CIRCUIT BOARD ARRANGEMENT AND ENERGY STORAGE DEVICE

A circuit board arrangement for a cell contacting system for contacting energy storage cells of an energy storage device, in particular an energy storage device for a vehicle, includes a circuit board on which open-loop and/or closed-loop control electronics for open-loop and/or closed-loop control of the energy storage device and/or the respective energy storage cell are located. An additional circuit board includes at least one sensor element. The circuit board and the additional circuit board are electrically connected to each other by a contacting device. The additional circuit board is spaced apart from the circuit board and the spacing between the additional circuit board and the circuit board is bridged by the contacting device. An energy storage device, in particular an energy storage device for a vehicle, is also provided.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority, under 35 U.S.C. § 119, of German Patent Application DE 10 2022 114 652.9, filed Jun. 10, 2022; the prior application is herewith incorporated by reference in its entirety.

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to a circuit board arrangement for a cell contacting system for contacting energy storage cells of an energy storage device, in particular an energy storage device for a vehicle, including a circuit board on which open-loop and/or closed-loop control electronics for open-loop and/or closed-loop control of the energy storage device and/or the respective energy storage cell are located, and an additional circuit board including at least one sensor element, wherein the circuit board and the additional circuit board are electrically connected to each other by a contacting device. The invention also relates to an energy storage device, in particular an energy storage device for a vehicle in the automotive sector, including a plurality of energy storage cells disposed in a row.

A central point in the development of electrically powered means of transport, for example electric vehicles, is energy storage. This requires energy storage devices with a high power density and energy density. Energy storage devices are regularly formed of a plurality of individual energy storage cells (for example lithium ion battery cells) that are electrically connected to each other. Energy storage devices usually require temperature management to ensure their operation in an optimized temperature range. The energy storage cells usually have a narrow operating temperature range (for example between +15° C. and +45° C.). The functional safety, service life and cycle stability of the energy storage cell and thus also the functional safety of the entire energy storage device depend significantly on the energy storage cell not leaving this range. If the temperature exceeds a critical level, a so called “thermal runaway” occurs. In the case of thermal runaway, an unstoppable chain reaction is set in motion. The temperature rises extremely within milliseconds and the energy stored in the energy storage cell is released suddenly. In this way, temperatures of over 1000° C. can occur. The contents of the energy storage device become gaseous and a fire occurs that is difficult to extinguish by conventional measures. The danger of a thermal runaway starts at a certain temperature (for example 60° C.) and becomes extremely critical at a further temperature threshold (for example 100° C.). As a result, energy storage devices, especially energy storage devices for electric vehicles, use an energy storage device management system that not only provides open loop or closed loop control of the charging and discharging behavior of the energy storage cells, but also takes measures with regard to temperature management and emergency management in the event of a thermal runaway. In order to ensure a targeted escape of gases in the event of a thermal runaway, the gas tightly sealed energy storage cells can have degassing openings. The degassing openings can, for example, be configured as predetermined breaking points which allow gases to escape from the interior of the energy storage cell to the surrounding environment above a certain internal pressure. The escaping gases may contain electrolytes that can react with water to form hydrofluoric acid. In order to reduce the danger to surrounding components and/or individuals, such gases must be discharged in a controlled and targeted manner.

In order to provide the electrical connection of the energy storage cells, energy storage devices have so called cell connectors that electrically connect two or more poles of two or more energy storage cells, depending on the circuit type. In a series circuit, for example, the anode of one energy storage cell is connected to the cathode of another energy storage cell. In order to be able to monitor and control the state of charge of each energy storage cell, each cell connector can be electrically connected to the open loop and/or closed loop control electronics of the energy storage device. This allows the cell voltage of each individual energy storage cell to be measured and the state of charge of each particular energy storage cell to be deduced by the cell voltage. Furthermore, sensors, for example temperature sensors for monitoring the surface temperature of the energy storage cells, can also be provided, which are connected to the open loop and/or closed loop control electronics. In previous solutions, the open loop and/or closed loop control electronics are located in an independent module.

DESCRIPTION OF THE RELATED ART

German Patent Application DE 10 2007 063 178 A1 discloses a battery with a heat conducting plate for controlling the temperature of the battery. The battery includes a plurality of interconnected individual cells. The heat conducting plate has holes and/or incisions in the region of the poles of the individual cells, through which the poles of the individual cells protrude in or out. The heat conducting plate is disposed between the individual cells and contacting elements placed on the poles. Electrical cell connectors and/or a cell connector circuit board are provided as contacting elements for the electrical connection of the poles of the individual cells. Furthermore, elastic elements and/or contacting elements may be located on the upper side of the heat conducting plate. This sequence of these individual layers must be clamped to the individual cells by screws during the assembly process. The assembly is therefore time consuming.

German Patent Application DE 10 2009 046 385 A1, corresponding to U.S. Patent Application Publication No. 2013/0059175 A1, discloses a battery with a degassing system. The degassing system is located on the side opposite the poles of the battery cells. A base plate provided specially for this purpose is provided there, with passages for degassing openings and a collection basin for collecting the gases from the battery cells.

German Patent Application DE 10 2012 219 784 A1 discloses a battery module including a gas channel, a printed circuit board and a battery module housing which accommodates a plurality of battery cells. The gas channel is formed by a U profile with through openings to the degassing openings of the battery cells and by a printed circuit board closing the U profile on the side facing away from the degassing openings. The printed circuit board thus forms a wall of the gas channel and can come into direct contact with the gas when gas escapes from a gas outlet opening of a battery cell. During assembly, the printed circuit board is attached directly to the busbars. The U profile is not directly connected to the busbars. The disadvantage of this arrangement is that escaping gas can destroy the unprotected circuit board. In this case, open loop and/or closed loop control of the battery module is no longer ensured. Furthermore, no active temperature control of the battery cell surface or of the cell connectors is provided.

European Patent Application EP 3 316 384 A1, corresponding to U.S. Pat. No. 11,127,990 B2, discloses a circuit board arrangement as described above. A rigid circuit board for open loop and/or closed loop control electronics is provided, to the surface of which there are directly applied cell connectors for connecting the energy storage cells. Due to this direct connection of the cell connectors to the open loop and/or closed loop control electronics, a direct heat transfer from the electrical connections of the energy storage cells to the open loop and/or closed loop control electronics takes place. Such an arrangement leads to unavoidable measurement deviations in the voltage and temperature measurement. Furthermore, a C shaped flexible printed circuit board carrying a temperature sensor element is fixed to the rigid circuit board. The flexible printed circuit board extends through a slot shaped through opening in the rigid circuit board. The construction is complex and costly, both in terms of the production of the individual parts and in terms of final assembly.

SUMMARY OF THE INVENTION

It is accordingly an object of the invention to provide a circuit board arrangement for a cell contacting system for energy storage cells and an energy storage device, which overcome the hereinafore-mentioned disadvantages of the heretofore-known arrangements and devices of this general type and which simplify an assembly effort but are nevertheless operationally reliable.

With the foregoing and other objects in view there is provided, in accordance with the invention, a circuit board arrangement for a cell contacting system for contacting energy storage cells of an energy storage device, in particular an energy storage device for a vehicle, comprising a circuit board on which open-loop and/or closed-loop control electronics for open-loop and/or closed-loop control of the energy storage device and/or the respective energy storage cell are located, and an additional circuit board including at least one sensor element, wherein the circuit board and the additional circuit board are electrically connected to each other by a contacting device. According to the invention, the additional circuit board is spaced apart from the circuit board of the open-loop and/or closed-loop control electronics in each case with respect to their main surfaces, wherein the spacing between the additional circuit board and the circuit board is bridged by the contacting device. The additional circuit board for example firstly allows the temperature of the surface of the energy storage cell to be measured by a sensor element located there. Secondly, other physical and/or chemical parameters can also be measured in the region of the energy storage cells by using sensor elements fitted to the additional circuit board. Since the additional circuit board is spaced apart from the circuit board and the spacing between the additional circuit board and the circuit board is bridged only by the contacting device, it is possible to provide a separating wall between the circuit board and the additional circuit board, with the result that the circuit board can be positioned, for example, outside a degassing channel, whereas the additional circuit board can be positioned inside a degassing channel.

For this purpose, the main surfaces of the circuit board and the additional circuit board can preferably be disposed vertically offset.

The additional circuit board can be plate-shaped, like a conventional circuit board in particular.

The at least one sensor element can advantageously have a thermally conductive, preferably elastic, contact element through which the sensor element can be contacted with the surface of an energy storage cell. This is advantageous particularly in the case of a temperature sensor element since the contact element is thermally conductive. Furthermore, contacting of the surface of the energy storage cell is improved due to the elasticity of the contact element. In addition, manufacturing tolerances can be compensated for during assembly due to the elasticity.

The fact that the additional circuit board and the circuit board are each elongate and run adjacent to each other means that a plurality of sensor elements can be positioned along the additional circuit board, along the course of the circuit board and/or along the surface of the energy storage cell using a single component. As a result, assembly can be simplified.

According to an expedient embodiment of the present invention, a support structure mountable on the energy storage device or its energy storage cells is provided, wherein the support structure has a first side facing the energy storage device in the installed state and a second side facing away from the energy storage device in the installed state, the circuit board is fastened to the second side of the support structure and the additional circuit board is positioned on the first side of the support structure. The support structure is preferably a profiled structure. The support structure shields the circuit board, in particular the circuit board on which the open-loop and/or closed-loop control electronics of the energy storage device or the energy storage cells is located, from the surface of the energy storage cells, whereas the additional circuit board is positioned on the side of the support structure facing the energy storage device or the energy storage cells. Spacers are preferably provided between the first side of the support structure and the additional circuit board.

The spacers can advantageously have at least one connection element, in particular a snap connection element, on the side facing the support structure or the side facing the additional circuit board, or preferably two connection elements, in particular two snap connection elements, on the side facing the support structure and the side facing the additional circuit board and can be connected to the support structure and/or the additional circuit board. This allows particularly simple assembly of the additional circuit board.

The contacting devices are preferably conductor bars protruding from the additional circuit board which pass through the circuit board, preferably in the region of a through-opening in the circuit board or preferably in the form of a press-fit arrangement.

The conductor bars can be contacted on the side of the circuit board facing away from the additional circuit board, preferably with the aid of an in particular plug-mountable contacting strip.

According to a particular embodiment of the present invention, the support structure can be connected to cell connectors provided for electrically connecting the energy storage cells to form a unit that can be mounted collectively. This embodiment allows the support structure, the circuit board, the additional circuit board and the cell connectors to be prefabricated as a unit that can be mounted collectively, so that the entire unit only has to be fixed, in particular welded, to the energy storage cells of the energy storage device by the cell connectors during assembly.

The support structure can preferably have a degassing channel integrated into the support structure and/or at least one temperature control channel integrated into the support structure. The at least one degassing channel and the at least one temperature control channel thus form an integral part of the support structure and thus an integrated compact, scalable cell contacting system. As a result of the fact that both the at least one temperature control channel and the degassing channel are an integral part of the support structure, the assembly effort required to complete an energy storage device can be significantly reduced. In addition, the functional reliability of the energy storage device is increased and a reduction in the required installation space is achieved. The degassing channel enables a targeted removal of hot gases during a thermal runaway of the energy storage device. Compared to conventional embodiments, the number of parts can be reduced.

Advantageously, the at least one degassing channel and the at least one temperature control channel are each molded into the support structure. This means that the support structure is configured as a single component and can be produced in a single manufacturing step. In addition, a higher functional safety is achieved due to the one piece configuration without connection points of the various channels.

It is expedient that the support structure has a wall delimiting the degassing channel, the side of the wall opposite the degassing channel serving as a mounting base for further components. The aforementioned side of the wall can thus serve for the assembly of further components of the cell contacting system, for example for assembly of the circuit board and the additional circuit board. The wall therefore fulfils a dual function. The circuit board is protected from thermal and/or chemical influences by the wall.

Preferably, the wall extends between two temperature control channels.

According to an advantageous embodiment, the inner side of the degassing channel has a protective layer, in particular protecting against heat and/or abrasive media and/or chemical influences (for example by acids). In addition, the underside of the corresponding temperature control channel can also have a protective layer.

The protective layer can be an applied coating (for example a liquid, curable coating, for example lacquers with the addition of ceramic particles, foamed and cured coating or for example a powder coating) or a layer placed on and/or bonded to the wall or the wall portion in question (for example a mica sheet, a ceramic fiber mat, a glass fiber mat, a carbon mat or a cork sheet).

The at least one temperature control channel as well as temperature control lines connecting to the at least one temperature control channel are preferably sealed at all interfaces.

The wall extends expediently between two or at least two temperature control channels. The temperature control channels are preferably each located in the outer region of the support structure.

The support structure also makes it possible to have a third or a third and fourth temperature control channel between two edge temperature control channels. This allows additional temperature control of the circuit board disposed on the upper side of the support structure.

The support structure allows the cell connectors, the support structure and the circuit board and the additional circuit board to be connected to form a module that can be mounted collectively. The cell connectors serve to establish an electrical connection between the individual energy storage cells and are therefore fixed, for example welded, to their pole contacts. By connecting the cell connectors, the support structure and the circuit board and the additional circuit board to form a collectively mountable module, a readymade or preassembled module can thus be created. By mounting the cell connectors on the energy storage cells, the support structure with the degassing channel, the temperature control channels and the circuit board and the additional circuit board can be mounted in a single operation. The cell contacting system can thus be advantageously kept in stock as a readymade or pre-assembled mounting module.

Furthermore, the at least one temperature control channel can have through openings disposed laterally to its longitudinal axis. These can serve to receive the cell connectors and/or overmolded temperature control geometries of the cell connectors and/or to fix them there.

The fact that the support structure is formed as a shaped part, preferably as an injection-molded part or as an extruded part, means that the required geometries can be easily implemented.

Preferably, the support structure is made of plastic. Plastic offers a high corrosion resistance, thermal insulation capability, and also electrical insulation capability with low weight. In addition, an electrically conductive fluid can be used in the temperature control channels. Aluminum or an aluminum alloy offer the advantage of increased mechanical resistance. Alternatively, the support part can be formed of aluminum or an aluminum alloy.

For example, the support structure is a profile structure, preferably a hollow profile structure.

The additional circuit board is preferably positioned in the degassing channel.

The degassing channel is preferably configured to be open on the first side of the support structure. The degassing channel of the support structure which is open on one side is thus located on the upper side of the energy storage cells, so that, when gases or vapors exit at the upper side of the energy storage cells, they can be conducted away along the degassing channel.

The support structure can advantageously have through-openings and/or fastening and/or centering devices and/or spacers for the circuit board. The fastening and/or centering devices serve, in particular, to fasten the circuit board in the correct position. Spacers can serve to ensure a certain spacing between the lower side of the circuit board and the support structure. Through-openings can serve to lead the contacting device between the circuit board and the additional circuit board through the support structure.

The support structure can further have a mounting recess in which the circuit board is positioned. This firstly influences the mechanical stability of the support structure. Secondly, the installation space at the top, i.e. in the direction away from the surface of the energy storage device, is reduced. Furthermore, the circuit board is located in a non-exposed position on the upper side of the support structure and is therefore more effectively protected against mechanical damage.

The sensor element can be a sensor element measuring an ambient parameter, preferably a temperature sensor element, a gas sensor element, a moisture sensor element or a pressure sensor element.

Furthermore, the sensor element can be fastened, preferably soldered, to the additional circuit board on the side facing away from the circuit board or on the side facing the circuit board. A temperature sensor element can advantageously be fastened to the additional circuit board on the side facing away from the circuit board. The sensor element can be contacted with the energy storage cell in this way. As an alternative or in addition, for example, a temperature sensor element, a gas sensor element, a moisture sensor element or a pressure sensor element can be fastened to the additional circuit board on the side facing the circuit board.

The sensor element, in particular a temperature sensor element, can expediently be disposed in the region of the spacers, i.e. adjacent to them.

The present invention further relates to an energy storage device, in particular an energy storage device for a vehicle, comprising a plurality of energy storage cells disposed in a row, wherein a circuit board arrangement according to the invention is provided on the energy storage device.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the figures of the drawings in detail and first, particularly, toFIG.1thereof, it is seen that reference numeral3designates an energy storage device in its entirety. This is in particular a battery, for example for an electric vehicle with an electric drive. The energy storage device3has a plurality of energy storage cells2a,2b,2zconnected in series. Reference numeral1denotes an example of a cell contacting system which is intended for electrically connecting the individual energy storage cells2a,2b,2zto one another.

The energy storage cells2a,2b,2zeach have two pole contacts22a,22b(of which only one pole contact22acan be seen inFIG.2), specifically one pole contact22afor an anode and one pole contact22bfor a cathode. The pole contacts22a,22bcan have a substantially flat surface or can be formed as small plates.

The cell contacting system1further includes a support structure13as well as cell connectors11a,11battached to the support structure13, which serve to electrically contact and connect the individual energy storage cells2a,2b,2z. Furthermore, open loop and/or closed loop control electronics16are positioned on the support structure13and are electrically connected to the cell connectors11a,11bby connection elements15. The open loop and/or closed loop control electronics16include a circuit board161awhich is equipped with corresponding electronic components162and which is connected to the support structure13.

Since the cell connectors11a,11bare connected to the cell contacting system1, the complete cell contacting system1can be attached to the energy storage cells2a,2b,2zof the energy storage device3by the cell connectors11a,11b. For this purpose, the cell connectors11a,11bcan be welded to the pole contacts22a,22b, for example. The cell contacting system1can thus be kept in stock as an assembled module and can be mounted on the energy storage cells2a,2b,2zas a unit in a single process step within an automated production line.

The cell contacting system1includes temperature control channels131and a degassing channel132, each described in greater detail below, which are integrated into the support structure13in accordance with the invention. The temperature control channels131serve to conduct a gaseous or liquid fluid (not shown in the figures) through the energy storage device3in order to control the temperature of the latter. The degassing channel132serves to remove, in a controlled manner, gases released in the event of a so called “thermal runaway” of the energy storage device3. A degassing opening21can be seen inFIG.2. It opens out into the degassing channel132. The degassing opening21can, for example, be formed as a predetermined breaking point, so that in the event of a thermal runaway the gases produced inside the energy storage cells2a,2b,2zcan escape at this point.

In the exemplary embodiment, fourteen energy storage cells2a,2b,2zare shown, which are electrically connected to each other in a series circuit by the cell contacting system1. For this purpose, the energy storage cells2a,2b,2zare each disposed rotated relative to one another, so that the pole contact22aof the anode of the energy storage cell2ais opposite the pole contact22bof the cathode of the adjacent energy storage cell2b, or the pole contact22bof the cathode of the energy storage cell2bis opposite the pole contact22aof the anode of the adjacent energy storage cell2a. The pole contact22bof the cathode of the first energy storage cell2ais connected to the terminal cell connector11b. The pole contact22aof the anode of the first energy storage cell2ais connected by the cell connector11ato the pole contact22bof the cathode of the adjacent, second energy storage cell2b. The pole contact22aof the anode of the second energy storage cell2bis in turn connected to the pole contact22bof the cathode of the third energy storage cell by a cell connector11a, and so on. The pole contact22aof the anode of the last energy storage cell2zis connected to the cell connector11b. The cell connectors11bare intended to electrically connect the energy storage device3to an electrical consumer, not shown, for example the electric motor of an electric vehicle. The two cell connectors11bthus form the energy storage device connections, i.e. the cathode and anode of the entire energy storage device3.

In alternative embodiments of an energy storage device3, a different number of energy storage cells can also be provided and/or the energy storage cells can be connected in parallel by the cell contacting system1. For this purpose, the cell connectors11a,11bcan, for example, connect the electrical connections22aof the anodes of two or more energy storage cells or the electrical connections22bof the cathodes of two or more energy storage cells. The energy storage cells can also be disposed in a row in the same orientation, i.e. not rotated, so that the electrical connections of the cathodes of the energy storage cells of the energy storage device3are disposed along a first line and the electrical connections of the anodes of the energy storage cells are disposed along a second line running parallel to the first line.

FIG.3shows a front view of the cell contacting system1. The support structure13has a first side137facing the energy storage device3or the energy storage cells2a,2b,2z, which serves as the mounting side for mounting on the energy storage device3or the energy storage cells2a,2b,2z(not shown inFIG.3), and a second side138facing away from the energy storage device3or the energy storage cells2a,2b,2z. Furthermore, the support structure1has two lateral temperature control channels131located in the region of the cell connectors. The temperature control channels131and the degassing channel132are molded into the support structure1in accordance with the invention.

The degassing channel132is formed by the lateral temperature control channels131, which are opposite each other, and by a wall139, which runs between the temperature control channels131. The degassing channel132is open on the first side137of the support structure13to the energy storage cells2a,2b,2z. This allows gases to pass from the degassing openings21of the energy storage cells2a,2b,2zinto the degassing channel132in the assembled state of the cell contacting system1and to be discharged from there in a controlled manner. This increases the protection of vehicle occupants.

As can be seen fromFIG.4a, the support structure13is embodied as a shaped part, in particular as an injection-molded part or extruded part, preferably in particular as an injection-molded plastics part or an extruded plastics part. The support structure13can be formed as a profile structure, preferably as a hollow profile structure. In this way, a cell contacting system1with a comparatively low weight can be created.

The support structure13is provided with a protective layer133(seeFIG.3) in the region of the first side137, in particular for protecting against heat and/or abrasive media and/or chemical influences (for example by acids). The protective layer133may be formed of a heat resistant and/or acid resistant material. The protective layer133may be either an applied coating (for example a liquid, curable coating, for example a lacquer with the addition of ceramic particles, a foamed and cured coating, or a powder coating) or a layer applied to the wall (for example mica sheets, ceramic fiber mats, glass fiber mats or carbon mats, or cork sheets) or a combination thereof. The protective layer may also be provided additionally under the temperature control channels131a,131bif required (not shown in the figures).

The temperature control channels131are each formed by a hollow chamber. As can be seen inFIG.3, the temperature control channels131have lateral through openings140, into which cell connectors11a,11bovermolded with a cooling structure12are inserted and fastened. The cooling structure12can, for example, be adhesively bonded and/or welded to the support structure1. In this way, the through opening140is tightly sealed. The cooling structure12of the cell connectors11a,11bis surrounded by the fluid for temperature control in the temperature control channels131and are in thermal contact with the fluid.

Furthermore, the support structure13has a mounting recess135on the second side138opposite the degassing channel132. This is formed by an offset of the wall139. The mounting recess135serves to position the open loop and/or closed loop control electronics16in a particularly space saving manner. Fastening and/or centering device136can be provided at the mounting base of the mounting recess139for fastening and/or centering the circuit board of the open loop and/or closed loop control electronics16. Spacers136amay also be provided, which cause the underside of the open loop and/or closed loop control electronics16or circuit board161athereof to be spaced apart from the mounting base of the mounting recess139. The mounting recess135allows a flat structure of the cell contacting system1. The offset of the wall139forming the mounting recess135also serves to increase the mechanical stability of the support structure13. The offset acts in this case as a bead, i.e. a channel shaped stiffening device, which increases the second moment of area of the support structure13. The support structure13can thus better withstand, for example, an increase in pressure in the degassing channel132occurring during degassing of the energy storage cells2a,2b,2z. Furthermore, the wall139has through openings141for temperature sensor arrangements17a,17band/or for contacting a sensor circuit board18a,18b.

The circuit board161ahas, for example, holes through which the circuit board161ais fitted on the fastening and/or centering device136, which in the exemplary embodiment are in the form of “domes.” The ends of the domes can then be upset to form mushroom heads, thereby fastening the circuit board161ato the support structure13.

If required, more than two temperature control channels131may also be formed in the support structure13. For example, as shown inFIG.4b, an additional temperature control channel131can be located in the middle on the underside of the wall139, whereby the wall139between the two outer temperature control channels131and thus a circuit board located on the upper side can be additionally temperature controlled.

According to the embodiment shown inFIG.4c, a second temperature control channel131is provided in each side region.

FIG.5shows the cell contacting system1according to the invention as a pre-assembled module including the cell connectors11a,11b, the temperature control channels131, the degassing channel132and the open loop and/or closed loop control electronics16. The cell contacting system1simplifies the manufacture of energy storage devices3considerably in that only the cell connectors can be mounted on the energy storage cells, for example by welding.

Alternatively, the cell connectors can also be screwed or soldered to the energy storage cells.

Through openings111, for example through holes, can be provided on the cell connectors11a,11b. These can serve as inspection openings. Furthermore, if required, measuring lines can also be attached, through these through openings111, to threaded holes located beneath the through openings111on the pole contacts22a,22b. In this way, for example, the contacting of the cell connectors11a,11bto the pole contacts22a,22bcan be checked.

Alternatively, the cell connectors11a,11bcould also be connected, for example screwed, to the pole contacts22a,22bby the through openings111if required.

FIGS.6aand6bshow two exemplary embodiments of temperature sensor arrangements17a,17bfor detecting the temperature on an upper side23, not shown, of an energy storage cell2a,2b,2z. In the exemplary embodiments, the temperature sensor arrangement17ais mounted on the circuit board161aand the temperature sensor arrangement17bis mounted on the circuit board161bby a snap connection in each case. The circuit board161bcan also be provided for temperature sensor arrangements17a.

FIGS.7aand7bshow a perspective illustration and a sectional illustration of a first exemplary embodiment of the temperature sensor arrangement17a.

The temperature sensor arrangement17aincludes a flexible sensor circuit board176ahaving a sensor element171aintegrated on the sensor circuit board176aand a shaped housing element172afor mounting on the circuit board161a,161bfromFIGS.6a,6b.

The shaped housing element172aincludes a guide channel179afor the flexible sensor circuit board176aand thus serves to position and hold the sensor element171a. Furthermore, the shaped housing element172ahas a base178awith a connection device175aand an elastically deflectable spring arm177a. The connection device175ais configured as a snap connection with two resilient detent arms. They are used to connect to the circuit board161afromFIG.6a. Steps178care also provided on the connection device175aand serve as a contact point on the underside of the circuit board161a.

The sensor circuit board176ahas electrical connections174awhich are electrically connected to the sensor element171aby conductor tracks that are not shown.

In addition, an elastic, thermally conductive contact element173ais provided on the underside of the temperature sensor arrangement17ain the region of the sensor element171ain order to avoid gap formation and to transfer the temperature of the energy storage cells to be detected to the sensor element171a.

FIG.9ashows the temperature sensor arrangement17aofFIGS.7aand7bin the assembled state without the support structure13. The detent arms engage through recesses provided on the circuit board161aand thus establish a mechanical connection to the circuit board161a. The spring arm presses the sensor element171aonto the upper side23of the energy storage cell2a. The electrical connections174aextend through the circuit board161athrough a slot shaped recess162aand are connected to the circuit board161a, for example soldered by solder pads.

When mounting the temperature sensor arrangement17a, the shaped housing element172acan first be connected to the sensor circuit board161a. The sensor circuit board176acan then be inserted from the side opposite the shaped housing element172athrough the slot shaped recess162aof the circuit board161ainto the guide channel179aof the shaped housing element172a. After the sensor circuit board176ais positioned in the guide channel179a, the electrical connections174aof the sensor circuit board176acan be connected to the circuit board161a. This facilitates handling. In addition, the assembly can be automated as a result.

As can be seen fromFIG.3, the temperature sensor arrangement17aextends through the through opening141(cf.FIG.4a) of the support structure13and can thus be positioned in the degassing channel132. The support structure13causes a thermal separation of the circuit board161afrom the sensor element171a. As a result, the circuit board161aremains intact even in the event of thermal destruction of the temperature sensor arrangement17a, and the defect in the temperature sensor arrangement17a,17bcan still be detected by the open loop and/or closed loop control electronics16. The steps178clie against the underside of the circuit board161a.

The base178ais provided to cover or close the through opening141of the support structure on the first side137thereof. A flow of gases through the through opening141is thus prevented or at least reduced.

FIGS.8aand8bshow a perspective view and a sectional view of a further embodiment of a temperature sensor arrangement17b.

The temperature sensor arrangement17bincludes a sensor element171band a shaped housing element172b. The shaped housing element172bincludes a base178bwith a connection device175band a step178d, which have a corresponding structure and the same function as the base178a, the connection device175aand the step178cof the temperature sensor arrangement17aaccording toFIGS.7aand7b.

In this embodiment, the shaped housing element172bof the temperature sensor arrangement17bhas a chamber176bfor positioning the sensor element171b. The chamber176bis open on the side facing the circuit board161a,161b,161c. This allows the sensor element171bto be pushed into the chamber176b.

The sensor element171bmay be a wired electronic component for through hole technology (THT) with two electrical connections174b.

A contact element173b, which at least partially encloses the sensor element171a, is located on the side of the shaped housing element172bfacing away from the electrical connections174b. The contact element173bis formed of an elastic, thermally conductive material. Further, the contact element173bis partially enclosed by the chamber176band abuts a shoulder in the chamber176b.

FIG.9bshows the temperature sensor arrangement17bfromFIGS.8aand8bin the assembled state without the support structure13.

The temperature sensor arrangement17bis mechanically connected to the circuit board161bby snap connection by the connection device175b.

In order to connect the electrical connections174b, the circuit board161bcan have contact holes with contact rivets, for example. The electrical connections174bcan be inserted through these holes and soldered to the circuit board162bfrom the side opposite the sensor element171b.

The contact element173b, which is concealed by the shaped housing element172binFIG.9b, is compacted or compressed. This allows the sensor element171bto be installed pressing with a certain contact pressure onto the upper side23of the energy storage cell2a.

The temperature sensor arrangement17bmay be mounted on the circuit board161bas an assembled module.

By pressing the temperature sensor arrangements17a,17b, a good thermal contact is ensured. In addition, it is possible to compensate for manufacturing tolerances, thermal expansions or relative movements of the components.

One of the two temperature sensor arrangements17a,17bor a combination of both of them may be provided in the cell contacting system1.

A circuit board can be a printed circuit board, i.e. a printed circuit for carrying electronic components.

FIGS.10aand10bshow a circuit board arrangement of the cell contacting system1in the form of the circuit board161awith an additional circuit board18aon which sensor elements181band, inFIG.10b, sensor elements181aconcealed by contact elements173c, such as temperature sensor elements, gas sensor elements, moisture sensor elements or pressure sensor elements, are located.FIGS.2and3show the positioning of the circuit board arrangement according toFIGS.10aand10bon the energy storage cells2a,2b,2zof the energy storage device3.

FIGS.11aand11bshow the positioning of the circuit board arrangement according toFIGS.10aand10bon the energy storage cells2a,2b,2zof an energy storage device3, with omission of the support structure13for illustrative purposes. The circuit board arrangement can be used to position sensors for different parameters, for example for temperature, for gas, for pressure and/or for moisture, along the surface of the energy storage device3.

FIG.12ashows an enlarged detail of an additional circuit board18aaccording toFIGS.10aand10bin the region of the spacer19.

FIG.12bshows an enlarged illustration of the contacting device182abetween circuit board161aand additional circuit board18a.

FIG.12cshows an alternative embodiment of a circuit board161cand an additional circuit board18bwith alternative contacting device182b.

According toFIGS.10aand10b, the additional circuit board18aand the circuit board161aare spaced apart, vertically offset from each other and electrically connected to each other by a contacting device182a. In the assembled state of the cell contacting system1, the contacting device182aextend through a through opening141of the support structure13(seeFIG.3). In an advantageous manner, this allows the additional circuit board18ato be positioned on the side137of the support structure13facing the energy storage device within the degassing channel132. This results in a thermal separation of the additional circuit board18afrom the circuit board161athrough the wall139and/or the protective layer133of the support structure13.

The additional circuit board18ainFIGS.10a,10bis plate shaped and mechanically connected to the support structure13by spacers19. As shown inFIG.12a, the spacers19each have a connection device191on the side facing the additional circuit board18aand on the side facing the support structure13. The connection elements191may be in the form of a snap connection with two detent arms. The detent arms are resilient elements that can each engage through the additional circuit board18aand the support structure13to establish a mechanical connection to the additional circuit board18aand the support structure13. For this purpose, the additional circuit board18acan have recesses184and the support structure13can have recesses142(seeFIG.2) in which the connection elements191can engage.

Sensor elements181a,181bare provided on the additional circuit board18aand are electrically connected to the circuit board161aby conductor tracks, not shown, and by the contacting device182a,181b. The sensor elements181a,181bcan be SMD components, for example, which are soldered to the additional circuit board18aat solder pads.

According toFIG.10a, the sensor element181bis located on the side of the additional circuit board18afacing the circuit board161a. The sensor element181bcan be, for example, a sensor element measuring an ambient parameter, for example a temperature sensor element, a gas sensor element, a moisture sensor element or a pressure sensor element. The sensor element181bis not in direct contact with an energy storage cell when the cell contacting system1is assembled. As a result, the sensor element181bcan be used to measure, for example, a gas temperature, a gas composition, a moisture or a pressure in the degassing channel132. The sensor element181bcan also be an electronic component that can detect a plurality of ambient parameters.

As shown inFIG.12a, the sensor element181ais located on the side of the additional circuit board18afacing away from the circuit board or facing the energy storage cells. The sensor element181acan, for example, be a temperature sensor element, for example a Pt 100 resistor configured as an SMD component. A contact element173cis located on the sensor element181aand is in contact with the sensor element181a(shown enlarged and spaced apart inFIG.12a). The contact element173cis formed of a thermally conductive, elastic material. When mounting the cell contacting system1on the energy storage cells of the energy storage device3, the contact element173ccan be compacted or compressed. As a result, the sensor element181acan be pressed onto the upper side23of the energy storage cell with a certain contact force. For this purpose, the sensor elements181acan advantageously be located in the region of the spacers19. By pressing the sensor element181a, thermal contact is ensured. In addition, it is possible to compensate for manufacturing tolerances, thermal expansions or relative movements of the components.

According toFIGS.12band12c, the contacting devices182a,182bare protruding conductor bars183a,183b, which can be soldered, for example, to solder pads on the additional circuit board18a,18b.

According toFIG.12b, the circuit board161ahas through openings for the contacting device182aand a contacting strip163a. The contacting strip163acan be soldered to the circuit board161a. The conductor bars183acan be plugged into the contacting strip163a. The contacting strip163acan have spring contacts for this purpose, for example.

According toFIG.12c, the circuit board161chas press fit through openings for the contacting device182b. The conductor bars183bcan be pressed into the press fit through openings.

The additional circuit board18bhas a different configuration in the region of the contacting device182bas compared to the additional circuit board18a.

FIGS.13aand13bshow cell connectors11a,11bfor electrically contacting the pole contacts22a,22bof the energy storage cells2a,2a,2z. In the exemplary embodiment, two terminal cell connectors11band thirteen cell connectors11aare shown.

The cell connectors11aare intended to electrically connect a pole contact22aof one energy storage cell, for example2a, to a pole contact22bof an adjacent energy storage cell, for example2b. For this purpose, the cell connectors11ahave a main body110with a first contact face112aand a second contact face112b, which are each connected, for example welded, to a pole contact22a,22b.

The two cell connectors11bare intended to provide, at the first energy storage cell2aand the last energy storage cell2z, a contacting device to an electrical consumer, not shown, for example an electric motor of an electric vehicle, or to an adjacent energy storage device. The cell connectors11bhave a main body113with a contact face112awhich is connected, for example welded, to the pole contact22bof the cathode of the first energy storage cell2aor the pole contact22aof the anode of the last energy storage cell2z. Furthermore, the main body113has a current tap110d. The current taps110dof the two cell connectors11bthus form the connections of the anode and cathode of the energy storage device3.

The main body110,113of the cell connector11a,11bis formed of an electrically conductive flat material with preferably a constant layer thickness, for example a sheet metal. The main body110,113has a first side S1, S1′ and a second side S2, S2′ and is overmolded in each case in the region of the second side S2, S2′ in a partial region110awith a temperature control structure12which increases the surface area of the cell connector11a,11b. The temperature control structure12has, for example, a plurality of temperature control ribs124arunning parallel to one another.

The temperature control structure12is preferably a thermally conductive, electrically insulating material, in particular plastic.

In the cell connector11a, the temperature control structure12extends along the entire length L1of the first side S1. In the cell connector11b, the temperature control structure12extends only along the length L2of the first side S1′ in the region of the contact face112a.

A recess114may be provided between the contact faces112a,112bof the cell connector11a. On the one hand, this recess shifts the flow of current and the resultant heat into the partial region110aovermolded by the temperature control structure12. On the other hand, the main body110thus has a higher elasticity. It is thus possible to better compensate for thermal expansions or movements of the adjacent energy storage cells2a,2b,2zrelative to each other.

Furthermore, the main bodies110,113of the cell connectors11a,11bcan have recesses115, for example in the form of crescent shaped through openings. These also increase the elasticity of the main bodies110,113.

FIGS.14ato14dshow various embodiments of the temperature control structure12. Temperature control wave structures124b, temperature control nubs124c, temperature control pins124d, or temperature control bars124emay be provided as the temperature control structure.

FIGS.15a,15b,16a,16b,17aand17bshow alternative embodiments of cell connectors11a, in which an additional contact element121a,121b,121cis provided which is in direct contact with the upper side23of the energy storage cell by a contact face122a,122b,122c. This allows for temperature control of the energy storage cells2a,2b,2z.

The contact element121aof the temperature control structure12fromFIGS.15aand15bis injection molded in this case around the end region of the main body110in such a way that its contact face122arests on the surface of the energy storage cells2a,2bor bridges the height of the pole contacts22a,22b, cf.FIGS.15a,15b.

FIGS.16aand16bandFIGS.17aand17bshow two further alternative embodiments of cell connectors11awith a contact element121b,121c, for example a contact plate.

According toFIGS.16aand16b, the contact element121bis overmolded by the temperature control structure12and has an offset127a. The offset127amay have substantially the same height as the pole contacts22a,22bwith respect to the surface23. This allows the main body110and the contact element121bto be connected to each other, for example, in one plane, with the result that the contact element121brests directly on the upper side of the energy storage cells. A gap129ais provided between the main body110and the contact element121bso that the main body110and the contact element121bare not in direct contact with each other. The main body110and the contact element121bare connected to each other by the temperature control structure12. The main body110and the contact element121b,121ccan thus be electrically insulated from each other by an electrically non conductive temperature control structure12. The contact element121bcan be made of the same material as the main body110.

The variant ofFIGS.17aand17bhas an additional offset127bbetween the two contact faces112a,112b. The contact element121cextends as far as the degassing openings21and surrounds the pole contacts22a,22bof the energy storage cells2a,2b. The additional offset127bcan additionally increase the heat conduction between the contact element121cand the temperature control structure12as well as the mechanical stability of the cell connector11a.

The offset127a,127bcan be created, for example, by two folds of a plate shaped raw material, for example a metal sheet, as can be seen inFIG.17b, in which the temperature control structure has been omitted for illustrative purposes.

The main body110and the contact elements121b,121ccan advantageously be made, for example cut or punched, from a common plate shaped blank.

Corresponding contact elements can also be provided for the terminal cell connectors11b. The geometry of the contact element for a cell connector11bcan be easily adapted to the geometry of the cell connector11b.

The cell connectors11a,11bcan have an interface to a temperature control channel131and can be connected to the latter, for example welded or adhesively bonded, preferably in the region of the temperature control structure12. For this purpose, the through openings140of the support structure13can be disposed laterally in the direction of the pole contacts and/or in the direction of the degassing channel and/or in the direction of the battery storage cells.

The temperature control structure12of the cell connectors can close the through openings140of the support structure13. In addition, the temperature control structure12may insulate the base element110,113and/or the contact element121b,121cwith respect to a temperature control fluid located in the temperature control channel131. Thus, for example, a fluid formed of an electrically conductive fluid may be provided. The temperature control structure12may likewise insulate the base element110,113and/or the contact element121b,121cwith respect to the support structure13. Alternatively, the support element in this variant could, for example, be formed of a metal, for example aluminum or an aluminum alloy.

Alternatively, the embodiments of the cell connectors11a,11bcan also be used without a temperature control channel131. In this case, the ambient air can be used for temperature control, for example.

LIST OF REFERENCE SIGNS