Battery device with extruded core structure

Abstract

The invention relates to a battery device, in particular for a motor vehicle or for a battery storage in a building. The battery device has a core structure (10) and at least one battery cell (14), which core structure forms at least one battery cell receiving space (12) and a cooling channel (16) extending in a flow plane. Here, the cooling channel (16) is formed for a cooling fluid to flow through in the flow plane and the at least one battery cell (14) is arranged in the battery cell receiving space (12). The core structure (10) forms a longitudinal profile with a constant cross section, wherein the longitudinal profile extends transversely to the flow plane. Furthermore, the invention relates to a manufacturing method for producing a battery device.

Description

Technical Field

[0001] This invention relates to a battery device and a method for manufacturing the battery device. Background Technology

[0002] For modern applications (such as energy storage in electric vehicles or drones), batteries need to provide high currents. However, this can lead to very rapid heating of the corresponding battery cells. Batteries have an optimal operating temperature range, for example, close to room temperature. Within this temperature range, the battery can be particularly efficient. Conversely, at excessively high or low temperatures, battery degradation is accelerated. Exceeding the maximum temperature can even lead to spontaneous combustion of the battery, also known as thermal runaway. Correspondingly, temperature is typically controlled by a thermal control system.

[0003] Battery temperature control systems can be classified into two types based on their operating principles. Active cooling allows setting the battery's operating temperature, for example, through a settable flow rate of cooling fluid. However, active cooling requires energy, which can reduce system efficiency. Furthermore, during shutdown, it's impossible to prevent the battery from being cooled or heated by the environment. Additionally, integrating cooling channels can be very costly. Passive cooling consumes no energy, but it cannot maintain the operating temperature within the desired range. Overall, battery cooling requires additional structural space and can be very difficult. Additionally, battery heating can be implemented depending on the climate zone. Heating can also be active or passive.

[0004] A battery with a phase change material is described in US 2013 / 00844871 A1.

[0005] DE 10 2022 111 769 B1, which has not yet been published, describes a battery device with a core structure. The core structure has walls of minimal area with a triple periodic shape, thereby achieving heat transfer with particularly high efficiency and thus cooling the battery.

[0006] Manufacturing battery devices with efficient and compact cooling systems can be very cost-intensive. The complex cooling channel geometries that may be necessary to cool the corresponding battery cells in a space-saving manner are typically not fabricable using common large-scale manufacturing methods. Summary of the Invention

[0007] The first aspect of the invention relates to a battery device, which can be configured for use in motor vehicles, such as electric vehicles. The battery device can be configured as a battery storage device in buildings, particularly in wall-mounted charging boxes for charging electric vehicles. The battery device can also be used, for example, in drones, boats, or electric motorcycles. The battery device can be configured as an energy storage device for electrical energy. The battery device can be configured for multiple charge-discharge cycles.

[0008] The battery device may have a housing. The housing may define an internal space. The housing may be formed, for example, of plastic or metal. The housing may have multiple wall elements or may be formed integrally. The housing may protect other components of the battery device from environmental influences and may enable fastening, particularly in vehicles and / or buildings. The battery device may have electrical contacts.

[0009] The battery device has a core structure, which is arranged, for example, within the housing and / or can accommodate corresponding battery cells. The core structure can be configured to divide the interior space of the housing into at least two sub-spaces. The core structure can, for example, form the inner wall of the battery device. The core structure can provide additional protection to protect the battery cells from mechanical impacts. The core structure can form a load-bearing structure. The core structure can, for example, be permanently connected to or integrally formed with the housing. By connecting to the housing, the core structure can support the housing and thus further reinforce it.

[0010] The battery device has cooling channels and at least one battery cell receiving space, which are arranged, for example, within the housing. The core structure forms the cooling channels and the at least one battery cell receiving space. The battery device may, for example, have only one cooling channel and multiple battery cell receiving spaces. All battery cell spaces can be formed by the core structure. Each battery cell receiving space may, for example, contain only one battery cell. The battery cell receiving spaces may, for example, have identical shapes. The battery cell receiving spaces may, for example, have a constant cross-section that extends transversely to the cooling channels and / or parallel to the longitudinal profiles of the core structure. The battery cell receiving spaces may be formed by the longitudinal profiles of the core structure.

[0011] The cooling channel extends in a flow plane. The cooling channel is formed to allow cooling fluid to flow through the flow plane. The battery device may have the cooling fluid. The cooling fluid moves, for example, only within the flow plane in the region of the core structure. In the case of a vehicle, the flow plane may extend, for example, in the longitudinal and lateral directions of the vehicle. In the case of a stationary battery device, the flow plane may extend, for example, horizontally or vertically. The flow channel may have a certain height in a direction orthogonal to the extension of the flow plane. This height of the flow channel may remain constant. In the flow plane, the cooling channel may flow around a corresponding battery cell or battery cell receiving space. The cooling channel may be separated from the battery cell receiving space, for example, by the core structure. At the inlet and outlet, the height may be less than the rest of the cooling channel. However, the height of the inlet and / or outlet may also be exactly the same as the height of the rest of the cooling channel. The inlet and / or outlet may have a cross-section extending orthogonally to the flow plane. At the inlet and / or outlet, the cooling fluid flow, for example, does not deflect from the flow plane. The flow plane may extend between the inlet and the outlet. The inlet and outlet may be formed on opposite sides of the core structure. However, the inlet and outlet may also be arranged on the same side of the core structure, for example. The inlet and outlet may define the flow plane. The inlet and outlet may be slightly offset orthogonally to the flow plane, as long as they do not extend over the entire height of the core structure. The height of the core structure may be an extension of the core structure orthogonal to the flow plane. The core structure may be formed symmetrically about the flow plane.

[0012] The battery device may include a pump configured to propel the cooling fluid through the cooling channel. The pump may be fluidly connected to the inlet and outlet. The pump may be disposed inside or outside the housing. Additionally, particularly outside the housing, a heat exchanger may be provided, for example, to cool the cooling fluid. Alternatively or additionally, the battery device may include a heater, for example, to heat the cooling fluid. Thus, the battery device may have active temperature control, particularly at least configured for cooling, to reliably maintain the operating temperature within a desired range. Alternatively or additionally, the battery device may also be heated by means of the cooling fluid according to the ambient temperature. The cooling fluid may, for example, be water, air, or a water-glycol mixture. The cooling fluid may also be a slurry or dielectric liquid, such as oil. The cooling fluid may always be in a liquid state within the battery device. The battery device may also be configured to use a gaseous cooling fluid and / or allow the cooling fluid to be converted to a gaseous state. The cooling fluid may, for example, evaporate in the cooling channel and thus be at least partially converted to its gaseous state. The additional heat can thus be absorbed by the cooling fluid.

[0013] The battery device may have multiple layers of battery cells. Each layer may be associated with a flow plane. Each layer may be associated with a cooling channel. Each cooling channel may have a flow plane in which it extends. The cooling channels of different layers may be connected to each other. These layers of the battery cell are stacked on top of each other, for example, orthogonal to the flow plane. Each layer may have an associated core structure or may also have a shared core structure. The battery device, in particular its core structure, may be modularly and scalably configured.

[0014] The cooling channel can have a varying or constant cross-section. The width of the cooling channel along its extension can vary, for example, from the inlet to the outlet. When the cross-section of the cooling channel is narrower in the flow plane, the battery cell density can be higher. When the cross-section of the cooling channel is wider in the flow plane, the pressure loss in the cooling channel may be smaller. The cooling channel can, for example, widen in regions farther from the battery cells and narrow in regions with closely spaced battery cells. Thus, the cooling channel shape can be adapted to the cross-sectional shape and arrangement of the corresponding battery cells.

[0015] The cooling channel can, for example, be formed to be fluid-tight. For instance, the core structure can only form the wall of the cooling channel extending transversely to the flow plane. Other wall areas can be formed by additional elements, such as those connected to the core structure in a fluid-tight manner. The battery cell receiving space can also be formed to be fluid-tight. A temperature buffer medium can be arranged in the battery cell receiving space along with the battery cell. However, the battery cell receiving space can also be formed to be non-fluid-tight. For example, no additional medium can be arranged in the battery cell receiving space. The battery cell can directly contact the core structure in the battery cell receiving space. Thermal paste can be arranged between the battery cell and the core structure. For example, the core structure can only form the wall of the battery cell receiving space extending transversely to the flow plane. Other wall areas can be formed by additional elements, such as those connected to the core structure.

[0016] The battery device has battery cells. The battery cells are arranged in a battery cell receiving space. The battery cells can be formed, for example, as primary cells. The battery cells can be electrochemical energy storage devices and transducers. The battery cells can be, for example, cylindrical or prismatic battery cells. The battery cells can also have a hexagonal or triangular cross-section. The battery device can have multiple battery cells, which can be arranged in the housing in a specific filling manner. The battery cells can be arranged uniformly in a plane at a certain distance from each other, particularly in the flow plane of the cooling fluid. All battery cells of the battery device can be formed identically. However, the battery device can also have two or more different types of battery cells. For simplicity, the term "battery cell" is generally used below, where, if applicable, this always also refers to multiple or all of the battery cells. For simplicity, the term "battery cell receiving space" is also generally used, where, if applicable, this always also refers to one, multiple, or all of the battery cell receiving space.

[0017] The core structure forms a longitudinal profile with a constant cross-section, wherein the longitudinal profile extends transversely to the flow plane. The core structure can be a straight member with a constant cross-section. The core structure is formed, for example, from profiled steel or aluminum profiles. The core structure can be formed from multiple profile portions, wherein the orientation of these profile portions relative to their longitudinal profiles can be parallel. Thus, the core structure is simply modularly expandable. Nevertheless, complex cooling channels can be formed by the transverse extension of the longitudinal profile relative to the flow plane, through which the battery cell or battery cell receiving space flows over a large area and has a larger length in the flow plane compared to the extension of the core structure. This allows for highly efficient heat exchange between the cooling fluid and the battery cell, and even so, efficient large-scale manufacturing can be achieved. The extension of the longitudinal profile can be longitudinal. The extension of the longitudinal profile can correspond, for example, to the manufacturing direction during extrusion. The core structure can be formed, for example, from a metallic material or from a plastic.

[0018] The shape of the battery cell receiving space, particularly its cross-section in the longitudinal extension direction of the longitudinal profile, can match the basic shape of the battery cell. In the case of a cylindrical battery cell, the battery cell receiving space may, for example, have a circular cross-section. In the case of a prismatic battery cell, the battery cell receiving space may, for example, have a polygonal cross-section.

[0019] In one embodiment of the battery device, the core structure is manufactured via an extrusion process. Extrusion is a low-cost method for mass production. In the case of extrusion, mold costs can be very low. Furthermore, the core structure manufactured by extrusion can be particularly stable under pressure. Complex shapes can also be produced from materials that are difficult to deform through extrusion. Extrusion can be pressure-deformed. The longitudinal extension of the longitudinal profile can, for example, correspond to the pressing direction. The core structure can, for example, be formed from a single extruder or from multiple extruders. In the case of multiple extruders, they can be formed to be the same or different.

[0020] In one embodiment of the battery device, the longitudinal profile extends orthogonally to the flow plane. The cooling channels can thus have complex shapes. Furthermore, the core structure therefore has a large extension in the flow plane.

[0021] In one embodiment of the battery device, the cooling channel extends in a tortuous manner in the flow plane, particularly between the respective battery cells. The cooling channel may, for example, meander through the space between the respective battery cells. The cooling channel can thus have a considerable length. This allows for particularly good heat transfer between the cooling fluid and the battery cells. The tortuous shape can, for example, be curved. The cooling channel may, for example, have no corners and / or angles. Therefore, the pressure loss in the cooling channel can be low.

[0022] In one embodiment of the battery device, the core structure has a first wall element and a second wall element. These two wall elements can be inserted into each other, for example, to form the core structure. The two wall elements can be arranged side-by-side in the flow plane. The two wall elements can be non-contact and / or connected to each other only via other elements. The two wall elements can be formed as general-purpose parts and / or extruded parts. Due to the two or more wall elements, the core structure can be particularly complex. The two wall elements can have complementary longitudinal profiles. The two wall elements can, for example, jointly define the cooling channel in the flow plane. Viewed in the flow direction, the first wall element can, for example, define the cooling channel on the left and the second wall element can define the cooling channel on the right. The two wall elements can, for example, form battery cell receiving spaces separately from each other. The first wall element can, for example, define at least one first battery cell receiving space in the flow plane and the second wall element can, for example, define at least one second battery cell receiving space in the flow plane. Thus, the battery cell receiving space can be particularly robust. With multiple wall elements, the battery device or the core structure can be modularly expanded particularly easily. These two wall elements can extend parallel to each other with their longitudinal profiles. Thus, a double-wall structure can be easily formed. These two wall elements can separate the cooling channel and the battery cell receiving space from each other.

[0023] In one embodiment of the battery device, the first wall element and the second wall element are manufactured as separate extrusion members. Manufacturing can then be very simple. Alternatively, the first wall element and the second wall element can be manufactured as a common extrusion member, with the wall elements separated from each other to form the flow channel. Installation can then be particularly simple. For example, a semi-finished product with two wall elements can be prepared by an extrusion process. This semi-finished product can then be fastened. Subsequently, the two wall elements are separated by cutting the semi-finished product. Thus, the orientation of the two wall elements can be easily preset during installation. Separation can be achieved, for example, by sawing, cutting, grinding, or laser. The separation location can, for example, form the inlet and outlet of the cooling channel. In both cases, the two wall elements in the battery device are separate elements.

[0024] In one embodiment of the battery device, the battery device has a first cover layer and a second cover layer. These two cover layers may be arranged on opposite sides of the core structure. These two cover layers may extend substantially parallel to the flow plane. This results in the following difference: the cover layers are not formed in a plate-like manner, for example. The cover layers may be formed in a plate-like manner, for example. The cover layers may form the top and bottom surfaces of the battery device and / or the housing. The cover layers may define the cooling channels along the flow plane.

[0025] The cover layer can be connected to the core structure. Each cover layer can be non-conductive. Each cover layer can be formed, for example, as a plate made of an electrically insulating material. The cover layer can also be formed of a conductive material such as metal. Such cover layers can have an electrically insulating coating on the side facing the battery cell and / or on the side facing away from the battery cell, where contact plates can be arranged, for example. Each cover layer can also be formed of a composite material and thus have particularly high mechanical strength. The cover layer can be partially adjacent to the core structure and / or form a sandwich structure with the core structure. Thus, the battery device can be formed as a load-bearing structure. Thus, for example, reinforcements in the vehicle can be omitted when installing this battery device. The battery device can then be formed as a load-bearing component of the vehicle body, for example. The cover layer can, for example, lie flat on the core structure on the opposite side and thereby define or completely enclose the corresponding battery cell receiving space on the top and bottom surfaces. The cover layer can be connected to the core structure, for example, by bonding methods such as welding, adhesive bonding, or brazing. However, these two covering layers can also be connected to each other in other ways, such as by screwing, and the core structure can be clamped therebetween. The two covering layers can also be pressed against the core structure by the housing.

[0026] In one embodiment of the battery device, at least one of the cover layers has at least one through-opening for accessing the battery contacts of the battery cell. Separate through-openings may also be provided for electrical contact. These through-openings may, for example, be oriented towards the battery cell receiving space. An associated through-opening may be provided for each battery cell. The through-openings may be provided in only one or two cover layers. One or more wires, such as current wires and / or fluid wires, can be guided through the through-openings. Alternatively, the through-openings may be sealed. This allows fluid and / or current to be introduced and discharged into the battery cell receiving space.

[0027] In one embodiment of the battery device, at least one of the cover layers has a conductor track that contacts the battery cell, particularly wherein the conductor track is arranged on the outer side of the cover layer. The conductor track is connected to the battery cell, for example, through the through-hole. One associated conductor track can be provided for each battery cell. However, the conductor track can also be electrically connected to one or more battery cells, for example. The conductor track can be secured to the cover layer. The conductor track can also be integrally formed with the cover layer, for example, by etching in the cover layer or depositing onto the cover layer. The conductor track allows for a compact, robust, and space-saving arrangement of electrical connections to the respective battery cells.

[0028] In one embodiment of the battery device, the battery device has a first sealing element and a second sealing element. The first sealing element may be formed from the first cover layer or, for example, formed thereon as an injection-molded sealing lip. The second sealing element may be formed from the second cover layer or, for example, formed thereon as an injection-molded sealing lip. The first sealing element and / or the second sealing element may also be components separate from the cover layer. The first sealing element may, for example, be sandwiched between the core structure and the first cover layer. The second sealing element may, for example, be sandwiched between the core structure and the second cover layer. The sealing element may be fastened to the core structure, for example, by bonding or welding the sealing element to the core structure. The sealing element may, for example, be formed as a rubber component, a metal component, or a plastic component.

[0029] The first sealing element can close the cooling channel at a first end of the longitudinal profile of the core structure. The second sealing element can close the cooling channel at a second end of the longitudinal profile of the core structure, opposite to the first end in the longitudinal direction of the profile. These two sealing elements can, for example, form the top and bottom surfaces of the cooling channel. The battery device may also, for example, have only the first sealing element or the second sealing element.

[0030] In one embodiment of the battery device, the core structure has a through-opening that extends, for example, parallel to the longitudinal profile. The through-opening extends, for example, downwards through the core structure. Multiple such through-openings may also be provided. These through-openings may be separate from the battery cell receiving space. Due to the through-openings, the core structure can be particularly simple. The through-opening extends, for example, parallel to the battery cell receiving space between sub-regions of the battery cell receiving space and / or the cooling channel. The through-opening can be formed for centering. For example, other components of the battery device (such as the cover and / or the housing) can be centered at the core structure using the through-opening. Thus, the battery device can also be centered in a vehicle. The through-opening can be formed for fastening. For example, a corresponding cover can be threaded onto the through-opening. The battery device can be fastened to the vehicle, for example, at the through-opening. Corresponding through-openings can be provided in the corresponding cover.

[0031] The through-hole can be configured to receive a temperature buffer medium, particularly a phase change material. For this purpose, the through-hole can be closed, for example, by the cover layer and / or the sealing element together with the cooling channel. The temperature buffer medium can have a higher specific heat capacity than the material used to form the core structure. Therefore, the thermal inertia of the battery device can be particularly high, thereby allowing the cooler to have lower power. The battery device can have a temperature buffer medium, for example, received within the through-hole.

[0032] Phase change materials (PCMs) can have high enthalpy of fusion. For example, PCMs can be paraffin wax. Another example of a PCM is an aluminum-silicon alloy. Other examples of PCMs include hydrated salts, alcohols, fatty acids, and salts. Additionally, fire-retardant additives can be added to the PCM. The PCM can be selected to change between two phases, particularly liquid and solid, within or near the desired operating temperature range of the battery device. The PCM can have a large effective thermal mass, which significantly improves the thermal inertia of the battery device. This can prevent or at least delay undesirable rapid and / or high temperature rises or falls. This makes it easier to maintain the desired operating temperature of the battery device. Furthermore, the size of the active cooler can be made smaller because the active cooler no longer needs to separately absorb the corresponding thermal reactions of the battery.

[0033] The temperature buffer medium can buffer load peaks to reduce the load on the active cooler and / or heater. Furthermore, even during shutdown, i.e., when the battery device is turned off, the temperature buffer medium or phase change material can maintain the temperature of the battery device better or with less mass and volume than it could without the phase change material. This results in a longer battery life. Due to the phase change material, the battery device can be particularly lightweight because the corresponding active cooling components can be made smaller. Additionally, systems with such battery devices can be more efficient because the active cooling can require less energy. Because the battery device can be better maintained within its optimal operating temperature range, its lifespan can also be particularly long.

[0034] In one embodiment of the battery device, the cooling channel extends from the inlet end into the battery device first in the central region of the flow plane and then to the outlet end in the outer region of the flow plane. Thus, for example, freshly flowing, cold cooling fluid can initially flow into the central part of the core structure, where the temperature typically rises most dramatically. A large amount of heat can then be rapidly dissipated there due to the higher temperature difference. In the outer regions (e.g., at the edges of the core structure or battery device), the battery device typically heats up less dramatically, for example because heat can be passively dissipated to the environment and the battery cells are not adjacent to each other on the sides of the flow plane. Cooling can then always be adequately achieved through the cooling fluid, which has already been heated in the center. Thus, cooling can be particularly efficient.

[0035] A second aspect of the invention relates to a method for manufacturing a battery device. The battery device can be configured as a battery device according to the first aspect. Corresponding advantages and other features can be understood from the description of the first aspect, wherein the design of the first aspect also forms the design of the second aspect, and vice versa.

[0036] The method includes the step of generating a core structure. This generation step can be performed, for example, by extrusion and / or extrusion methods. The resulting core structure can form at least one battery cell receiving space and a cooling channel extending in a flow plane, wherein other elements can completely define the battery cell receiving space and the cooling channel together with the core structure. However, the core structure can also define the battery cell receiving space and the cooling channel independently. The core structure is generated as a longitudinal profile with a constant cross-section and thus forms a longitudinal profile with a constant cross-section. The longitudinal profile extends transversely to the flow plane. Correspondingly, the generation direction (e.g., a pressing direction and / or an extrusion direction) can extend transversely to, and in particular orthogonally to, the flow plane. The method may include the step of inserting a corresponding battery cell into a corresponding battery cell receiving space. Before insertion, a thermally conductive device (such as thermal paste) can be applied to the battery cell. The generation of the core structure may include generating two wall elements. The wall elements can be generated separately. The production of the wall element may alternatively include the production of a common semi-finished product, which is divided into two elements, for example by sawing, punching, cutting or laser cutting, to provide the two wall elements.

[0037] In one embodiment of the battery device, the method further includes the step of closing the cooling channel in the longitudinal extension direction of the longitudinal profile. The closure of the cooling channel can be achieved, for example, by a sealing element and / or a covering layer. The closure of the cooling channel can, for example, include arranging a corresponding sealing element and / or a corresponding covering layer at the top and / or bottom surface of the core structure. The closure of the cooling channel can, for example, include fastening the corresponding sealing element and / or the corresponding covering layer at the top and / or bottom surface of the core structure, for example, by bonding, screwing, and / or welding. The sealing element can, for example, be prepared by injection molding or punching. The method can include providing or preparing the corresponding sealing element and / or covering layer. Attached Figure Description

[0038] Figure 1 A schematic perspective view illustrates a first embodiment of the core structure of the battery device.

[0039] Figure 2 A schematic top view shows the situation based on Figure 1 The first embodiment of the core structure.

[0040] Figure 3 A schematic 3D diagram is shown based on Figure 1 The corresponding elements of the first embodiment of the core structure.

[0041] Figure 4 A first embodiment of the core structure having a sealing element fastened thereto is shown in a schematic perspective view.

[0042] Figure 5 A schematic 3D diagram is shown. Figure 4 Sealing elements.

[0043] Figure 6 A second embodiment of the core structure of the battery device is shown in a schematic top view.

[0044] Figure 7 A third embodiment of the core structure of the battery device is shown in a schematic top view.

[0045] Figure 8 A fourth embodiment of the core structure of the battery device is shown in a schematic top view.

[0046] Figure 9 A fifth embodiment of the core structure of the battery device is shown in a schematic top view.

[0047] Figure 10 A sixth embodiment of the core structure of the battery device is shown in a schematic top view.

[0048] Figure 11 A seventh embodiment of the core structure of the battery device is shown in a schematic top view.

[0049] Figure 12 An eighth embodiment of the core structure of the battery device is shown in a schematic top view.

[0050] Figure 13 A ninth embodiment of the core structure of the battery device is shown in a schematic top view.

[0051] Figure 14 Three variations of the first embodiment of the core structure of the battery device are shown in a schematic top view.

[0052] Figure 15 A first embodiment of the core structure of the battery device with battery cells is shown in a schematic perspective view.

[0053] Figure 16 A schematic perspective view illustrates a first embodiment of the core structure of the battery device with a cover layer.

[0054] Figure 17A vehicle battery having one embodiment of the battery device is shown in a schematic exploded view.

[0055] Figure 18 Showing according to Figure 17 The battery equipment in the vehicle battery. Detailed Implementation

[0056] Figure 1 A first embodiment of the core structure 10 of the battery device is shown in a schematic perspective view. The battery device has a housing (not shown), which is, for example, rectangular and completely houses the core structure 10. The core structure 10 is, for example, partially adjacent to and secured by the housing on its outer side.

[0057] The core structure 10 forms two rows of battery cell receiving spaces 12. These battery cell receiving spaces 12, in the illustrated embodiment, have a generally circular shape into which cylindrical battery cells 14 of the battery device are inserted. Figure 15 The image shows the battery cell 14 in its inserted state. In the installed state, the battery cell 14 is fully received within the battery cell receiving space 12. Correspondingly, the battery cell receiving space 12 is formed as a cylinder with a constant cross-section. The battery cell receiving space 12 is formed as a through-hole in the core structure 10.

[0058] Additionally, the core structure 10 forms cooling channels 16 extending in the flow plane. Figure 1 Arrow 18 indicates the flow direction. The flow plane extends orthogonally to the longitudinal axis or central axis of the battery cell receiving space 12. Cooling fluid flows from inlet 20 through cooling channel 16 to outlet 22 in the flow plane. Inlet 20 and outlet 22 are arranged on opposite sides of the core structure 10 in the flow plane.

[0059] The core structure 10 has a longitudinal profile with a constant cross-section. The longitudinal profile forms a battery cell receiving space 12 and a cooling channel 16. The longitudinal profile extends orthogonally to the flow plane. Figure 2 The core structure 10 is shown in a top view, where the flow plane corresponds to the plane of the drawing. Cooling channels 16 are formed as continuous slots in the height direction within the core structure 10. Figure 2 As can be clearly seen, the cooling channel 16 extends in a tortuous manner around each of the two rows of battery cell receiving spaces 12. Thus, each battery cell 14 is almost completely surrounded by the cooling channel 16, thereby enabling efficient heat transfer between the cooling fluid and the battery cell 14. The cooling channel 16 has no corners or edges and is uniformly curved to minimize pressure loss within the cooling channel 16 and optionally achieve laminar flow even at bends.

[0060] exist Figure 1 Arrow 24 indicates the longitudinal direction of the longitudinal profile of the core structure 10. The longitudinal direction 24 of the longitudinal profile of the core structure 10 corresponds here to the longitudinal axis or central axis of the battery cell receiving space 12 and the manufacturing direction of the core structure 10. The core structure 10 is manufactured by an extrusion process, wherein the pressing direction corresponds to arrow 24. This allows for the low-cost manufacture of the core structure 10.

[0061] Figure 3 A schematic perspective view shows a first wall element 30 and a second wall element 32 that together form the core structure 10. These two wall elements 30 and 32 have complementary wall profiles that extend parallel to each other. Each of the wall elements 30 and 32 forms a row of battery cell receiving spaces 12 and completely defines them in a flow plane. A cooling channel 16 is formed by the free space between the two wall elements 30 and 32 and is therefore jointly defined in the flow plane by the wall elements 30 and 32. That is, the cooling channel 16 is defined on one side of the flow plane by the first wall element 30 and on the other side by the second wall element 32.

[0062] In the illustrated embodiment, the two wall elements 30 and 32 are manufactured as separate components using an extrusion process. In the illustrated embodiment, the two wall elements 30 and 32 are formed as universal parts that simply rotate toward the battery device and nest into each other. Figure 3 The image shows how the two wall elements 30 and 32 are pushed into each other along the longitudinal axis of their longitudinal profiles or in the direction of arrow 24.

[0063] The two wall elements 30 and 32 can also be manufactured together. For example, a semi-finished product is first manufactured by extrusion, which already has longitudinal profiles of the two wall elements 30 and 32 and is closed by connecting walls at the inlet 20 and outlet 22, respectively. To separate the two wall elements 30 and 32, the two connecting walls are cut, for example, by means of a laser. This separation can also be performed, for example, after the semi-finished product has been installed in the battery device. Thus, installation can be particularly simple because the two wall elements 30 and 32 maintain the desired distance through these connecting walls even when they are fastened and can then be separated.

[0064] exist Figure 4 and Figure 5 The image shows a sealing element 40 that encloses the cooling channel 16 on its top surface. The sealing element 40 has a support surface on which it rests flat on the core structure 10. Additionally, the sealing element 40 has a protruding lip that corresponds to the orientation and width of the cooling channel 16 and extends into the cooling channel in the longitudinal direction of the longitudinal profile. Thus, the sealing element 40 is centered within the core structure 10. Figure 5The lip is particularly well seen in the figure, which shows the sealing element 40 from its side, lying flat on the core structure 10. The battery device has an additional sealing element 40 on the bottom surface, which encloses the cooling channel 16 on the bottom surface. This additional sealing element 40 can be formed in exactly the same manner.

[0065] In the illustrated embodiment, the sealing element 40 is formed as a separate component and manufactured by injection molding. The sealing element 40 is bonded to the core structure 10 in a fluid-tight manner. Alternatively, the sealing element 40 may also be, for example, a sheet metal prepared by punching. The aforementioned lip may be omitted here. The sealing element 40, formed as a sheet metal, may, for example, be welded to the core structure 10.

[0066] Figure 6 A schematic top view shows a second embodiment of the core structure 10 of the battery device, which is formed similarly to the first embodiment. Therefore, only the differences are illustrated, and the same reference numerals are used. This core structure 10 has only one row of battery cell receiving spaces 12. However, the number of rows and the length of the rows of battery cell receiving spaces 12 can be freely chosen.

[0067] In the second embodiment, the cooling channel 16 has a variable width along its direction. That is, the cooling channel 16 has a wide section 50 and a narrow section 52. In the first embodiment, the width of the cooling channel 16, as well as its cross-section, is constant along its direction. In the second embodiment, the cooling channel 16 is wider in region 54 of the flow plane between two adjacent battery cell receiving spaces 12 or battery cells 14. As a result, the cooling fluid flows more slowly in this region 54 and there is more cooling fluid in this region 54. There, the waste heat of the two battery cells 14 can be effectively discharged. In addition, the pressure loss in the wide section 50 can be less than that in the narrow section 52. Conversely, in the outer region 56 of the core structure 10, the cooling channel 16 has a narrow section 52. As a result, the extension of the core structure 10 in the flow plane can be smaller and thus the overall size of the battery device is also smaller. In addition, the wall thickness of the core structure 10 in the outer region 56 can be greater so that the battery cell 14 can be protected particularly well by the core structure 10, and thus the core structure 10 can be particularly robust.

[0068] Figure 7A schematic top view illustrates a third embodiment of the core structure 10 of the battery device, which is formed similarly to the first embodiment. Therefore, only the differences are explained, and the same reference numerals are used. In the third embodiment, cooling channels 16 are coiled around a smaller proportion of each battery cell receiving space 12. The cooling channels 16 extend laterally between the rows of battery cell receiving spaces 12. Some battery cell receiving spaces 12 are, for example, coiled around about 75%, while other battery cell receiving spaces 12 are only passed through by the cooling channels 16 on both sides. Thus, in the third embodiment, the cooling channels 16 have fewer bends than in the first embodiment. Consequently, the pressure loss in the cooling channels 16 can be lower.

[0069] Figure 8 A schematic top view shows a fourth embodiment of the core structure 10 of the battery device, which is formed similarly to the first embodiment. Therefore, only the differences are illustrated, and the same reference numerals are used. This core structure 10 has three rows of battery cell receiving spaces 12. However, the number of rows and the length of the rows of battery cell receiving spaces 12 can be freely chosen. The orientation of the cooling channels 16 is similar to that of the third embodiment, thereby allowing for smaller pressure losses. The inlet 20 and outlet 22 extend and coil on opposite sides and are formed there to connect to additional [other channels]. Figure 8 The core structure 10 shown in the figure is thus modularly expanded to expand the battery device.

[0070] Figure 9 A fifth embodiment of the battery device's core structure 10 is shown in a schematic top view, forming a battery device similar to the first embodiment. Therefore, only the differences are illustrated, and the same reference numerals are used. In this embodiment, the cooling channels 16 extend in rows and thus have a few bends. Within a row, the cooling channels 16 extend almost straight alongside the battery cell receiving space 12. Consequently, the pressure loss in the cooling channels 16 is particularly low. Furthermore, the inlet 20 and outlet 22 are arranged on the same side of the core structure 10, thereby making the connection from the cooling channels 16 to the pump device particularly simple and space-saving. The inlet 20 and outlet 22 are located on... Figure 9 The middle section connects to the rest of the cooling channel 16 via a bend. This allows for flexible selection of the orientation of the inlet 20 and outlet 22 in a space-saving manner. However, instead of a bend, a curved transition section can also be provided. This results in lower pressure loss.

[0071] Figure 10A sixth embodiment of the core structure 10 of the battery device is shown in a schematic top view, which is formed similarly to the first embodiment. Therefore, only the differences are explained, and the same reference numerals are used. In this embodiment, the cooling channel 16 also extends in a different manner. The cooling channel 16 extends relatively shortly from the inlet or inlet 20 in the flow plane from the outer region 60 to the central region 62 into the battery device. At the center 62 in the flow plane, the cooling channel 16 coils around a single battery cell receiving space 12 and thus has a longer path in the central region 62. The cold cooling fluid thus flows first towards the particularly hot center of the core structure 10. Subsequently, the cooling channel 16 then extends along another longer outer region 64, almost around the entire outer edge of the core structure, to the outlet or outlet 22 in the flow plane of the battery device. Thus, the already heated cooling fluid can dissipate heat outwards. Furthermore, the edges of the core structure 10 are generally not very hot during operation, for example, because heat can be passively radiated outwards effectively.

[0072] In the sixth embodiment, the inlet 20 and the outlet 22 are directly adjacent to each other and share a wall section 66. Therefore, the inlet 20 and the outlet 22 require very little space, and the pump equipment can be connected in a very simple and space-saving manner, for example.

[0073] Figure 11 A seventh embodiment of the core structure 10 of the battery device is shown in a schematic top view. The core structure 10 can be easily modularly expanded, similar to... Figure 8 The fourth embodiment is shown in the figure. The core structure 10 here has multiple segments with periodically arranged battery cell receiving spaces 12.

[0074] Figure 12 An eighth embodiment of the core structure 10 of the battery device is shown in a schematic top view. The battery cell receiving spaces 12 are arranged in a hexagonal pattern. Periodic modular scalability can also be easily achieved here.

[0075] Figure 13 A ninth embodiment of the core structure 10 of the battery device is shown in a schematic top view, which is formed similarly to the second embodiment. Therefore, only the differences are explained, and the same reference numerals are used. In this embodiment, the wall structures of the wall elements 30, 32 are significantly simplified. For example, coiled bends are no longer provided in the cooling channel 16, and the longitudinal profile of the core structure 10 is substantially polygonal. This allows for particularly low manufacturing costs. Furthermore, the corresponding dead volume in the cooling channel 16 can form a temperature buffer. Therefore, this form of the cooling channel 16 can be particularly advantageous when the cooling fluid is formed as a slurry.

[0076] Figure 14 Three variations 80, 82, and 84 of the first embodiment of the core structure 10 of the battery device are shown in schematic top views. Here, additional through-holes 72 are arranged in the gaps 70 between the battery cell receiving spaces 12, extending parallel to the longitudinal extension of the longitudinal profile through the core structure 10. These through-holes 72 can be directly manufactured by extrusion and... Figure 14 The figure is shown above the core structure 10 in the plane.

[0077] Figure 14 The first variant 80 on the left side shows a circular through-hole 72. Using such a through-hole 72, the core structure 10 can be easily centered and fixed, for example. Figure 14 The second variant 82 in the middle section shows a triangular through-hole 72, whose sides follow the contour of the adjacent cooling channel 16 and the outer surface of the core structure 10. Using such a through-hole 72, the core structure 10 can be particularly lightweight because a significant amount of material is removed. Figure 14 The third variant 84 on the right also shows triangular through-holes 72, each side of which follows the contour of the adjacent cooling channel 16 and the outer surface of the core structure 10. Crossbeams extend within the through-holes 72, which can reinforce the core structure 10 and can be integrally formed during extrusion. The third variant can also be understood as having three through-holes 72 positioned in the gap 70. Using such through-holes 72, the core structure 10 can be lightweight and robust.

[0078] In each form of the through-opening 72, a temperature buffer medium, such as a phase change material, may optionally be arranged. Thus, the heat capacity of the core structure 10 can be particularly high. If the temperature buffer medium is arranged in the corresponding through-opening 72, the through-opening 72 can be closed, for example, by a sealing element 40 on the top or bottom surface and / or a covering layer.

[0079] On the top and bottom surfaces of the core structure 10, the battery device has a cover layer 90, which is adjacent to the core structure 10 and... Figure 16As shown in the diagram. The cover layer 90 can form part of the housing and together with the core structure 10 form a sandwich structure with high durability. Battery cells 14 are electrically connected on the top and / or bottom surfaces to enable current to be delivered to and charged electrical appliances. For this purpose, the cover layer 90 has associated through-holes aligned with the battery cells 14 and thus with the battery cell receiving space 12. These through-holes are, for example, smaller than the diameter of the battery cells 14. The battery cells 14 are covered with thermal paste to achieve good heat transfer to the core structure 10. The cover layer 90 is formed, for example, as a coated metal component, plastic, glass fiber reinforced polymer sheet, or carbon fiber reinforced polymer sheet. The cover layer 90 can be formed, for example, from an electrically insulating material in a sandwich construction, wherein corresponding conductor tracks can be deposited or etched on the sides facing away from the core structure 10. Electrical terminals, sensors, and electronic components can be arranged on the cover layer 90, for example. Additionally, plastic covers can be provided to protect these components from environmental impacts.

[0080] A sealing element 40 may also be injection molded onto the cover layer 90, or the cover layer 90 itself may form a seal for the cooling channel 16 or a top and bottom surface defining portion thereof. The cover layer 90 may be connected to the core structure 10 in a fluid-tight manner. The cover layer 90 may also clamp and fix the sealing element 40 to the core structure 10.

[0081] Figure 18 A vehicle battery based on one embodiment of the previously described battery device is shown. In addition to the upper cover 90, the lower cover 90 is now also visible. In the upper cover 90, electronics 92 providing a battery management system are now shown. The electronics 92 are electrically connected to the individual battery cells 14, for which one or both covers 90 have electrical contacts. On the upper cover 90, an inverter 94 is arranged to be housed within a housing, and this inverter is connected to the battery cells 14 and / or the electronics 92 via high-voltage terminals 96. Other electronic components may also be housed within the housing of the inverter 94.

[0082] The core structure 10 and battery cell 14 are externally surrounded by the frame member 98. The frame member 98 may be arranged in the height direction between the two cover layers 90. Alternatively, the cover layer 90 may also be externally (i.e., in the flow plane) surrounded by the frame member 98. A plastic cover 100 is provided on the top surface of the upper cover layer 90, which covers not only the inverter 94 and the electronic device 92 but also the upper cover layer 90. Another plastic cover 100 is provided below the lower cover layer 90, which covers the lower cover layer 90. These two plastic covers 100 can enclose the core structure 10, battery cell 14, and corresponding other components. These two plastic covers 100 can also wrap around the frame member 98 or can form a casing for the vehicle battery together with the frame member 98. The battery cell 14, inverter 94, and electronic device 92 can then be waterproofed, for example.

[0083] exist Figure 17 The top view shows the modular construction of the core structure 10. The core structure 10 is constructed from multiple modules, which are similar to... Figure 8 In this implementation, however, each module has multiple rows of battery cell receiving spaces 12 and battery cells 14. The vehicle battery has inlet conduits 102 on both sides, which extend longitudinally in the flow plane within the frame member 98 at the outer side. Each adjacent module of the core structure 10 is connected to the inlet conduit 102 by its inlet 20. The vehicle battery has an outlet conduit 104 in the middle. Between the inlet conduit 102 and the outlet conduit 104, each module of the core structure 10 is connected at its inlet 20 to the outlet 22 of the next module of the core structure 10 in the direction of the associated inlet conduit 102. The module adjacent to the outlet conduit 104 is connected to the outlet conduit 104 by its outlet 22. The cooling channels 16 of each module of the core structure 10 are thus modularly expanded and connected to each other. The size and capacity of the vehicle battery can thus be easily modularly expanded. All modules, and therefore the cooling channels 16 of the modules of the core structure 10, can be simply supplied with cooling fluid in the center and connected together.

[0084] List of reference numerals 10-core structure 12 Battery Cell Acceptance Space 14 battery cells 16 cooling channels 18 arrows / Flow direction in the flow plane 20 entrances 22 Exports 24 Arrows / Longitudinal direction of longitudinal profiles or core structures 30, 32 wall elements 40 sealing elements 50 wide section 52 narrow sections Area 54 56, 60 outer areas 62 Central Region, Center 64 long external area 66 wall section 70 gap 72 through opening 80 First Variant 82 Second Variant 84 Third Variant 90 layers 92 Electronic Components 94 inverter 96 High Voltage Terminal 98 frame components 100 plastic caps 102 Inlet Catheter 104 outlet catheter

Claims

1. A battery device, particularly for use in motor vehicles or for use in buildings, wherein the battery device has a core structure (10) and at least one battery cell (14), the core structure forming at least one battery cell receiving space (12) and a cooling channel (16) extending in a flow plane, wherein the cooling channel (16) is configured to allow cooling fluid to flow through the flow plane, wherein the at least one battery cell (14) is arranged in the battery cell receiving space (12), wherein the core structure (10) forms a longitudinal profile having a constant cross-section, wherein the longitudinal profile extends transversely to the flow plane.

2. The battery device according to claim 1, wherein the core structure (10) is manufactured by an extrusion process.

3. The battery device according to claim 1 or 2, wherein the longitudinal profile extends orthogonally to the flow plane.

4. The battery device according to any one of the preceding claims, wherein the cooling channel (16) extends in a tortuous manner in the flow plane, particularly between the respective battery cells (14).

5. The battery device according to any one of the preceding claims, wherein the core structure (10) has a first wall element (30) and a second wall element (32), the wall elements having longitudinal profiles that are complementary to each other; and / or; Its longitudinal profiles extend parallel to each other; and / or The wall elements together define the cooling channel (16) in the flow plane.

6. The battery device according to claim 5, wherein the first wall element (30) and the second wall element (32) are made as separate extrusion members; or; wherein the first wall element (30) and the second wall element (32) are made as a common extrusion member, the wall elements being separated from each other to form the flow channel.

7. The battery device according to any one of the preceding claims, wherein the battery device has a first cover layer (90) and a second cover layer (90) disposed on opposite sides of the core structure (10), wherein the two cover layers (90) extend substantially parallel to the flow plane.

8. The battery device according to any one of the preceding claims, wherein the battery device has a first sealing element (40) and a second sealing element (40), wherein the first sealing element (40) closes the cooling channel (16) at a first end of the longitudinal profile of the core structure (10); and wherein the second sealing element (40) closes the cooling channel (16) at a second end of the longitudinal profile of the core structure (10), the second end being opposite to the first end in the longitudinal direction of the longitudinal profile.

9. The battery device according to any one of the preceding claims, wherein the core structure (10) has a through opening (72). The through opening (72) is formed for at least one of the following purposes: - Determine the center; -Accepts temperature buffering media, especially phase change materials; and - Tighten.

10. The battery device according to any one of the preceding claims, wherein the cooling channel (16) extends from the inlet end into the battery device first in the middle region (62) of the flow plane and then extends to the outlet end in the outer region (64) of the flow plane of the battery device.

11. A method for manufacturing a battery device, particularly a battery device according to any one of the preceding claims, comprising producing a core structure (10) to form at least one battery cell receiving space (12) and a cooling channel (16) extending in a flow plane, wherein the core structure (10) forms a longitudinal profile having a constant cross-section and wherein the longitudinal profile extends transversely to the flow plane.

12. The manufacturing method according to claim 11, wherein the method further comprises the step of closing the cooling channel in the longitudinal extension direction of the longitudinal profile.

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