, for example, (especially horizontal) spacing increases between the modules 12th arise. The elastic deformation of the connecting element 16 can then only turn out to be very small during normal operation or when it is first used, for example in order to merely achieve a hold on the inner walls by means of a friction connection, but not to avoid significant and / or permanently applied connecting forces F. to create. It is also possible that initially there is no significant elastic deformation of the connecting elements 16 he follows. Then the fasteners can 16 preferably via form-fit connections on or in the modules as explained below 12th held.

In 3 it is also shown that the base body 110 of a connecting element 16 an edge area 114 having opposite to each of the contact portions 102 laterally protrudes outwards. This is especially true in an orthogonal to the longitudinal axis X of the contact sections 102 running (virtual) plane. The edge area 114 thus forms a lateral projection that when inserted into a recess 24 can come into contact with this and / or be supported therein without the contact sections 102 must do this imperatively. Unwanted collisions of the module housing 14th with the contact sections 102 can thereby be avoided.

In 5 is finally a partial section of the energy storage system 10 shown and more precisely a bottom thereof. You can see areas of three neighboring modules 12th , with two immediately adjacent modules 12th by means of connecting elements 16 connected to each other (i.e. the middle to the left and the middle to the right). The recesses 24 the 2 and 3 are thereby through the respective connecting section 32 the fasteners used in it 16 covered.

An optional intervention structure can also be seen 34 on an underside of the connecting elements facing the viewer 16 or their connecting sections 32 . This is a threaded hole into which a corresponding counterpart of a tool (for example a threaded rod) can be screwed. This allows the connecting element 16 by making it easier to apply suitable removal forces (e.g. tilting forces) back from the modules 12th be solved.

In the following 6th to 9 are further embodiments of connecting elements 16 shown. This also includes the contact sections explained above 102 as well as breakthroughs 106 between the cavities 26th of the modules 12th entered, the above based on the 3 and 4th have been explained. In order to avoid repetitions, these features will not be discussed again separately in the following.

In the 6th and 7th are alternative designs of connecting elements 16 shown, the cross-sectional views shown in turn that of those from 3 resemble. In particular, the connecting elements 16 again in recesses 24 are used and lie on the inner walls of a (per se optional) lower cavity 26th at.

In case of 6th there is a form fit between the connecting element 16 and each of the modules or module housings 12th , 14th produced. For this purpose, a mechanical engagement is formed between the named elements. The inner walls of the Module housing 14th as well as the connecting elements 16 have corresponding engagement structures.

In the example shown, the connecting element comprises 16 preferably on the opposite inner sides of the clip sections 32 one recess each 50 (for example in the form of a groove or local depression). On the inside walls of the module housing 14th is a correspondingly dimensioned projection 52 educated. This is due to an insertion or pushing in of the connecting element 16 and resiliently urging the clip portions apart at least temporarily 32 in the recesses 50 recordable. The reverse case would also be possible, in which there is a projection on the clip sections 32 in recesses on the inner walls of the module housing 14th intervenes

Analogous to the discussion of 4th but it is also possible that even after the positive fit has been established, an elastic deformation of the connecting element 16 for example, is permanently maintained by expanding it.

In 7th a possibility for improved (ie more effective or stronger) production of a frictional connection is shown. For this purpose is on the mutually facing inner sides of the clip sections 32 each a jagged structure 60 shown with several protruding prongs (ie pointed and / or sharp-edged projections). This can create a stronger frictional connection, for example by microscopic intervention in the surface of the module housing 14th effect than, for example, in the case of 3 .

It is also possible to use the variants of the 6th and 7th to be combined with each other (e.g. by addressing extended bracket sections 32 who have made the structures 50 , 60 show one after the other, so to speak). Also, just one of the bracket sections could be 32 according to variants of the 6th and 7th be designed and the other according to the other of the 6th and 7th or according to the variant of 4th .

It is also in the case of the 6th and 7th possible that the fastener 16 is initially elastically undeformed after insertion (for example, as long as there are no undesired increases in the distance between the module housings 14th occur) or is permanently elastically deformed, so to speak, in order to generate correspondingly constant connecting forces.

In 8th which in turn have an analogous representation to the 4th , 6th and 7th contains, is finally another variant of a connecting element 16 shown, in turn in recesses 24 adjacent module housing 14th is used and rests against the inner walls. 8th shows the connector 16 in a perspective view of individual parts.

The connecting element 16 this variant is not necessarily elastically deformable, but this can also be provided. It has a fixed (ie preferably generally undeformable and / or non-displaceable) section 70 on. This is at a first end of the connecting element 16 positioned. At an opposite end of the connecting element 16 there is a relocatable component 72 . The displaceable component is cam-shaped. She is over a peg 74 rotatable on the connecting element or a base body 71 stored from it. The basic body 71 is generally rigid and preferably integral with the fixed portion 70 educated.

An axis of rotation R. to get the the relocatable component 72 is rotatable is in the 8th and 9 indicated runs generally vertically and in particular transversely to the longitudinal axis of the vehicle L. out 1 (ie there into the plane of the sheet).

It is preferred that the displaceable component 72 rotatably on the pin 74 is attached and the tenon 74 for example via an engagement structure not shown separately 34 on an underside of the connecting element 16 can be twisted. For example, the engagement structure 34 as an internal thread or a bore formed with a non-circular cross-section in the pin 74 realized. A correspondingly profiled or provided with an external thread tool can be in this engagement structure 34 engage and the tenon 74 and thus also the relocatable component 72 twist from the outside, so to speak. In particular, this allows the component 72 even after being inserted into the recesses 24 can be rotated afterwards.

Due to the shape of the relocatable component 72 , but especially due to an in 9 recognizable eccentric connection with the pin 74 is a distance A to an opposite face of the fixed section 70 in accordance with a rotation of the component 72 variable and in particular reducible.

This distance A is preferably initially comparatively large around the connecting element 16 into the recesses 24 insert and the walls of the module housing 14th to be able to record. Then the relocatable component 72 however, as the distance decreases, it rotates and comes into contact with it opposite inner wall of the corresponding module housing 14th . Any further rotation of the component 72 in the same direction then leads to the generation of clamping connecting forces F. and in particular to jamming the corresponding wall areas of the module housing 14th that is between the fixed section 70 and the relocatable component 72 are arranged. This will make the module housings 14th pushed together and held together to prevent relative movements.

This variant can also be used to achieve the advantages explained above in terms of space savings and maximum energy density, as well as preferred deformation behavior in the event of a collision.

Another general advantage of the invention and, in particular, of all the exemplary embodiments explained, lies in the low-cost assembly but also the disassembly of the connecting elements 16 . The production costs can also be limited since, for example, the modules themselves only have to be modified slightly, for example by making the cutouts 24 . Especially the deformable fasteners 16 are also comparatively inexpensive to manufacture.

List of reference symbols

1

Motor vehicle

2

front axle

3

rear axle

4th

Vehicle wheel

5

Body structure

6th

frame-like area

7th

Beam / structural component

10

Energy storage

11

Fastener

12th

Modules

13th

Battery cells

14th

Module housing

16

Connecting element

17th

Receiving slot

24

Recess

26th

upper cavity

28

lower cavity

30th

Bracket section

32

Connection section

34

Intervention structure

50

Recess

52

head Start

60

serrated structure

70

fixed section

71

Base body

72

relocatable component

74

Cones

100

Connection area

102

Contact section

104

Partition

106

Breakthrough

108

Ladder section

110

Base body

112

poetry

114

Edge area

R.

Axis of rotation

L.

Vehicle longitudinal axis

F.

Connecting force

X

Contact section longitudinal axis

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was 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.

Patent literature cited

• DE 102017202354 A1 [0003]
• DE 102017201710 A1 [0003]
• DE 102016209853 A1 [0003]

Claims (10)

An electrical energy store (10) for a motor vehicle (1), comprising: • a plurality of modules (12) arranged next to one another, each comprising a module housing (14) and at least one battery cell (13) accommodated therein and each with structural components (7) of the Motor vehicle (1) can be connected; and • at least one connecting element (16) which releasably connects two adjacent modules (12) to one another; wherein the connecting element (16) is elastically deformable and is set up to generate a connecting force (F) which urges the connected modules (12) towards one another as a result of an elastic deformation; characterized in that the adjustment element (16) is further set up to connect the modules (12) to one another in an electrically conductive manner. Electrical energy storage (10) according to Claim 1 , characterized in that the connecting element (16) comprises at least two electrical contact sections (102) which can each be brought into electrically conductive contact with one of the modules (16). Electrical energy storage (10) according to Claim 2 , characterized in that the connecting element (16) comprises two clip sections (30), one of the contact sections (102) being arranged on each clip section (30). Electrical energy storage (10) according to Claim 3 , characterized in that the alignment of at least one of the clip sections (30) can be varied in the event of an elastic deformation of the connecting element (16). Electrical energy store (10) according to one of the Claims 2 to 4th , characterized in that the contact sections (102) are electrically isolated from the module housings (14), and / or that the contact sections (102) are connected to one another by an electrically conductive conductor section (108), the conductor section (108) being at least partially electrically is received isolated from the environment in the connecting element (16). Electrical energy store (10) according to one of the Claims 2 to 5 , characterized in that the contact sections (102) are detachably received in the connecting element (16), in particular wherein the contact sections (102) are formed on screws which can be inserted into the connecting element (16). Electrical energy store (10) according to one of the Claims 2 to 6th , characterized in that the connecting element (16) has an edge region (114) which protrudes laterally beyond the contact sections (102). Motor vehicle (1) with an electrical energy store (10) according to one of the preceding claims, wherein the modules (12) are arranged parallel to one another in a receiving shaft (17) of a body structure (5) of the vehicle (1) and the module housings (14) are arranged separately are releasably attached to each other at both ends of the body structure (4) and are releasably connected to one another by means of the at least one connecting element (16) in an area between the housing ends. Connecting element (16) for the electrically conductive connection of modules (12) of an electrical energy store (10), wherein the connecting element (16) is elastically deformable and comprises two clip sections (30), the alignment of which can be changed within the scope of the elastic deformation and wherein the connecting element (16) comprises at least two electrically conductive contact sections (102) which can each be brought into contact with one of the modules (16) to be connected while establishing an electrical connection between the modules (16). Method for producing an electrical energy store (10) for a motor vehicle (1), wherein the electrical energy store (10) comprises a plurality of modules (12) arranged next to one another, each of which comprises a module housing (14) and at least one battery cell (13) accommodated therein and which can each be connected to structural components (7) of the motor vehicle (1); and wherein the method comprises: ◦ releasable and electrically conductive connection of two adjacent ones of the modules (12) with at least one connecting element (16); wherein the connecting element (16) is electrically conductive and elastically deformable and is designed to generate a connecting force (F) that forces the connected modules (12) towards one another as a result of an elastic deformation.

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