DE102020008015A1 - Connecting device - Google Patents

Abstract

The invention relates to a connecting device (10 ') for the mechanical and electrical coupling of at least two components (4), comprising a first connecting element (12') and a second connecting element (14 '), which are arranged on different components (4), wherein the first connecting element (12 ') and the second connecting element (14') each have an electrically conductive contact surface (24 ', 26') and an electrically insulating holder (16 ', 18') as well as mutually corresponding joining contours (20 ', 22') for mutual form-fitting connection, the joining contours (20 ', 22') being designed in such a way that, when a form-fitting connection is established, the joining contours (20 ', 22') interlock at least in sections and the contact surfaces (24 ', 26') ) Bring the connecting elements (12 ', 14') into electrically conductive contact.

Description

The invention relates to a connecting device for the mechanical and electrical coupling of at least two components, having a first connecting element and a second connecting element, which are arranged on different components. The invention further relates to a vehicle battery and an electrically powered or drivable motor vehicle.

Motor vehicles driven or drivable by electric or electric motors, such as for example electric or hybrid vehicles, generally comprise an electric motor with which one or both vehicle axles can be driven. To supply electrical energy, the electric motor is usually connected to a (high-voltage) battery inside the vehicle as an electrical energy store.

An electrochemical battery, in particular, is to be understood here and in the following text as a so-called secondary battery (secondary battery) of the motor vehicle. In the case of such a (secondary) vehicle battery, the chemical energy used can be restored by means of an electrical (charging) process. Such vehicle batteries are designed, for example, as electrochemical accumulators, in particular as lithium-ion accumulators. In order to generate or provide a sufficiently high operating voltage, such vehicle batteries typically have at least one battery module in which a plurality of individual battery cells are connected in a modular manner.

The battery modules of the vehicle battery are typically arranged in a common battery housing. To improve the power and energy density of the vehicle battery, it is desirable to construct the volume for the battery cells as large as possible and the battery housing as small as possible, with all mechanical load cases having to be endured without fire and without short circuits. For this, it is necessary that structural components are designed to save space and, if possible, without redundancies. At the same time, in addition to an installation space for the battery cells, sufficient installation space must also be kept within the battery housing for the electrical lines and control devices.

Nowadays, vehicle batteries generally have a comparatively large battery housing which typically fills an underbody of the motor vehicle essentially completely and which represents a rigid assembly. The mechanical stresses are typically dissipated via a framework or webs in the battery housing. This design is the mechanical. Structural integrity or torsional rigidity of the battery housing is comparatively high; so that no / minimal deformations within the battery housing are to be expected in the event of mechanical loads. The individual battery modules therefore experience only slight retative movements, so that the high-voltage connections, which are also accommodated in the battery housing, for interconnecting the battery modules also experience only slight stresses.

Due to the additional components for realizing the load paths within the battery housing, such battery housings have an increased structural weight, which has a disadvantageous effect on the weight of the motor vehicle and thus on the range of the electric motor drive. Furthermore, such battery housings have a comparatively large structural size along a vehicle height (Z direction), as a result of which the vehicle battery has an increased Z dimensional chain.

In other words, the maximum power and energy density is disadvantageously reduced by the separate load paths in the battery housing, since, in addition to the supporting structures, a greater distance from the battery modules is required due to the deformation to be taken into account. Furthermore, the associated complex tolerance chains must be taken into account. This means that less installation space is available for the battery modules or battery cells.

A further disadvantage of such battery housings is that individual removal of battery modules, for example in the case of servicing or for customer service purposes or for range adjustments on the customer side, is essentially not possible or only possible with great effort. To remove a battery module, it is necessary to dismantle the entire battery housing and then reassemble it, so that a great deal of effort is required in the event of servicing. Furthermore, complex and cost-intensive logistics and production are required in the manufacture of the vehicle battery.

As an alternative to a battery housing in which the battery modules are arranged together with the load-bearing structures, it is possible, for example, to design the module housings of the battery modules themselves as load-bearing structures of the vehicle battery. Here, load paths for mechanical loads that occur, for example, in a vehicle accident or a vehicle impact (vehicle crash)) are laid directly in the housing of the battery modules and thus more Space for battery cells, for example, is made available.

Such load-bearing battery modules often have an integrated battery management system (BMS) and are therefore also referred to as intelligent battery units (Smart Battery Units, -SBU).

In the case of such load-bearing battery modules or SBUs, it is necessary that the HV contact is made outside of the installation space of the SBU, since the individual SBUs represent self-contained and sealed housings and the load paths are designed without interruption. In SBU-based battery concepts, these HV contacts are usually made above the battery system and thus require additional installation space in the z-dimensional chain.

The connecting devices or HV connectors for interconnecting such battery modules often have purely electrical or electronic functions and have no mechanical function. Furthermore, such connecting devices typically build up in the z-direction due to a necessary overhead arrangement, whereby they require a larger z-dimension and compromises in the area of the vehicle center (center tunnel, supply channel, etc.).

From the DE10 2016 206 846 A1 A connecting device for producing an electrically conductive connection between two battery modules is known, in which a lower part, which has a first electrical conductor arranged in a housing of one battery module, and an upper part, which has a second electrical conductor arranged in a housing of the other battery module, be electrically and mechanically coupled by means of an additional screw element.

In the DE 10 2018 205 951 A1 describes a connection device for producing an electrically conductive connection between two battery modules, in which the contacts of the battery modules are arranged in plug-in openings of the respective module housing. To couple two battery modules, an additional plug connector is provided, which is plugged into a plug-in opening of a first battery module on the one hand and into a plug-in opening of the second battery module on the other hand.

The invention is based on the object of specifying a particularly suitable connecting device for the mechanical and electrical coupling of at least two components. In particular, a coupling that is as simple as possible and with reduced effort is to be implemented without additional components. The invention is further based on the object of specifying a particularly suitable vehicle battery and a particularly suitable motor vehicle.

With regard to the connecting device, the object is achieved according to the invention with the features of claim 1 and with regard to the vehicle battery with the features of claim 8 and with regard to the motor vehicle with the features of claim 9. Advantageous refinements and developments are the subject matter of the dependent claims. The advantages and refinements cited with regard to the connecting device can also be applied to the vehicle battery and / or the motor vehicle and vice versa.

The connecting device according to the invention is provided for the mechanical and electrical coupling of at least two components, and is suitable and set up for this. The connecting device here has a first connecting element and a second connecting element, which are arranged on different components. The connecting elements are in this case preferably arranged on facing end faces or side walls of the components, that is to say perpendicular to the upper sides of the components.

The first connection element and the second connection element each have an electrically conductive contact surface and an electrically insulating holder, as well as mutually corresponding joining contours for mutual positive connection. The electrically conductive contact surfaces are coupled to corresponding electronic or electrical components or elements of the respective component. The holder is used to mechanically fasten or hold the respective connecting element to the associated component.

A “form fit” or a “form fit connection” between at least two interconnected parts is understood here and in the following in particular to mean that the interconnected parts are held together at least in one direction by a direct interlocking of contours of the parts themselves or by an indirect one Interlocking takes place via an additional connecting part. The "blocking" of a mutual movement in this direction is therefore due to the shape.

According to the invention, the joining contours are designed in such a way that if a (mechanical) form fit is established between the connecting elements, at least the joining contours in sections directly, that is, without an additional component, engage in one another, and in doing so bring the contact surfaces of the connecting elements into electrically conductive contact. This means that for the electrical and mechanical connection of the components only the connecting elements and no additional components, such as connectors or. Screw elements, are necessary. According to the invention, the electrical connection between the components is thus effected at the same time in the course of the mechanical interlocking connection. A particularly suitable connecting device is thereby realized.

The connection device can be used, for example, for the mechanical and electrical connection of stationary energy systems, such as, for example, in private homes. In particular, the connection device is provided for the mechanical and electrical connection of components in which a relative displacement under load is to be prevented or reduced to a minimum, and at the same time an electrical connection is to be established.

In a preferred application, the connection device according to the invention is designed in particular as a high-voltage connector or HV connector for the mechanical and electrical coupling of two battery modules, a vehicle battery. In a particularly preferred embodiment, the battery modules are designed in particular as load-bearing battery modules or SBUs. The connecting device is integrated axially into a connection block of the SBU, for example. As a result, a particularly advantageous function integration is realized through a combination of electrical HV connector and mechanical connector. In particular, the risk of a relative displacement of the SBUs under load due to the form fit is advantageously prevented or at least significantly reduced.

The contact surfaces of the connecting elements are contacted or connected to the module poles of the respective battery module via electrical connectors or lines. In this case, the connecting device expediently has an arrangement of the connecting elements in pairs: with two first connecting elements and two second connecting elements in order to make contact with both module poles, that is to say the positive pole and the negative pole.

In an advantageous development, the joining contours are produced at least in sections from an electrically conductive material, for example a copper material, the contact surfaces being formed by the electrically conductive sections formed thereby. This results in a particularly advantageous functional integration of the mechanical and electrical connection.

In a structurally suitable embodiment, the form fit of the joining contours is designed as a plug-in connection or a plug-in-slide connection. As a result, a reliable and essentially simultaneous mechanical and electrical connection of the components is achieved by simply "plugging" the connecting elements into one another. This considerably simplifies the assembly or coupling of the components.

In an embodiment not according to the invention, the form fit is designed as a plug-in-slide connection, in particular in the form of a T-slot connection. This means that a first joining contour is designed essentially as a groove or profile rail or as a slot, and that the second joining contour is designed essentially as a connecting or joining head with an approximately T-shaped cross section. In the joining or form-fitting state, an undercut of the first joining contour is gripped from behind in a form-fitting manner, at least in sections, by means of the horizontal T-leg of the second joining contour. This creates a particularly stable connection.

In an embodiment not according to the invention, the joining contour of the first connecting element is a protruding bolt element and the joining contour of the second. Connecting element designed as a sleeve element with a groove-like (guide) slot opening into it. As a result, an expedient configuration of the joining contours is realized, which ensures a simple and cost-reduced form-fit connection, in particular a plug-in-slide connection, preferably a T-slot connection.

The joining contour of the second connecting element has an approximately U-shaped geometry, the guide slot being formed by the clearance between the two vertical U-legs, and the sleeve element extending along the lower U-bend or the horizontal U-leg . The contact surface of the first connecting element is in this case formed in particular by a jacket surface of the bolt element, the contact surface of the second connecting element on one of the. Guide slot facing surface of the sleeve element is provided. In a particularly preferred embodiment, the bolt element and / or the sleeve element are made from an electrically conductive material, for example from a copper material. The conjunction “and / or” is to be understood here and in the following in such a way that the features linked by means of this conjunction include both can be designed together as well as alternatives to one another.

In a further development not according to the invention, the slot of the joining contour of the second connecting element is made in a cambered area of the holder of the second connecting element. In other words, the holder has a curvature so that the holder is at least partially spaced from the associated component. The free space or intermediate space thus formed between the holder and the component enables the form-fitting. Engagement or engagement behind the slot through the joining contour of the first connecting element. As a result, the holder of the second connecting element can be made particularly flat or thin, that is to say in a material-saving and cost-effective manner.

According to the invention, the joining contours are designed as interlocking, clamp-like clamping pockets. In other words, according to the invention, the connecting device is designed as a connecting clamp system. As a result, relative movements of the components as a result of mechanical loading are significantly reduced, so that a risk of undesired dissolution of the mechanical and electrical connection is prevented or at least significantly reduced.

In a structurally particularly suitable embodiment, the holder of the first and / or second connecting element is formed at least partially or in sections by a housing of the respectively assigned component.

The vehicle battery according to the invention has a number of battery modules, at least two battery modules being mechanically and electrically coupled or connected to a connecting device described above. The battery modules are preferably load-bearing battery modules, the connecting device being designed as a mechanical and electrical high-voltage connector. This creates a particularly suitable vehicle battery. In particular, it is thus possible to dispense with a space-intensive battery housing and to use individual load-bearing battery modules, the occurring relative displacements and relative movements of the battery modules against each other by the mechanical, form-fitting coupling of the connecting device.

The electrically driven or drivable motor vehicle according to the invention is designed in particular as an electric or hybrid vehicle. The motor vehicle has a vehicle battery described above as a traction battery for supplying an electric motor drive.

• 1 in Draufsicht eine Fahrzeugbatterie mit einer Anzahl von lasttragenden Batteriemodulen, welche mittels nicht erfindungsgemäßen Verbindungsvorrichtungen mechanisch und elektrisch verbunden sind,
• 2 in Draufsicht eine Stirnseite eines Batteriemoduls mit zwei,ersten Verbindungselerrienten der nicht erfindungsgemäßen Verbindungsvorrichtung,
• 3 eine Schnittdarstellung des ersten Verbindungselements,
• 4 in Draufsicht eine Stirnseite eines Batteriemoduls mit zwei zweiten Verbindungselementen der Verbindungsvorrichtung,
• 5 in perspektivischer Darstellung ein erstes und zweites Verbindungselement,
• 6 in Seitenansicht ein erstes und zweites Verbindungselement in einer erfindungsgemäßen Ausführungsform,
• 7 in Seitenansicht die Verbindungselemente gemäß der erfindungsgemäßen Ausführungsform im Fügezustand,
• 8 in Draufsicht eine Stirnseite eines Batteriemoduls mit dem ersten Verbindungselement in der erfindungsgemäßen Ausführungsform, und
• 9 in Draufsicht eine Stirnseite eines Batteriemoduls mit dem zweiten Verbindungselement in der erfindungsgemäßen Ausführungsform.

Exemplary embodiments of the invention are explained in more detail below with reference to a drawing. They show in simplified and schematic representations:

• 1 a top view of a vehicle battery with a number of load-bearing battery modules which are mechanically and electrically connected by means of connecting devices not according to the invention,
• 2 a top view of an end face of a battery module with two, first connecting elements of the connecting device not according to the invention,
• 3 a sectional view of the first connecting element,
• 4th a top view of an end face of a battery module with two second connecting elements of the connecting device,
• 5 a first and second connecting element in a perspective view,
• 6th a side view of a first and second connecting element in an embodiment according to the invention,
• 7th in side view the connecting elements according to the embodiment according to the invention in the joined state,
• 8th a top view of an end face of a battery module with the first connecting element in the embodiment according to the invention, and
• 9 in plan view an end face of a battery module with the second connecting element in the embodiment according to the invention.

Corresponding parts and sizes are always provided with the same reference symbols in all figures.

the 1 shows a vehicle battery 2 an electrically powered or drivable motor vehicle, not shown in detail. The vehicle battery 2 is designed here essentially without a space-intensive battery housing. For this purpose, the vehicle battery is 2 with a number of load-bearing battery modules 4th or battery modules 4th with a load-bearing module housing 6th executed, where in the 1 for example three battery modules 4th are shown. In the module housings 6th are for example two cell stacks each 8th each with a number of interconnected battery cells added.

For electrical and mechanical coupling or connection of the battery modules 4th are connecting devices 10 provided, the connecting devices 10 in the 1 are provided with reference numerals merely by way of example. Any connecting device 10 here has two complementary connecting elements 12th , 14th on, which are positively coupled or can be coupled to one another.

In the embodiment of 1 until 5 assign the fasteners 12th , 14th each an approximately plate-shaped holder 16 , 18th made of an electrically insulating material. The fasteners 12th , 14th are here by means of the brackets 16 , 18th mechanically on the assigned end faces of the module housing 6th attached. The fasteners 12th , 14th continue to each have a joining contour 20th , 22nd for mechanical form fit and an electrical contact surface 24 , 26th for an electrically conductive connection.

As in particular in the representations of the 2 , 3 and 5 can be seen is the joint contour 20th of the connecting element 12th designed as an approximately cylindrical bolt element, which the bracket 16 - and thus the assigned module housing 6th - Raises axially or vertically. the 3 shows a sectional view along the line III-III according to FIG 2 . Like in the 3 can be seen comparatively clearly, the joining contour takes effect 20th or the bolt element here at least partially in the module housing 6th on.

In the 4th and 5 is the connecting element 14th shown in more detail. The bracket 18th of the connecting element 14th has a bulge or crown 28 on so that the bracket 18th . in the area of the crown 28 at a distance from the respective module housing 6th is. The joint contour 22nd of the connecting element 14th is as an approximately U-shaped sleeve element 30th with a groove-like (guide) slot 32 opening into it. The slot 32 is to the edge of the sleeve element 30th opened as an insertion opening.

For connecting two load-bearing battery modules 4th are on an end face of the first battery module 4th two fasteners 12th ( 1 , 2 ) and on the front of the second battery module ( 1 , 4th ) two fasteners 14th arranged. The fasteners 12th , 14th are positively plugged in for the connection and thus mechanically coupled. In addition to the mechanical connection, the electrical connection of the battery modules at the same time 4th The joining contours or bolt elements are to be guaranteed 20th and the sleeve elements 30th each made of electrically conductive materials such as a copper material. This makes the electrically conductive contact surfaces 24 , 26th the fasteners 12th , 14th essentially through the bolt elements 20th and the sleeve elements 30th self educated. As in particular in the 1 can be seen are bolt elements 20th and the sleeve elements 30th are here via electrical connectors 34 with the module poles 36 , 38 the cell stack 8th contacted. The connectors 34 and module poles 36 , 38 are in the 1 provided with reference numerals merely by way of example.

Due to the positive interlocking of the joining contours 20th , 22nd thus, in addition to the mechanical connection, there is also the electrical connection between the battery modules 4th realized.

The form-fit connection of the joining contours 20th , 22nd is designed as a plug connection, in particular as a plug-slide connection, preferably as a T-slot connection. To this end, the bolt element 20th - as in 5 visible - a T-shaped or mushroom head-shaped free end for interlocking engagement behind the slot 32 in the area of the crown 28 on. The bolt element 20th is here over the edge-side opening of the slot 32 inserted and then along the bracket 18th to the sleeve element 30th guided.

the 6th until 9 show an embodiment of the connecting device according to the invention 10 ' . the 6th shows the connecting device 10 ' in a separate, and the 7th in a connected or coupled state.

The joining contours 20 ' , 22 ' the connecting device 10 ' are designed as a pair of interlocking, clip-like clamping pockets. In other words, is the connector 10 ' in this exemplary embodiment implemented as a, i connecting bracket system.

The fasteners 12 ' , 14 ' essentially have the same structure. The electrically insulating brackets 16 ' , 18 ' are in particular due to the respective module housing 6th educated. The contact areas 24 ' , 26 ' are metallic molded parts with an * in particular L-shaped cross-sectional shape. The contact areas 24 ' , 26 ' are, for example, stamped and bent parts, in particular busbars. The contact areas 24 ' , 26 ' are here via a housing opening 40 ( 8th , 9 ) to the corresponding connector 38 guided. The contact areas 24 ' , 26 ' are from the outside of the joining contour designed as a bracket or clamping pocket 20 ' , 22 ' edged ...

The joining contours 20 ' , 22 ' have a clip or pocket opening 42 in which the respective corresponding joining contour 22 ' , 20 ' can be inserted in sections with a form fit ( 7th ).

The claimed invention is not restricted to the exemplary embodiments described above. Rather, other variants of the invention can also be derived therefrom by the person skilled in the art within the scope of the disclosed claims without departing from the subject matter of the claimed invention. In particular, all of the individual features described in connection with the various exemplary embodiments can also be combined in other ways within the scope of the disclosed claims without departing from the subject matter of the claimed invention.

List of reference symbols

2

Vehicle battery:

4th

Battery module

6th

Module housing

8th

Cell stack

10, 10 '

Connecting device

12, 12 '

Connecting element

14, 14 '

Connecting element

16, 16 '

bracket

18, 18 '

bracket

20, 20 '

Joining contour

22, 22 '

Joining contour

24,

24 ' Contact area

26, 26 '

Contact area

28

Crowning

30th

Sleeve element

32

slot

34

Interconnects

36, 38

Module pole

40

Housing opening

42

Clamp opening

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 102016206846 A1 [0013]
• DE 102018205951 A1 [0014]

Claims (9)

Connecting device (10 ') for the mechanical and electrical coupling of at least two components (4), having a first connecting element (12') and a second connecting element (14), which are arranged on different components (4), - wherein the first connecting element (12 ') and the second connecting element (14') each have an electrically conductive contact surface (24 ', 26') and an electrically insulating holder (16 ', 18') as well as mutually corresponding joining contours (20 ', 22 ') for mutual positive connection, - The joining contours (20 ', 22') being designed in such a way that, when a form fit is established, the joining contours (20 ', 22') at least in sections interlock and the contact surfaces (24 ', 26') of the connecting elements (12 ', 14') bring them into electrically conductive contact, and - The joining contours (12 ', 14') are designed as interlocking clamping pockets. Connection device (10 ') according to Claim 1 , characterized in that the joining contours (20 ', 22') are made at least in sections from an electrically conductive material, the contact surfaces (24 ', 26') being formed by the electrically conductive portions formed thereby. Connection device (10 ') according to Claim 1 or 2 , characterized in that the form fit of the joining contours (20 ', 22') is designed as a plug-in connection or a plug-in-slide connection. Connecting device (10 ') according to one of the Claims 1 until 3 , characterized in that the holder (16 ', 18') of the first and / or second connecting element (12 ', 14') is formed at least in sections by a housing (6) of the respectively assigned component (4). Connecting device (10 ') according to one of the Claims 1 until 4th , characterized in that the contact surfaces (24 ', 26') are stamped and bent parts. Connecting device (10 ') according to one of the Claims 1 until 5 , characterized in that the contact surfaces (24 ', 26') are designed as metallic molded parts with an L-shaped cross-sectional shape. Connection device (10 ') according to Claim 6 , characterized in that the joining contours (20 ', 22') have a pocket opening (42) into which the respectively corresponding joining contour (22 ', 20') can be inserted in sections in a form-fitting manner. Vehicle battery (2) having a number of battery modules (4), at least two battery modules (4) having a connecting device (10 ') according to one of the Claims 1 until 7th are mechanically and electrically coupled. Electrically powered or drivable motor vehicle having a vehicle battery (2) according to Claim 8 .

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