Cooling plate, battery separation unit, and drive system

Abstract

The invention relates to a cooling plate (10) for cooling at least one component (12), in particular a plurality of components (12), of at least one power electronics (14) and for cooling at least one relay (16) of a battery separation unit (18) for separating a battery unit (20) from at least one load (22) of a drive system (24), comprising a first plate part (26), wherein at least one component (12) can be mounted on the first panel (26); at least one first flow space (30) for a coolant is provided between the first plate part (26) and the second plate part (28) in order to directly underflow at least one component (12) of the power electronics (14), and wherein the second plate part (28) has at least one fastening tab (32) for fastening at least one relay (16), in order to dissipate heat of the at least one relay (16) by means of the fastening tab (32) and the second plate (28).

Description

Technical Field

[0001] The invention relates to a cooling plate having the features of independent claim 1 , a battery disconnect unit having the features of independent claim 7 , and a drive system having the features of independent claim 10 . Background Art

[0002] According to the prior art, a battery disconnect unit (BDU) is used to switch the battery of an electric vehicle on and off depending on the operating state. In this context, three BDU configurations are usually used:

[0003] 1. Fuse devices and relays

[0004] 2. Pyrotechnic fuses and relays

[0005] 3. Safety devices, pyrotechnic safety devices and relays.

[0006] When a combination of relays and circuits is used for BDUs with the aid of semiconductors based on silicon carbide (SiC) (AMB modules), active cooling of these components is necessary. This is achieved, for example, with cooling plates through which a coolant flows. Here, according to the prior art, cooling plates produced from aluminum sheets in a brazing process can be used. Depending on the requirements with regard to the current to be switched and the resulting power loss in the form of heat, these cooling plates can be equipped with additional water fins (internal inserts) to increase the cooling performance.

[0007] DE 10 2020 206 338 and DE 10 2020 206 339 describe how heat dissipation of the relay can be achieved via a thermal connection of a busbar (busbar) next to the relay and / or a thermal connection of the relay itself to the battery housing (heat sink).

[0008] DE 11 2015 003 530 describes a heat exchanger consisting of a pair of plates.

[0009] When cooling the AMB assembly together with one or more relay components by means of a single cooling plate, the problem that arises due to the available structural space is that the two areas to be cooled can negatively influence each other in terms of heat. That is, when cooling the AMB assembly, the heat flow can negatively influence the area of ​​the relay cooling, and vice versa. This leads not only to a temperature increase at the AMB assembly, but also at the components of the relay component, which, for example, has a negative impact on the service life of the components. Summary of the invention

[0010] The invention provides a cooling plate having the features of independent claim 1, a battery separation unit having the features of independent claim 7, and a drive system having the features of independent claim 10. Further features and details of the invention are derived from the dependent claims, the description and the drawings. Features and details described in conjunction with the cooling plate according to the invention are of course also applicable to features and details described in conjunction with the battery separation unit according to the invention and / or in conjunction with the drive system according to the invention, and vice versa, respectively, so that reference can always be made to the disclosure of the individual inventive aspects interchangeably.

[0011] A first aspect of the present invention is a cooling plate for cooling at least one component, in particular a plurality of components, of at least one power electronic device and for cooling at least one battery separation unit, the battery separation unit being used to separate the battery unit from at least one load of a drive system, the cooling plate comprising: a first plate, wherein at least one component can be mounted on the first plate; and a second plate, wherein at least one first flow space for a coolant is provided between the first plate and the second plate in order to directly underflow at least one component of the power electronic device. And wherein the second plate has at least one fastening tab for fastening at least one relay, so that heat of the at least one relay is dissipated through the fastening tab and the second plate.

[0012] The cooling plate makes it possible to decouple the power electronics via the component section and the relay heat dissipation region via the relay section in a geometrically and hydraulically thermally decoupled manner, which minimizes negative influences of the interaction of the two regions.

[0013] When the cooling plate is flowed through with coolant, the power electronics or at least one component of the power electronics is directly underflowed by the coolant. This is advantageous because a high heat flow must be conducted over a very small surface, whereas the fastening web absorbs the heat of the at least one relay and conducts it into the second plate, where it is then absorbed by the coolant and can thus be discharged.

[0014] By providing essentially constant cooling of the power electronics while dissipating heat from the relay by means of the geometry according to the invention of the cooling plate, the overall temperature of the battery disconnect unit can be reduced, thereby increasing the service life of the components and thus the safety of the battery disconnect unit.

[0015] At the same time, the cooling plate allows a cost reduction, since due to the reduced temperature more favorable components can be used for the battery disconnect units.

[0016] For heat transfer or heat conduction, it is particularly advantageous if the first sheet metal part and the second sheet metal part comprise an aluminum alloy. The first sheet metal part and the second sheet metal part can be connected to one another in a fluid-tight manner by coating with solder in a brazing process.

[0017] The separation of the battery cell from the load is achieved by power electronics (e.g., silicon carbide metal oxide semiconductor field effect transistor (SiC Mosfet) AMB) and / or by relays. Here, the relay is part of the battery separation unit. Likewise, the power electronics are part of the battery separation unit. Relays are required in order to meet the requirements of electrical separation. The relay separates the positive electrode of the battery from the load. The power electronics separates the negative electrode of the battery from the load.

[0018] Within the scope of the invention, it can be advantageous if at least one flow space has a coolant distribution region with a coolant inlet, a coolant collecting region with a coolant outlet, and a first flow region, wherein the first flow region is arranged between the coolant distribution region and the coolant collecting region.

[0019] The shape of the coolant distribution area (which is usually V-shaped and widens toward the flow area) ensures that the coolant entering through the coolant inlet is distributed over the entire cross-sectional area, so that the bottom surface of the power electronic device is underflowed to remove its heat. The flow speed of the coolant is increased by the reduction of the cross section in the coolant collection area, so that the heated coolant can flow out of the flow space quickly.

[0020] It is ensured in an easy manner that the heat generated by the power electronics can be removed quickly and efficiently.

[0021] In the context of the present invention, it is conceivable to provide a flow guide plate having a deflection opening, wherein the flow guide plate is arranged in the flow space between a first plate and a second plate so as to divide a second flow area from the first flow area by the deflection opening, thereby causing the flow of the coolant to change direction, wherein a coolant distribution area is arranged between the first plate and the flow guide plate, and wherein a coolant collecting area is arranged between the flow guide plate and the second plate.

[0022] The cooling of the power electronics and the heat dissipation of the relay can be optimally decoupled from each other by the flow guide plate. The power electronics are first cooled by the flow of the coolant in the first flow region, and after the flow direction is deflected into the second flow region, the heat dissipation of the relay can be dissipated by overflowing the second plate and heat conduction via the fastening tabs.

[0023] In this case, the flow guiding plate can also comprise an aluminum alloy and be connected to the first plate part and the second plate part in a materially bonded manner by a brazing process.

[0024] Within the scope of the invention, it can be provided that the coolant distribution region and the coolant collecting region are arranged opposite one another or offset relative to one another along the longitudinal axis of the cooling plate.

[0025] Here, "oppositely" is understood to mean that the coolant inlet of the coolant distribution area and the coolant outlet of the coolant collecting area are arranged in such a way that the coolant flows out of the cooling plate again directly after underflowing the power electronics. It is particularly advantageous here if the first plate or the second plate has not only a coolant inlet but also a coolant outlet.

[0026] In the case of an offset arrangement of the coolant distribution area and the coolant collecting area, the first plate or the second plate is longer in its length extension than the respective other plate, wherein the flow guide plate then serves as a fluid-tight cover for the longer plate. This is particularly advantageous when the coolant inlet and the coolant outlet are to be arranged close to one another in order to be able to utilize less installation space or existing connections. It is particularly advantageous here if the flow guide plate has a coolant inlet or a coolant outlet so that the connecting sleeves are arranged parallel to one another and in the same direction.

[0027] Furthermore, it is conceivable to arrange a flow grid in the flow space between the coolant distribution region and the coolant collecting region, in particular in the first flow region between the coolant distribution region and the deflection opening.

[0028] By means of the flow grid, the turbulence in the flow space can be increased, which increases the heat transfer to the coolant. In addition, the flow grid serves to support the internal pressure generated by the coolant.

[0029] The flow grid can be connected in a materially bonded manner to the first plate and / or the second plate or, if present, to the first plate and / or the flow guide plate.

[0030] It is also conceivable that the second plate has a flow structure for influencing the flow of the coolant, the flow structure having a roughened surface and / or a plurality of projections.

[0031] Not only the roughened surface but also the projections serve to increase the surface in order to optimize the heat transfer from the second plate to the coolant. This can improve the heat output from the second plate and the fastening tab, so that the heat can be optimally dissipated for at least one relay.

[0032] Since the first plate member and the second plate member can be manufactured by a stamping process and / or a deformation process, the shape of the protrusion of the second plate member is not limited. The protrusion can be, for example, cross-shaped and / or spherical segment-shaped and / or rib-shaped.

[0033] A second aspect of the present invention is a battery separation unit for separating a battery cell from at least one load, the battery separation unit comprising: a cooling plate according to the first aspect of the present invention; at least one ceramic substrate; at least one component of at least one power electronic device, wherein the at least one ceramic substrate is arranged on the outer side of a first plate, wherein at least one flow space is arranged below the at least one component of the power electronic device; and at least one relay, wherein the relay is arranged on at least one fastening tab of a second plate via at least one bus bar.

[0034] In order to thermally and mechanically connect at least one component of the power electronics, a cold injection molded copper layer can be applied to the first plate of the cooling plate. In this case, the at least one component is materially connected to the copper layer on the cooling plate with its bottom side having a copper alloy by a further soldering process. This achieves a very good heat transfer from at least one component of the power electronics to the cooling plate and thus to the coolant.

[0035] At least one relay can be arranged directly on at least one fastening lug, wherein the electrical connection is implemented via a busbar arranged between the at least one relay and the fastening lug. It is also conceivable that at least one relay is arranged on the busbar and the busbar positions the at least one relay on the fastening lug.

[0036] In order to dissipate heat for at least one relay, a heat conducting medium for thermal contact with the second plate can be provided between the busbar and the at least one fastening tab. This improves the heat transfer between the busbar and the fastening tab. The heat dissipation from the fastening tab to the cooling fluid is primarily influenced by the material thickness of the second plate.

[0037] Within the scope of the invention, it is optionally possible for each power electronic component to be assigned a relay.

[0038] A plurality of regions can be provided on the cooling plate, which are respectively used for power electronics and their relays in at least one component. Advantageously, each power electronics is assigned its own relay, thereby ensuring the functional mode of the battery separation unit.

[0039] It is conceivable here to provide at least one fastening lug, preferably two fastening lugs, for each relay on the second plate. The fastening lugs can be arranged on one side or on the opposite side of the second plate.

[0040] Furthermore, within the scope of the invention it can be provided that the relay is arranged on two fastening webs via a busbar, in particular two busbars.

[0041] This makes it possible to better distribute the weight of the relay, thereby reducing the locally generated bending moments. At the same time, the heat generated in the relay can be conducted into the second plate via the two fastening elements and then quickly discharged.

[0042] A third aspect of the present invention is a drive system comprising a battery cell, a load and a battery separation unit according to the second aspect of the present invention, wherein the battery cell and the battery separation unit are electronically connected to each other via a battery interface of the battery separation unit, and wherein the load and the battery separation unit are connected to each other via a load interface of the battery separation unit.

[0043] The advantages described in detail with respect to the cooling plate according to the first aspect of the present invention also apply to the battery split unit according to the second aspect of the present invention and to the drive system according to the third aspect of the present invention.

[0044] The drive system includes the battery separation unit described above and its advantages. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Further advantages, features and details of the invention are obtained from the following description, in which several exemplary embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description can be important to the invention individually or in any combination. The invention is shown in the following drawings:

[0046] Figure 1 shows an isometric view of a cooling plate according to the invention,

[0047] Figure 2 shows a cross-sectional view of a cooling plate according to the invention,

[0048] Figure 3 shows a schematic diagram of a battery separation unit according to the present invention,

[0049] Figure 4 A schematic diagram of a drive system according to the present invention is shown. DETAILED DESCRIPTION

[0050] exist Figure 1 and Figure 2 1 and 2 show a cooling plate 10 for cooling at least one component 12, in particular a plurality of components 12, of at least one power electronic device 14 and for cooling at least one relay 16 of a battery disconnect unit 18 for disconnecting a battery cell 20 from at least one load 22 of a drive system 24. Figure 2 It is shown in Figure 1 sectional view of a cooling plate 10 .

[0051] Figure 1 and Figure 2 The cooling plate 10 has a first plate 26 and a second plate 28. Here, at least one component 12 for the subsequent battery separation unit 18 can be mounted on the first plate 26. Figure 2 As can be seen in FIG. 1 , at least one first flow space 30 for a coolant is provided between the first plate 26 and the second plate 28 in order to directly underflow at least one component 12 of the power electronics 14. In addition, the second plate 28 has at least one fastening tab 32 for fastening at least one relay 16 in order to dissipate heat from the at least one relay 16 via the fastening tab 32 and the second plate 28.

[0052] In order to optimally design the flow in the flow space 30 , at least one flow space 30 has a coolant distribution area 34 with a coolant inlet 36 , a coolant collecting area 38 with a coolant outlet 40 , and a first flow area 42 , wherein the first flow area 42 is arranged between the coolant distribution area 34 and the coolant collecting area 38 .

[0053] Additionally provided is a flow guide plate 44 having a deflection opening 46. The flow guide plate 44 is arranged between the first plate 26 and the second plate 28 in the flow space 30 and is connected to the first plate 26 and also to the second plate 28 at the connection boundary in a materially bonded manner, for example by a soldered connection.

[0054] The deflection opening 46 serves to separate the second flow region 48 from the first flow region 42, so that the flow of the coolant changes direction. The flow path is positively extended by the deflection of the flow in the flow space 30. In this case, the first flow region 42 is first flowed through, wherein the power electronics 14 is cooled, and then the flow is deflected so that it then flows through the second flow region 48, wherein heat is absorbed from the second plate 28, thereby dissipating heat from the relay 16. The flow guide plate 44 thus thermally decouples the cooling of the power electronics 14 from the heat dissipation of the relay 16.

[0055] In the present embodiment, the coolant distribution region 34 is disposed between the first plate 26 and the flow guide plate 44 , and the coolant collection region 38 is disposed between the flow guide plate 44 and the second plate 28 .

[0056] Here, the coolant distribution area 34 and the coolant collecting area 38 are arranged offset from each other along the longitudinal axis L of the cooling plate 10. The coolant inlet 36 and the coolant outlet 40 are therefore arranged substantially side by side with each other, so that the pipelines to be connected can also be arranged side by side with each other, so that the structural space can be reduced. For this purpose, the second plate 28 is longer than the first plate 26 in its longitudinal extension, and the second flow area 48 and the coolant collecting area 38 are closed fluid-tightly by the flow guide plate 44. The coolant inlet 36 is arranged at the first plate 26, wherein the coolant outlet 40 is arranged at the flow guide plate 44, so as to ensure that the installation directions of the coolant inlet 36 and the coolant outlet 40 are the same.

[0057] In order to increase the surface for flow through and to generate turbulence of the flow for improved heat transfer, a flow grid 50 is arranged in the flow space 30 between the coolant distribution area 34 and the coolant collecting area 38 , in particular in the first flow area 42 between the coolant distribution area 34 and the deflection opening 46 .

[0058] In order to optimally dissipate heat for at least one relay 16 via at least one fastening tab 32 and the second plate 28, the second plate 28 has a flow structure 52 for influencing the flow of the coolant, wherein the flow structure 52 has a plurality of protrusions. Figure 2 As can be seen in the figure, these projections are in the form of spherical segments. It is conceivable here as an additional or alternative solution to use a roughened surface in order to increase the flow surface.

[0059] exist Figure 3 FIG. 2 shows a battery separation unit 18 for separating a battery cell 20 from at least one load 22. The battery separation unit 18 has a Figure 1 or Figure 2 The first plate 26 is provided with a cooling plate 10, at least one ceramic substrate 54, at least one component 12 of at least one power electronic device 14, and a relay 16. In this case, the at least one ceramic substrate 54 is arranged on the outer side 56 of the first plate 26. At least one flow space 30, in particular the first flow area 42, is arranged below the at least one component 12 of the power electronic device 14. The relay 16 is arranged on at least one fastening tab 32 of the second plate 28 via at least one busbar 58. Figure 3 As shown in FIG. 1 , the relay 16 is arranged on each of the fastening webs 32 via two busbars 58 . The relay 16 is then arranged between the two fastening webs 32 and is supported on the fastening webs 32 via each of the busbars 58 and dissipates heat.

[0060] In the exemplary embodiment shown, only one relay 16 is shown. However, it is conceivable to provide a plurality of power electronic components 14, wherein each power electronic component 14 is assigned a relay 16. These can then be arranged opposite each other on the cooling plate 10, whereupon further fastening tabs 32 are provided on the second plate 28.

[0061] exist Figure 4 The drive system 24 is shown in FIG. 1 , which has a battery unit 20, a load 22 and a Figure 3 The battery cell 20 and the battery disconnect unit 18 are electronically connected to each other via a battery interface 60 of the battery disconnect unit 18. The load 22 and the battery disconnect unit 18 are connected to each other via a load interface 62 of the battery disconnect unit 18.

Claims

1. A cooling plate (10) for cooling at least one component (12), in particular a plurality of components (12), of at least one power electronic device (14) and for cooling at least one relay (16) of a battery disconnect unit (18) for disconnecting a battery cell (20) from at least one load (22) of a drive system (24), the cooling plate comprising: A first plate (26), wherein The at least one component (12) is mountable to the first plate (26); The second plate (28), At least one first flow space (30) for a coolant is provided between the first plate (26) and the second plate (28) so as to directly flow under at least one component (12) of the power electronic device (14), and the second plate (28) has at least one fastening tab (32) for fastening the at least one relay (16) so as to dissipate heat of the at least one relay (16) via the fastening tab (32) and the second plate (28).

2. The cooling plate (10) according to claim 1, It is characterized in that The at least one flow space (30) comprises: a coolant distribution area (34) with a coolant inlet (36), a coolant collecting area (38) with a coolant outlet (40), and a first flow area (42), wherein the first flow area (42) is arranged between the coolant distribution area (34) and the coolant collecting area (38).

3. The cooling plate (10) according to claim 1 or 2, It is characterized in that A flow guide plate (44) having a deflection opening (46) is provided, wherein the flow guide plate (44) is arranged in the flow space (30) between the first plate (26) and the second plate (28) so as to divide a second flow area (48) from the first flow area (42) by the deflection opening (46), thereby changing the flow direction of the coolant, wherein the coolant distribution area (34) is provided between the first plate (26) and the flow guide plate (44), and wherein the coolant collection area (38) is provided between the flow guide plate (44) and the second plate (28).

4. The cooling plate (10) according to claim 3, It is characterized in that The coolant distribution region (34) and the coolant collecting region (38) are arranged opposite one another or offset relative to one another along a longitudinal axis (L) of the cooling plate (10).

5. The cooling plate (10) according to any one of the preceding claims, It is characterized in that A flow grid (50) is arranged in a flow space (30) between the coolant distribution region (34) and the coolant collecting region (38), in particular in a first flow region (42) between the coolant distribution region (34) and the deflection opening (46).

6. The cooling plate (10) according to any one of the preceding claims, It is characterized in that The second plate (28) has a flow structure (52) for influencing the flow of the coolant, wherein the flow structure (52) has a roughened surface and / or a plurality of protrusions.

7. A battery separation unit (18) for separating a battery unit (20) from at least one load (22), the battery separation unit comprising: A cooling plate (10) according to any one of the preceding claims; at least one ceramic substrate (54); At least one component (12) of at least one power electronic device (14), wherein: The at least one ceramic substrate (54) is arranged on an outer side (56) of the first plate (26), wherein the at least one flow space (30) is arranged below at least one component (12) of the power electronic device (14); and At least one relay (16), wherein the relay (16) is arranged on at least one fastening tab (32) of the second plate (28) via at least one busbar (58).

8. The battery separation unit (18) according to claim 7, It is characterized in that A relay (16) is assigned to each power electronic device (14).

9. The battery separation unit (18) according to any one of claims 7 or 8, It is characterized in that The relay (16) is arranged on two fastening straps (32) via a busbar (58), in particular two busbars (58).

10. A drive system (24) comprising a battery cell (20), a load (22) and a battery disconnect unit (18) according to any one of claims 7 to 9, wherein: The battery cell (20) and the battery separation unit (18) are electronically connected to each other via a battery interface (60) of the battery separation unit (18), and the load (22) and the battery separation unit (18) are connected to each other via a load interface (62) of the battery separation unit (18).

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