Body member for vehicle body

Abstract

The present disclosure relates to a body part (10) for a vehicle body (100), the body part (10) configured for enclosing a vehicle battery comprising a plurality of battery cells (200), the body part (10) comprising a bottom section (11) configured to form at least a portion of the vehicle body (100) and a battery housing structure (12) arranged on the bottom section (11), the battery housing structure (12) comprises a plurality of compartment walls (13) separating the battery housing structure (12) into a plurality of compartments (14), each of the plurality of compartments (14) being adapted to accommodate one of the plurality of battery cells (200), and at least one of the plurality of compartment walls (13) comprising at least one flow channel (15), the at least one flow channel (15) is configured for conveying a coolant to cool at least one of the plurality of battery cells (200).

Description

Technical Field

[0001] The present disclosure relates to a body component for a vehicle body, a battery pack including the body component, a vehicle including the battery pack, a method for manufacturing the battery pack, and a mold configured for casting the body component. Background Art

[0002] Vehicles, in particular electric vehicles, may include a battery pack mounted on the vehicle body to provide power to the vehicle. The battery pack is a complex system including a plurality of battery cells and a cooling system for preventing the battery cells from overheating. Today, the vehicle body and the battery pack are built separately and connected together at a later stage of manufacturing. Their connection requires handling of sensitive battery cells and cooling systems and arranging them on the vehicle body in a compact manner. The interface formed between the separate battery pack and the vehicle body may have negative effects, such as increased weight, cost and lead to inefficiencies, especially thermal inefficiencies.

[0003] Such an interface may include different connection devices for connecting the battery pack to the vehicle body, such as bolts, which may additionally need to be sealed. Each additional connection device may affect the rigidity of the vehicle in a negative way. The connection devices also require a downstream manufacturing footprint, resulting in additional product costs. In addition, accommodating the connection devices and / or the sealing results in wasted space, which could otherwise be used more efficiently. In addition, the separate mounting of the battery pack and the cooling system on the vehicle body results in a reduction in cooling capacity, thereby affecting the thermal efficiency of the battery. The effective arrangement of the cooling system in the battery pack is also crucial to improving the mileage of a vehicle with a battery pack.

[0004] Recently, attempts have been made to co-design the battery pack and vehicle body to provide a compact and efficient installation. However, this leaves a large number of interfaces between these components, which still leads to inefficiencies. Summary of the invention

[0005] This problem is at least partly solved or alleviated by the subject matter of the independent claims of the present disclosure, wherein further examples are incorporated in the dependent claims.

[0006] According to a first aspect, a body component for a vehicle body is provided. The body component is configured to enclose a vehicle battery including a plurality of battery cells. The body component includes a bottom section configured to form at least a portion of the vehicle body and a battery housing structure at the bottom section. The battery housing structure includes a plurality of compartment walls. The plurality of compartment walls separate the battery housing structure into a plurality of compartments. Each of the plurality of compartments is configured to accommodate one of a plurality of battery cells. At least one of the plurality of compartment walls includes at least one flow channel, the at least one flow channel being configured to transport a coolant to cool at least one of the plurality of battery cells.

[0007] The body component includes a plurality of compartment walls that form a plurality of compartments at a bottom section of the body component. The plurality of compartment walls may include a plurality of walls that are added to each other to form a single-wall structure, or may be formed by a single wall. The vehicle body may be a frame on which vehicle components may be constructed. The bottom section of the body component may be disposed at a lower portion of the body component. For example, the bottom section may include a section of a chassis of the vehicle, such as a base of the vehicle body. Battery cells of a vehicle battery may be accommodated within each compartment. By forming the bottom section of the body component to be integral with the vehicle body, the need for a separate housing structure for the battery cells may be avoided. Therefore, the prior art of providing a battery cell including a battery pack and mounting the battery pack on a vehicle body may be improved.

[0008] By providing the body component as part of the vehicle body, the interface between the vehicle body and the battery pack can be reduced, thereby making the vehicle lighter. Furthermore, the use of any connection means for fastening the battery pack to the vehicle body can be reduced or even avoided. The compartment walls separating the battery housing structure can allow for efficient utilization of the battery housing structure. The number of compartment walls can be optimized. The battery housing structure can be better divided.

[0009] In order to maintain the best performance and life of the battery pack, the vehicle may include a thermal management system. The thermal management system may include at least one flow channel for circulating a cooling liquid to regulate the temperature of the battery cells. The flow channel may also be referred to as a cooling channel. The coolant may be conveyed through the flow channel, or in other words, flow through it to pass through one or more battery cells, actually cooling them. The coolant may be any fluid, for example, in particular any liquid, such as water. Antifreeze may be included in the coolant, for example, such as ethylene glycol. At least one flow channel may be a single channel or a combination of channels connected to each other. At least one flow channel may be arranged inside the compartment wall or on at least one side of the compartment wall. When at least one flow channel is arranged inside the compartment wall, cooling of multiple battery cells at opposite sides of the wall may be achieved. However, when at least one flow channel is arranged on either side of the compartment wall, the battery cells on the corresponding side of the compartment wall may be cooled. In any case, providing at least one flow channel at the compartment wall may prevent the flow channel from being fixed to additional components of the vehicle body. Providing at least one flow channel at multiple compartment walls provides effective cooling of the battery cells. Heat or energy loss caused by inefficient utilization of the battery housing structure can be minimized.

[0010] According to an example, a plurality of compartments may be arranged in a honeycomb pattern. The honeycomb pattern may be a repeated arrangement of compartments. The honeycomb pattern may have radial symmetry. Although the honeycomb may be a hexagonal structure (a six-sided polygon with straight sides and corners), it may have any number of sides, ranging from three (such as a triangle) to eight (an octagon) or more up to the circular shape of a circular battery cell. The compartments may have a uniform size and / or shape. In principle, a compartment may be surrounded by other compartments from each side, in other words, a compartment is surrounded by a number of other compartments equal to the number of its sides. This may provide a uniform distribution of the compartments on the battery housing structure.

[0011] In an example, the compartments may have any shape, such as a circle. According to the present invention, this arrangement may also be referred to as a honeycomb pattern. The compartments may have a uniform size and / or shape. Maintaining consistent size throughout the body component may contribute to structural stability.

[0012] According to an example, the body component can be monolithic. Monolithic can mean that the portion of the vehicle body can be configured to form the body component. For example, the body component can be located directly on the chassis. The chassis can provide structural support and / or can form the basis of various vehicle systems. The body component can be located at a portion of the chassis (vehicle body), while other portions of the chassis can be used to enclose at least one of, for example, an engine, a transmission, a suspension, or a wheel. In particular, while the bottom section of the body component is configured to form a portion of the vehicle body, another section of the body component (e.g., an upper section on the bottom section) can be configured to enclose components such as electrical connectors, cover elements, and / or devices for insulating the battery housing structure at the bottom section.

[0013] According to an example, the main body component may further include at least one inlet and at least one outlet. The at least one inlet may be arranged on a side of the main body component opposite to the outlet. At least one flow channel may be arranged between the inlet and the outlet. The coolant may flow from the inlet through the flow channel and to the outlet. The coolant may circulate from the outlet to the inlet. The heat exchange device may cool the coolant before the coolant circulates back to the inlet. Providing the inlet and the outlet on the main body component provides a simple and compact design for cooling the battery cells placed on the main body component. An additional cooling system installed on the main body component may be avoided.

[0014] According to an example, at least one section of at least one flow channel may have a serpentine shape. A serpentine shape may be defined as a curve that transitions from one side of a battery cell to the opposite side of a consecutive battery cell. The shape may be described as an "S" shape, with two consecutive battery cells being arranged on recesses on opposite sides. The arrangement of the flow channels between consecutive battery cells may increase the heat exchange surface between the flow channels and the battery cells, thereby providing better cooling for the battery cells.

[0015] According to an example, the body component may further include a cover at the top of at least one of the plurality of compartments. The cover may be configured to cover at least one busbar component connecting at least two battery cells to each other. The connection between the two battery cells may be an electrical connection. Additionally, the connection may be a mechanical connection. At least one section of at least one flow channel may be configured to cool the busbar component, or in other words, to convey a coolant for cooling the busbar component. The cover may be positioned at an upper section of the body component. The flow channel may be at least partially covered by the cover.

[0016] The busbar can provide a low resistance path for current to flow between battery cells. Since the busbar is usually made of a material with high electrical conductivity, such as copper or aluminum, the busbar can dissipate high levels of heat while enabling efficient transmission of current. Therefore, the cooling of the busbar can support the efficient operation of the vehicle. The cover covering the busbar component can help prevent heat dissipation outside the main body component and effectively cool the main body component in place.

[0017] In addition to the cooling from the at least one flow channel at the compartment wall, a section of the at least one flow channel at the compartment top may provide cooling of the battery cell placed inside the compartment from the top side, the at least one flow channel preferably being on one side of the battery cell placed inside the compartment. Thus, by providing a section of the at least one flow channel to cool the busbars enclosed by the cover, increased heat exchange may be provided from multiple sides of the battery cell placed inside the compartment.

[0018] According to an example, at least one of the plurality of compartment walls may include at least two flow channels. The flow channels may be arranged adjacent to each other. The flow channels may be arranged substantially parallel to each other or at an angle. When there are more than two flow channels, the flow channels may be arranged at equal intervals, or may be concentrated in an upper or lower section of the compartment wall. The section where the flow channels are concentrated may correspond to a portion of the battery cell that heats up more, for example, in the compartment wall corresponding to an upper portion of a battery cell electrode.

[0019] According to an example, the body component may include a sealing frame on top of the battery housing structure. The body component may also include an additional adhesive between the sealing frame and at least one of the compartment walls of the battery housing structure. The adhesive between the sealing frame and the compartment wall can fix the sealing frame to the battery housing structure while providing electrical insulation of the battery cells from each other.

[0020] According to a second aspect, a battery pack is provided, comprising a main body component according to the first aspect and a vehicle battery. The vehicle battery comprises a plurality of battery cells. Each of the plurality of battery cells is disposed in a corresponding one of the plurality of compartments of the main body component.

[0021] The battery pack can be used as a structural support to stabilize the battery cells within the compartment of the body component. The battery pack can distribute weight and minimize vibration. The battery cells can be preferably electrically connected to each other through a busbar component to achieve a desired voltage and / or capacity level.

[0022] According to an example, at least one of the plurality of compartments may include a space between a compartment wall and a battery cell inside the compartment. The compartment may have a size and / or shape corresponding to a commercial battery cell. Different types of batteries, such as lithium-ion, nickel metal hydride (NiMH) and lead-acid batteries, may have different sizes. Among them, lithium-ion batteries may be considered to be the most commonly used in (electric) vehicles. As an example, the compartment may have a suitable shape to accommodate a cylindrical battery having a diameter of about 21 mm and a length of 70 mm. Of course, the battery cell may have a prismatic form or a pouch form. The diameter of the space between the compartment wall and the battery cell may, for example, be in the range of 5 mm to 0.5 mm, for example 2 mm.

[0023] According to an example, the space may be filled with an adhesive. The adhesive may provide mechanical stability, electrical isolation and / or thermal conduction. The adhesive may hold the battery cells in their respective compartments within the battery pack, preventing movement and minimizing vibrations that may cause physical stress on the battery cells. In addition, it may enhance the structural integrity of the battery pack by strengthening the joints and connections between the battery cells. The adhesive may have good thermal conductivity, which may help transfer heat generated during charging and / or discharging away from the battery cells, thereby contributing to effective thermal management. The adhesive may have insulating properties for preventing electrical contact between adjacent batteries, reducing the risk of short circuits and ensuring proper electrical isolation. Last but not least, the adhesive may be applied in a thin layer, allowing compact and efficient use of the space within the battery pack. Assembly may thereby be simplified and the use of additional mechanical fastening components may be avoided.

[0024] According to an example, a vehicle battery may include at least one busbar component connecting at least two battery cells. At least one cover of the body component may cover the busbar component. At least one section of at least one flow channel may be configured to cool the busbar component. The busbar component may be a metal strip or a metal strip that serves as a conductor for distributing current from one battery cell to another battery cell and / or for distributing electrical energy collected from the battery cells to various devices of the vehicle.

[0025] The sealing frame may be disposed on top of the battery housing structure. Additional adhesive between the sealing frame and at least one of the compartment walls of the battery housing structure may be configured to secure the sealing frame to the battery housing structure while providing electrical insulation of the battery cells from one another. The sealing frame may include at least one opening for connection to a busbar component of the battery cell.

[0026] According to the foregoing example, the cover may further include an elevated portion extending away from at least one of the plurality of battery cells. The elevated portion may be configured to enclose a busbar component and a section of at least one flow channel. The elevated portion may provide space for enclosing the busbar component and a section of the flow channel that is further away from the battery cell. Thus, the elevated portion may help dissipate heat from the busbar component.

[0027] According to a third aspect, there is provided a vehicle comprising the battery pack according to the second aspect.

[0028] In one example, the vehicle may further comprise at least a second vehicle body component joined to the vehicle body component (as in the first aspect).The second body component may be different from the body component of the first aspect such that together they form the vehicle body.

[0029] According to a fourth aspect, a method for manufacturing the battery pack of the second aspect is provided. The method comprises:

[0030] providing the main body component of the first aspect, and

[0031] Each of the plurality of battery cells of the vehicle battery is provided in a corresponding one of the plurality of compartments of the body member.

[0032] According to a fifth aspect, there is provided a mould configured for casting a body component according to the first aspect. The mould may be configured so that the body component can be cast in a single step. The mould may include a core portion for creating a cavity inside the cast body component, for example for forming a compartment.

[0033] It should be noted that the above examples can be combined with each other, regardless of the aspects involved. Thus, the method can be combined with structural features, and likewise, the apparatus and system can be combined with the features described above with respect to the method.

[0034] These and other aspects of the disclosure will be apparent from and elucidated with reference to the examples described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Examples of the present disclosure will be described below with reference to the following drawings.

[0036] Figure 1 A vehicle body 100 according to the present disclosure is schematically and exemplarily shown.

[0037] Figure 2 A battery pack 20 of a vehicle body 100 according to the present disclosure is schematically and exemplarily shown.

[0038] Figure 3 A main body component 10 of a battery pack 20 according to the present disclosure is schematically and exemplarily shown.

[0039] Figure 4 The battery pack 20 according to another angle of the present disclosure is schematically and exemplarily shown.

[0040] Figure 5 A flow chart of a method 300 for manufacturing a battery pack 20 according to the present disclosure is schematically and exemplarily shown. DETAILED DESCRIPTION

[0041] The drawings are merely schematic representations and serve merely to illustrate examples of the present disclosure. Identical or equivalent elements are in principle provided with the same reference numerals.

[0042] Figure 1 A vehicle body 100 is schematically and exemplarily shown. The vehicle body 100 includes a battery pack 20. The battery pack 20 includes a body part 10 arranged adjacent to another body part 10. The body part 10 includes a bottom section 11. The bottom section 11 is configured to form at least a portion of the vehicle body 100. Here, the bottom section 11 is the base of the vehicle body 100. The body part 10 also includes a battery housing structure 12 at the bottom section 11. The battery housing structure 12 includes a plurality of compartment walls 13 that divide the battery housing structure 12 into a plurality of compartments 14. Figure 1 In the embodiment, one of the plurality of compartments 14 accommodates one of the plurality of battery cells 200 .

[0043] Figure 2 A battery pack 20 is schematically and exemplarily shown. The battery pack 20 includes a main body component 10. The battery housing structure 12 of the main body component 10 includes a plurality of compartment walls 13 that divide the battery housing structure 12 into a plurality of compartments 14. The compartment walls 13 include flow channels 15 configured to cool at least one of the plurality of battery cells 200 ( Figure 2 1 and 1 ). The plurality of compartment walls 13 include at least two flow channels 15. The flow channels 15 are arranged adjacent to each other. The flow channels 15 may be arranged substantially parallel to each other or at an angle. From a cross-sectional view, the flow channels 15 are depicted as being parallel to each other. The section of the compartment wall 13 where the flow channels 15 are concentrated may correspond to a portion of the battery cell 200 that is heated more than the rest of the battery cell 200, for example, an upper portion of the compartment wall 13 corresponding to a battery cell electrode (not shown).

[0044] Figure 3The main body part 10 of the battery pack 20 is schematically and exemplarily shown. The main body part 10 includes two battery cells 200 distributed into two compartments of a plurality of compartments 14. The compartment 14 includes a space 21 between the compartment wall 13 and the battery cell 200 in the compartment 14. One of the plurality of spaces 21 is schematically shown as being filled with an adhesive 22. A sealing frame 24 is disposed on top of the battery housing structure 12. Another adhesive 22 between the sealing frame 24 and at least one of the compartment walls 13 of the battery housing structure 12 is configured to fix the sealing frame 24 to the battery housing structure 12. The additional adhesive also provides electrical insulation of the battery cells 200 from each other. The adhesive 22 and the additional adhesive 22 may be the same material or may be different materials. The sealing frame 24 includes at least one opening 25 for connecting to a busbar component 201 of the battery cell 200. The connection may extend through the continuous opening 25 of two consecutive busbar components 201 for connecting the battery cells 200 to each other.

[0045] like Figure 3 As shown, the body member 10 further includes a cover 18 at the top of the plurality of compartments 14. The cover 18 covers a busbar member 201 that connects at least two battery cells 200 to each other. At least one section of the flow channel 15 for cooling the busbar member 201 is provided at the cover 18, in other words, below the cover 18. More specifically, a section of the flow channel 15 is provided at a raised portion 23 of the cover 18 that extends away from the plurality of battery cells 200.

[0046] like Figure 3 As shown, the body part 10 includes at least one inlet 16 and at least one outlet 17. The flow channel 15 is arranged between the inlet 16 and the outlet 17. The coolant can flow from the inlet 16 through the flow channel 15 and flow to the outlet 17. In this example, the compartment wall 13 includes different numbers of flow channels 15 to show the difference in cooling capacity, which can be provided by changing the number of flow channels 15 in the compartment wall 13, however, the number of flow channels 15 in each compartment wall 13 can also be equal.

[0047] Figure 4 The battery pack 20 is schematically and exemplarily shown from another angle. The body part 10 includes a plurality of inlets 16 and a plurality of outlets 17. The inlets 16 are arranged on a side of the body part 10 opposite to the outlets 17. The flow channel 15 is arranged between the inlets 16 and the outlets 17. Figure 4 A perspective view of a plurality of body components 10 parallel to each other within an exemplary battery pack 20 is shown. Battery cells 200 are disposed in a plurality of compartments 14 arranged in a partial honeycomb pattern, where only a few rows of the honeycomb pattern are shown for clarity, without showing the rows in between. Here, the compartments 14 of the honeycomb pattern have a circular shape. Figure 4 The cover 18 and the sealing frame 24 are omitted.

[0048] Figure 5 A flow chart schematically and exemplarily shows a method 300 for manufacturing a battery pack 20. The method 300 includes providing a body component S1, and providing each of a plurality of battery cells 200 of a vehicle battery in a corresponding one of a plurality of compartments 14 of the body component S2.

[0049] As used herein, the phrase "at least one" with respect to a list of one or more entities should be understood to mean at least one entity selected from any one or more entities in the list of entities, but does not necessarily include at least one of each entity specifically listed within the list of entities, and does not exclude any combination of entities in the list of entities. This definition also allows that entities other than the entities specifically identified within the list of entities to which the phrase "at least one" refers may optionally be present, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B", or equivalently, "at least one of A and / or B") may refer in one example to at least one A, optionally including more than one A, with no B present (and optionally including entities other than B); in another example, to at least one B, optionally including more than one B, with no A present (and optionally including entities other than A); in yet another example, to at least one A, optionally including more than one A, and at least one B, optionally including more than one B (and optionally including other entities). In other words, the phrases "at least one," "one or more," and "and / or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" may represent A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B, and C together, and optionally any of the foregoing in combination with at least one other entity.

[0050] Other variations of the disclosed examples may be understood and effected by those skilled in the art in practicing the claimed disclosure, by studying the drawings, the disclosure and the appended claims. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope of the claims.

[0051] Reference numerals list

[0052] Main body 10

[0053] Vehicle body 100

[0054] Battery Cell 200

[0055] Method 300

[0056] Bottom section 11

[0057] Battery housing structure 12

[0058] Compartment wall 13

[0059] Compartment 14

[0060] Flow channel 15

[0061] Inlet 16

[0062] Outlet 17

[0063] Cover 18

[0064] Battery Pack 20

[0065] Busbar component 201

[0066] Space 21

[0067] Adhesive 22

[0068] Elevated section 23

[0069] Sealing rack 24

[0070] Method steps S1, S2

Claims

1. A body component (10) for a vehicle body (100), the body component (10) being configured to enclose a vehicle battery comprising a plurality of battery cells (200), the body component (10) comprising: a bottom section (11) configured to form at least a portion of the vehicle body (100), and A battery housing structure (12), wherein the battery housing structure (12) is at the bottom section (11), the battery housing structure (12) includes a plurality of compartment walls (13), the plurality of compartment walls (13) divide the battery housing structure (12) into a plurality of compartments (14), each of the plurality of compartments (14) is configured to accommodate one of the plurality of battery cells (200), and at least one of the plurality of compartment walls (13) includes at least one flow channel (15), the at least one flow channel (15) is configured to transport a coolant for cooling at least one of the plurality of battery cells (200).

2. The body component (10) according to claim 1, wherein: The plurality of compartments (14) are arranged in a honeycomb pattern.

3. The body component (10) according to claim 1, wherein: The main body component (10) is integral.

4. The body component (10) according to claim 1, wherein: The main body component (10) further comprises at least one inlet (16) and at least one outlet (17), wherein the at least one inlet (16) is arranged on a side of the main body component (10) opposite to the outlet (17), and the at least one flow channel (15) is arranged between the inlet (16) and the outlet (17).

5. The body component (10) according to claim 1, wherein: At least one section of the at least one flow channel (15) has a serpentine shape.

6. The body component (10) according to claim 1, wherein: The main body component (10) also includes a cover (18) at the top of at least one compartment among the plurality of compartments (14), wherein the cover (18) is configured to cover at least one busbar component (201), the busbar component (201) electrically connecting at least two battery cells (200) to each other, and wherein at least one section of the at least one flow channel (15) is configured to cool the busbar component (201).

7. The body component (10) according to claim 1, wherein: At least one of the plurality of compartment walls (13) comprises at least two flow channels (15) arranged adjacent to each other.

8. A battery pack (20), comprising a main body component (10) according to any one of claims 1 to 7 and a vehicle battery, wherein the vehicle battery comprises a plurality of battery cells (200), wherein: Each of the plurality of battery cells (200) is disposed in a corresponding one of the plurality of compartments (14) of the body member (10).

9. The battery pack (20) according to claim 8, wherein: At least one of the plurality of compartments (14) includes a space (21) between the compartment wall (13) and the battery cell (200) within the compartment (14).

10. The battery pack (20) according to claim 9, wherein: The space (21) is filled with an adhesive (22).

11. The battery pack (20) according to claim 8, wherein: The vehicle battery comprises at least one busbar component (201) connecting at least two battery cells (200), at least one cover (18) of the body component (10) covering the busbar component (201), and at least one section of the at least one flow channel (15) configured to cool the busbar component (201).

12. The battery pack (20) according to claim 11, wherein: The cover (18) also includes a raised portion (23) extending away from the at least one of the plurality of battery cells (200), wherein the raised portion (23) is configured to enclose the busbar member (201) and the section of the at least one flow channel (15).

13. A vehicle comprising a battery pack (20) according to any one of claims 8 to 12.

14. A method (300) for manufacturing a battery pack (20) according to any one of claims 8 to 12, comprising: providing a body component (10) (S1) according to any one of claims 1 to 7, and Each of a plurality of battery cells (200) is provided (S2) in a corresponding one of a plurality of compartments (14) of the body member.

15. A mould configured for casting the body component (10) according to any one of claims 1 to 7.

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