Method for manufacturing an inter-cell cooling element with bulge compensation function

Abstract

The present invention relates to a method for manufacturing an inter-cell cooling element with bulge compensation function, the method comprising the following steps: - providing two metal half-shell elements (200, 300), the two half-shell elements being designed to have closed channel structures (220, 320) on their inner sides; - aligning the half-shell elements (200, 300) so that their inner sides face each other, and placing a compression insert (400) between the half-shell elements (200, 300); - connecting the half-shell elements (200, 300) to each other by joining the half-shell elements together along their edge segments (240, 340).

Description

Technical Field

[0001] This invention relates to a method for manufacturing an inter-cell cooling element with bulging compensation function. Background Technology

[0002] The relevant cell cooling unit is configured to be arranged between adjacent cells of the drive battery or power battery, and on the one hand, it should cool the relevant cells and heat them if necessary, and on the other hand, it should compensate for the so-called swelling characteristics of the cells (also known as cell swelling or simply swelling).

[0003] DE 10 2023 108 732 A1 describes an inter-cell cooling element with bulge compensation function for placement between two battery cells. A method for manufacturing the inter-cell cooling element is also described, in which a spacer element segment for providing a defined minimum spacing is injection molded using an injection molding process, or in which the spacer element segment is designed as a two-piece component and the individual segments are snap-fitted or joined together. Furthermore, embodiments of such an inter-cell cooling element are described, in which at least one so-called buffer element is integrated to ensure the minimum distance. Summary of the Invention

[0004] The object of this invention is to provide a method for manufacturing an inter-cell cooling element with a buffer element (hereinafter referred to as a compensation plug) that can be cost-effectively implemented.

[0005] This objective is achieved by the method according to the invention as described in claim 1. The invention is extended by the parallel independent claims to the preferred application of the inter-cell cooling element manufactured according to the invention. Additional features of both inventive subjects are similarly derived from the dependent claims, the following description of the invention (which also explicitly includes features described optionally and exemplarily), and the drawings.

[0006] The method for manufacturing an inter-cell cooling element with bulging compensation function, particularly a plate-shaped inter-cell cooling element according to the present invention, comprises at least the following steps:

[0007] - Provide two metal, particularly aluminum alloy, half-shell elements, both of which are designed to have enclosed channel structures on their inner sides;

[0008] - Align the half-shell components so that the insides of the half-shell components face each other through the channel structure located thereon, and place / position the compression plug, that is, at least one compression plug, between the half-shell components.

[0009] - (In the case of embedded compression inserts) the half-shell elements are joined together by joining them together along their edge segments, especially along flange-shaped or flange-shaped edge segments, particularly circumferentially, wherein the joining is preferably achieved by bonding, brazing, fusion welding and / or crimping.

[0010] Preferably, the method according to the present invention further includes the following preliminary steps:

[0011] - Providing extruded profiles, which refers to metal extruded profiles, especially aluminum extruded profiles, wherein the extruded profiles have flat sides and sides configured to have raised cavities;

[0012] - Cut two extruded profile segments from the extruded profile and further process the extruded profile segments into semi-shell components, especially by cutting, machining and / or forming.

[0013] Further processing of the extruded profile segment may include: manufacturing dispensing and collecting areas, particularly by removing or cutting away protruding cavities in the axial end region of the extruded profile segment.

[0014] Further processing of the extruded profile segment may include: installing cooling medium connections, specifically cooling medium inlet connections and cooling medium outlet connections, particularly pipe-type connections, which are inserted and properly secured in the dispensing and collecting areas and sealed, for example by pressing, brazing, fusion welding and / or bonding.

[0015] Further processing of the extruded profile segment may include: manufacturing surrounding flange-like or flange-like edge segments, preferably by crimping or pressing the edge areas, which can also be done in a stamping die similar to a deep drawing die.

[0016] Preferably, the channel structure has parallel cooling channels on the inside of the half-shell elements, and these cooling channels are staggered from each other after the half-shell elements are connected. That is, the half-shell elements are prepared or provided such that after connection, the cooling channels of one half-shell element extend between the cooling channels of the other half-shell element, and vice versa.

[0017] The purpose of setting up the compression plug is to allow the connected half-shells to support each other planarly without affecting the channel structure or the cross-section of the cooling channel, and to enable the half-shells to elastically deform under reverse pressure, thereby achieving bulging compensation. This, in turn, has a beneficial effect on the aging characteristics of the cell. Bulging compensation is achieved without reducing or losing cooling power.

[0018] The compression inserts are preferably made of a resiliently compressible material, such as plastic foam or non-woven fabric, and multiple compression inserts can be provided equivalently. Preferably, the compression inserts are provided as cut-out parts of the corresponding blanks, especially for faceted blanks.

[0019] Preferably, the manufactured inter-cell cooling elements are subjected to a sealing test, especially under external pressure loading (to simulate bulging characteristics). Preferably, the sealing test is performed immediately after manufacturing.

[0020] Within the scope of this invention, the features described above and explained below can be applied not only in the corresponding combinations of features given, but also in other combinations of features or individually. This also applies to the features shown in the figures. Attached Figure Description

[0021] The invention will now be described in more detail in a non-limiting manner with reference to the accompanying drawings. Features shown in the figures and / or explained below (even independently of specific combinations of features) may be general features of the invention and may improve the invention accordingly.

[0022] Figures 1 to 4 Different stages of a method according to the present invention for manufacturing an inter-cell cooling element with bulging compensation function are shown. Detailed Implementation

[0023] Figure 1 A flat, thin-walled extruded profile segment 100, cut from an extruded profile, particularly an aluminum extruded profile, is shown. As can be seen from the cross-sectional view (AA), the extruded profile segment 100 has flat or smooth sides and sides (back side) configured with a raised cavity 110. The cavity 110 has a closed profile. The extruded profile segment 100 has, for example, a wall thickness of 0.4 mm to 0.6 mm and a cavity height or channel height of 0.8 mm to 1.2 mm.

[0024] Manufactured from extruded profile section 100 Figure 2 The half-shell element 200 shown has a closed channel structure 220 formed by a cavity 110, which has parallel cooling channels 221. As can be seen from the cross-sectional view (BB), the cooling channels 221 have a closed profile, that is, the cooling channels 221 are completely surrounded in the circumferential direction. The half-shell element 200 has a distribution area 231 and a collection area 232 for the cooling medium in its axial end region, for which the protruding cavity 110 is removed in these regions—especially by machining. The distribution area 231 and the collection area 232 also have openings 251, 252, which are configured for fixing pipe-joint-shaped cooling medium connections 261, 262 (see...). Figure 3Furthermore, it is manufactured, particularly by cutting or punching. Additionally, the profile of the axial end region is adapted to a specified shape, particularly by cutting. Furthermore, the half-shell element 200 has a surrounding flange-like edge segment 240, which to some extent forms a flange, and is manufactured, particularly by crimping or pressing the edge region of the extruded profile segment 100.

[0025] Figure 3 The prepared half-shell element 200 and another half-shell element 300 are shown, the other half-shell element being designed to be substantially mirror-symmetrical to half-shell element 200 and, in particular, manufactured in the same manner (see above). Half-shell elements 200 and 300 are positioned and aligned with each other so that the channel structures 220, 320 or parallel cooling channels 221, 321, and the distribution areas 231, 331 and collection areas 232, 332 face each other. A compression insert 400 is placed between half-shell elements 200 and 300. The two half-shell elements 200 and 300 are then brought into contact, and with the compression insert 400 embedded, the two half-shell elements are joined and sealed together along edge segments 240, 340.

[0026] Figure 4 The completed inter-cell cooling element 500 is shown, which has a plate-like shape. As can be seen from the cross-sectional view (CC), enclosed cooling channels 221 and 321 are interlaced, as described above. An enclosed compression insert 400 extends meanderingly between the cooling channels 221 and 321. The outer surface or outer side of the inter-cell cooling element 500 is designed to be flat and can be planarly attached to the cell to be cooled. The cooling channels 221 and 321 are integrated to some extent into the outer wall. The inter-cell cooling element 500 has a small thickness D, for example, only 4 mm to 6 mm.

[0027] The advantages of the described manufacturing method are that it allows the use of extruded profiles as the initial material, which are readily available as blanks and possess high shape accuracy. Furthermore, the same extruded profile can be used for both half-shell elements 200 and 300. Additionally, the circumferential flange-like edge segments 240 and 340 are joined in the same plane, allowing the joining process (e.g., welding) to be completed in a short cycle time.

[0028] Other features and implementation possibilities of the present invention have been described above.

Claims

1. A method for manufacturing an inter-cell cooling element (500) with bulging compensation function, the method comprising the following steps: - Two metal half-shell elements (200, 300) are provided, each half-shell element being designed to have a closed channel structure (220, 320) on its inner side. - Align the half-shell components (200, 300) so that their inner surfaces face each other, and place the compression plug (400) between the half-shell components (200, 300); - The half-shell elements (200, 300) are connected to each other by joining the half-shell elements together along the edge segments (240, 340).

2. The method of claim 1, wherein, The half-shell components (200, 300) are bonded, brazed, fused and / or crimped together along their edge segments (240, 340).

3. The method according to any of the preceding claims, characterized in that, The method also includes preliminary steps: - Provide extruded profiles, especially aluminum extruded profiles, having flat sides and sides configured to have raised cavities (110); - Take two extruded profile segments (100) and further process the extruded profile segments (100) into semi-shell components (200, 300), especially by cutting, machining and / or forming.

4. The method of claim 3, wherein, Further processing of the extruded profile segment (100) includes manufacturing distribution areas (231, 331) and collection areas (232, 332).

5. The method according to claim 3 or 4, characterized in that, Further processing of the extruded profile section (100) includes: installing cooling medium connection parts (261, 262).

6. The method of claim 3, 4 or 5, characterized in that, Further processing of the extruded profile segment (100) includes: manufacturing surrounding flange-shaped edge segments (240, 340).

7. The method according to any of the preceding claims, characterized in that, The channel structure (220, 320) has parallel cooling channels (221, 321) inside the half-shell elements (200, 300), which are staggered after the half-shell elements (200, 300) are connected.

8. The method according to any of the preceding claims, characterized in that, The compression insert (400) is made of a material that can be elastically compressed, especially as a cutting part for the corresponding blank.

9. The method according to any of the preceding claims, characterized in that, The manufactured inter-cell cooling element (500) was subjected to a sealing test, especially under external pressure loading.

10. An application of a cell cooling element (500) manufactured according to the method of any one of the preceding claims for cooling cells in a power battery, wherein, Inter-cell cooling elements (500) are arranged between the relevant cells.

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