Detection system for detecting a deformation of a battery, motor vehicle and method for manufacturing a detection system

Abstract

The present invention relates to a detection system (10) for detecting deformation (D) of a battery, wherein the detection system includes a housing component (20, 22) for a battery housing (54) and a detection device (12) having detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) by means of which deformation can be detected. Hereinafter, the housing component is designed as a support frame (22) for receiving a cell array (34), wherein the support frame includes a first long side (24) and a second long side (26), and a first high side (28) and a second high side (30), wherein the first long side and the second long side, as well as the first high side and the second high side, enclose a receiving area (32) for receiving the cell array, wherein the detection elements are arranged on the first long side and / or the second long side, and / or the detection elements are arranged in the first long side and / or the second long side.

Description

Technical Field

[0001] This invention relates to a detection system for detecting deformation / deformation of a battery, wherein the detection system includes a housing component for the battery casing and a detection device having a detection element disposed on and / or within the housing component, by means of which deformation can be detected. Furthermore, this invention relates to a motor vehicle having such a detection system and a method for manufacturing the detection system. Background Technology

[0002] Modern batteries or battery systems are typically mounted on the underside of motor vehicles. Therefore, these battery systems are very close to the roadway. Objects that may be present in the roadway pose a potential risk. If a vehicle drives over an excessively large object, it could crush the battery and damage the battery or individual cells. In extreme cases, this could even cause the battery to catch fire, potentially leading to a vehicle fire. Therefore, it is highly advantageous to have a detection system that can detect deformation in the battery area.

[0003] DE 10 2020 119 287 A1 describes a vehicle with a battery, comprising a battery casing, a plurality of battery cells housed therein, and a protective plate disposed on one side of the battery. Furthermore, the mounting system includes damage detection equipment having a damage indicator disposed on and embedded in the protective plate. The protective plate may be designed as a multi-layered structure, and multiple strain gauges may be embedded therein.

[0004] DE 10 2021 109 135 A1 describes a deformation detection device that includes strain measuring elements constructed on an outer shell structural element of a accumulator system's housing structure to obtain changes in electrical operating characteristic parameters.

[0005] Motor vehicle batteries, such as high-voltage batteries, are typically very large. Therefore, such testing equipment usually needs to be designed accordingly to cover a large area and requires complex mounting on or around the battery casing. Summary of the Invention

[0006] The object of the present invention is to provide a detection system, a motor vehicle, and a method that can provide the highest possible safety in relation to batteries, while also allowing for the simplest possible manufacture and assembly.

[0007] This objective is achieved by a detection system, vehicle, and method having the features described in the respective independent claims. Advantageous embodiments of the invention are the subject of the dependent claims, the description, and the drawings.

[0008] The detection system for detecting battery deformation according to the present invention includes a housing component for a battery casing and a detection device having a detection element disposed on and / or within the housing component, by means of which deformation can be detected. Here, the housing component is designed as a support frame for receiving a cell array / cell group having at least one cell. The support frame includes a first long side / flattened side and a second long side opposite in a first direction, and a first high side / side along the height direction and a second high side opposite in a second direction. The first and second long sides, as well as the first and second high sides, enclose a receiving area for receiving the cell array. The detection element is disposed on the first and / or second long sides, and / or within the first and / or second long sides.

[0009] This configuration of the detection system offers several advantages: Firstly, the support frame enclosing the receiving area for accommodating the battery cell array provides very high mechanical protection for the cell array. Furthermore, this support frame makes the manufacture of the battery casing or battery particularly advantageous and simple. For example, the battery casing can consist of multiple such support frames stacked on top of each other in a third-order orientation. This battery casing can then optionally be additionally received within a general battery casing to further enhance protection. Here, each of these support frames can be designed with a detection element on at least one and / or in at least one long side. Because the detection element is arranged on at least one of the two long sides of this support frame, when the battery casing is assembled from multiple such support frames, a large-area detection capability for detecting deformation is automatically created without requiring the detection element itself to be constructed or assembled to a particularly large area. By arranging the detection element on at least one and / or in at least one long side of the two long sides of the support frame, the possibility of support frame-specific deformation detection is also advantageously realized. This, in turn, enables position-resolved deformation detection based on support frame-specific detection when the battery casing includes multiple such support frames with detection elements arranged therein or on them. By constructing this support frame and combining it with the detection elements, battery safety can be significantly improved, and it also provides particularly simple and advantageous manufacturing possibilities for the detection system, especially the detection system for the entire battery.

[0010] The first and second directions mentioned above can be perpendicular to each other. In particular, the third direction mentioned above can also be perpendicular to the first and second directions. The two long sides of the load-bearing frame can extend longitudinally in the second direction, and the two high sides of the load-bearing frame can extend longitudinally in the first direction. Therefore, the two long sides and the two high sides can together form a substantially rectangular frame. Furthermore, the long sides and high sides can have width in the third direction, particularly the aforementioned third direction. The length of the long side in the second direction can be greater than the height of the high side in the first direction. Moreover, the length of the long side in the second direction and the height of the high side in the first direction can both be greater than the width of the long side and the high side in the third direction.

[0011] A cell array receptacle within the receiving area of ​​the support frame preferably comprises not only a single cell but also multiple cells. In other words, the receiving area can be designed to receive a cell array having multiple cells arranged side-by-side in a second direction. The cells can be, for example, prismatic cells. Each cell can have two sides with the largest area. The cells in the cell array are preferably arranged side-by-side such that their sides with the largest area do not face each other. Specifically, each cell can include two additional, equally opposed sides, on which cell electrodes are arranged respectively. The cells in the cell array can be arranged relative to each other such that their cell electrodes face each other. This enables easy electrical connection between the cells.

[0012] Regarding the intended installation location in the motor vehicle, the second direction can correspond to the vehicle height direction. Referring to this installation location, for example, the first long side of the load-bearing frame can be located below the second long side. In this case, it is highly advantageous if the detection element is arranged on or in the first long side, as this first long side would be exposed to a significantly higher risk of deformation due to its closer proximity to the roadway. Nevertheless, additionally or alternatively, the detection element or another detection element can also be arranged on and / or in the second long side. This allows, for example, the detection of particularly severe deformations.

[0013] Typically, a detection device may also include multiple detection elements. These detection elements may be the same or different, or partially the same and partially different. In particular, the implementation methods of the detection elements and / or their positioning described above and below can be combined with each other in any way.

[0014] Furthermore, the detection element can be configured to extend across a large portion of the length of the first and / or second long side, or even almost the entire length or the whole length of the first and / or second long side. In this way, deformation in the entire region of the first and / or second long side can be reliably detected. It is also conceivable to arrange multiple detection elements along and / or within the length of the relevant long side. Similarly, deformation across the entire long side can be detected accordingly.

[0015] The deformation that can be detected by means of a detection element can be the deformation of the load-bearing frame, especially the deformation on and / or on the long side where the detection element is arranged. However, this is not necessarily required. For example, the deformation of a component located below the load-bearing frame in a second direction—such as a protective plate, which will be described later—towards the load-bearing frame can also be detected by means of a detection element. In this case, the load-bearing frame itself does not necessarily deform.

[0016] The detection device can be designed to output a signal when or once deformation is detected by means of a detection element. Based on this signal, a fault message or risk warning can be issued, or other measures can be initiated or triggered.

[0017] According to another advantageous design of the invention, the detection system has a cell module comprising a support frame. Furthermore, the cell module may have plates, particularly cooling plates, arranged on the support frame and defining a receiving area in a third direction, particularly the aforementioned third direction. Additionally or alternatively, the cell module may also include a row of cells arranged in the receiving area. If the cell module comprises plates and a row of cells, at least one cell preferably faces the plate with one of its largest side areas, particularly resting against the plate.

[0018] For example, if multiple such cell modules are arranged side-by-side in a third-direction orientation, the respective receiving areas of each support frame are separated by plates arranged on each support frame. This can further improve the stability of the entire system. Furthermore, it is advantageous to integrate one or more additional functions into such plates, for example, if the plate is designed as a cooling plate, then a cooling function is integrated. Such a cooling plate may, for example, include at least one cooling channel through which coolant can flow. Thus, in the case of multiple such cell modules arranged side-by-side in a third-direction orientation, inter-cell cooling can be advantageously provided, through which each cell row, and in particular each cell in each cell row, can be cooled on both sides of its side with the largest area. Therefore, it is also highly advantageous that at least one cell of a cell row faces and abuts against the plate with its side with the largest area, particularly in a planar form. Alternatively or additionally, such a plate can also act as a cell separating element. Through this plate, cell rows arranged side-by-side in a third-direction orientation can also be spatially separated and / or electrically and / or thermally insulated, for example.

[0019] The construction of this cell module, in turn, makes the battery construction particularly simple and advantageous, as the battery can be composed of multiple such cell modules. These multiple cell modules can then be arranged side-by-side or stacked, for example, simply in a third-order orientation. The cell modules can also be secured to each other by their respective support frames, such as by interlocking, and / or by tensioning devices that tension the multiple cell modules together.

[0020] The design of other components involving the support frame, cell array, or cell module can also be similarly applied to other optional support frames, cell arrays, or other components of the cell module, or to other optional cell modules.

[0021] If the plate is designed as a cooling plate, it is very advantageous in terms of structural space that the connectors for the coolant inlet and outlet are located in the end regions of the cooling plate, which define the cooling plate in the second direction and / or opposite to the second direction.

[0022] According to another advantageous design of the invention, the testing system includes a battery housing comprising a plurality of support frames arranged side-by-side in a third direction, particularly in the aforementioned third direction, and wherein the testing system comprises a plurality of cell modules arranged side-by-side in the third direction. Therefore, this enables a particularly simple and advantageous construction of the battery housing and the battery as a whole.

[0023] According to another advantageous embodiment of the invention, detection elements of a detection device are arranged on and / or in the first and / or second long sides of one or all of the load-bearing frames. The detection device is designed to determine, upon detecting deformation, which load-bearing frames are affected by the deformation based on which detection elements detected the deformation. For example, the detection device may include a control device designed to evaluate the detection signals provided by the respective detection elements. Here, the control device may include a distributor that distributes each detection element to the load-bearing frames on which or in which the detection elements are mounted. Based on which detection element detected the deformation, the control device can determine, based on the distributor, which load-bearing frames(s) are correspondingly affected by the deformation. This advantageously achieves position-resolved detection of the deformation. In other words, the location of the deformation can be determined, at least precisely down to the load-bearing frame. Depending on the configuration of the detection elements, the location of the deformation can also be determined more precisely, for example, at which location on the load-bearing frame, in a second direction.

[0024] If multiple support frames are equipped with their own detection elements, they can be connected, for example, to the same control device for evaluating the detection signal. Furthermore, the detection element itself does not necessarily provide this detection signal. Such a detection element can be part of a higher-level detection unit assigned to the support frame. This detection unit can, for example, include another element that is not directly arranged on the support frame, by means of which deformation can be detected in combination with the detection element. This element can also be connected to the control device, particularly additionally or alternatively connected to the detection element itself, and specifically provides the detection signal therein.

[0025] According to another advantageous design of the invention, the detection element is arranged on the inner side of the first long side and / or the second long side facing the receiving area and / or on the outer side of the first long side and / or the second long side facing away from the receiving area. It is also possible that one detection element is arranged on the inner side and the other on the outer side. By arranging the detection element on the inner or outer side, different types of deformation can be detected. For example, a less severe deformation can be detected by means of a detection element arranged on the outer side, which may not necessarily cause deformation of the long side itself, but only, for example, contact between the protective plate and the load-bearing frame or its first long side. In contrast, a detection element arranged on the inner side can identify, for example, more severe deformation, which may cause deformation of the load-bearing frame itself, particularly deformation of the long side of the load-bearing frame on which at least the detection element is arranged.

[0026] Furthermore, it is advantageous that the battery cell array is arranged in the receiving area of ​​the support frame such that the battery cell array, particularly at least one cell or multiple cells contained in the battery cell array, is spaced from the first long side of the support frame in a first direction. Therefore, a gap can exist between the first long side of the support frame and the battery cell array. This can be easily achieved, particularly by bonding the cells of the battery cell array to the aforementioned plate. This allows for precise positioning of the cells in the receiving area, thus making it very easy to provide such a gap. Bonding also results in particularly good thermal connection between the cells and the plate, which is especially advantageous when the plate is also designed as a cooling plate.

[0027] This gap allows the detection element to be easily positioned on the inner side of the relevant long side of the frame. Furthermore, it can then be easily determined with the help of the detection element that contact has been established with the cell received in the receiving area, even with such a large deformation on the relevant long side.

[0028] According to another advantageous design of the invention, the support frame is made of plastic. This also includes materials containing plastic as well as other additional components such as reinforcing fibers, for example, fiber-reinforced plastics and / or plastic composites. This makes the manufacture of the frame particularly advantageous and simple. In particular, it makes the manufacture and construction of the support frame as part of the battery cell module, as well as the integrated arrangement of the detection elements, particularly simple. The support frame can be manufactured, for example, by means of an injection molding process. In particular, it can be injection molded onto the aforementioned plate on the edge side within the scope of such an injection molding process. Thus, the support frame can simultaneously serve as an additional seal for the cooling plate. Furthermore, the support frame thus automatically engages with the plate, eliminating the need for a separate engagement-or assembly step. It is particularly advantageous here that, since the support frame is made of plastic, the detection elements can also be arranged on and / or within the support frame during the process of the support frame being made of plastic, for example by means of an injection molding process. However, the detection elements can also be engaged to the manufactured support frame in a separate assembly step.

[0029] According to another advantageous design of the invention, the sensing element is designed as a strain gauge, and is particularly at least partially embedded in the plastic of the support frame. A portion of the strain gauge, such as a connecting element, can be arranged on the surface of the support frame. Through this connecting element, the strain gauge can be connected, for example, to the aforementioned control device. In this way, i.e., the strain gauge is at least partially embedded in the plastic of the support frame, the strain gauge can be very easily fixed to or within the support frame. Therefore, the arrangement of the strain gauge on the support frame and the construction of the support frame can be carried out in a common manufacturing step. In particular, when the sensing element is designed as a strain gauge, it can be easily fixed to and / or within the support frame, extending across most, almost the entire, or the entire length of the relevant long side of the support frame. However, typically, such a strain gauge can also be arranged entirely on the surface of the support frame, for example, on the inner and / or outer side of at least one long side. Embedding in the plastic also provides additional protection for the sensing element against environmental factors such as dirt or moisture.

[0030] With the aid of such a strain gauge, the strain of the strain gauge can be detected via a corresponding signal, for example, provided at the aforementioned connecting element. Here, with the aid of such a signal, deformation of the strain gauge and therefore the long side on which the strain gauge is arranged can be detected and / or the amount of deformation can be detected, which in turn depends on the strain of the strain gauge. Based on the strain of the strain gauge, position identification can also be optimally achieved, through which the location of the deformation can be approximately determined. For example, the strain resulting from deformation in the central region of the strain gauge is less than that when such deformation occurs away from the center of the strain gauge (especially in the second direction).

[0031] Therefore, by using these mounted strain gauges, potential deformations, especially those on the long sides of the load-bearing frame, can be monitored or detected. Once the strain gauges detect values ​​exceeding a predetermined threshold, a fault message or risk warning can be issued, or other measures can be initiated or triggered.

[0032] Alternatively, such strain gauges can be arranged on the surface of the supporting frame, for example, on the inside or outside of the relevant long side.

[0033] According to another advantageous design of the invention, the detection element is designed as a pressure sensor membrane, wherein the detection device is designed to acquire the magnitude and / or location of the pressure acting on the pressure sensor membrane. With this pressure sensor membrane, deformation can also preferably be detected, particularly in components near the load-bearing frame, such as deformation of the protective plate or the load-bearing frame itself. The pressure sensor membrane can be designed to acquire the pressure acting on it in a position-resolved manner. In other words, corresponding pressures can be acquired in different regions of the pressure sensor membrane. If the pressure acquired in a certain region exceeds a threshold, deformation can be considered detected in that region. Thus, advantageously, in the event of deformation, not only can the deformation be detected based on the corresponding pressure acting on the pressure sensor membrane, but also by the magnitude of the pressure, and / or by the location of the deformation through the region of the pressure sensor membrane where high pressure is acquired.

[0034] Optionally, the pressure sensor diaphragm may also extend across multiple support frames, for example, extending across multiple first and / or second long sides of multiple support frames. However, it is advantageous to place the pressure sensor diaphragm on the respective support frame, particularly on at least one of the two long sides of the respective support frame, in that the support frame can be more easily assembled and combined into a battery cell module or battery casing.

[0035] According to another advantageous design of the invention, the detection element is designed as an airbag / cushion, wherein the detection device is designed to acquire the magnitude of the pressure present in the airbag, and / or to acquire the magnitude of the pressure present in the airbag when the pressure present in the airbag exceeds and / or falls below a preset pressure threshold. When the pressure present in the airbag exceeds and / or falls below the preset pressure threshold, deformation or damage can be considered detected.

[0036] For example, an airbag can be filled with air as a gas. However, it can also contain other gases. Here, "gas" should be understood as a substance that is gaseous under standard or normal conditions.

[0037] Therefore, such an airbag can have a gas-filled outer shell. A predetermined internal pressure of the airbag under normal conditions can be defined. For example, the airbag can be positioned on the inner side of one of the long sides, thus located between that long side and the battery cell array. Deformation of that long side of the battery cell array correspondingly causes compression of the airbag, resulting in an increase in pressure within the airbag. This pressure increase indicates that deformation has occurred. The amount of pressure increase can correspondingly provide information about the amount of deformation. A detection device can accordingly acquire or monitor the pressure present in the airbag, and once the pressure exceeds a predetermined limit, deformation can be considered detected.

[0038] The airbag can also be positioned on the outer side of the corresponding long side, for example, between the long side and the detection system protective plate (e.g., the bottom protective plate). If the bottom protective plate deforms sufficiently towards the frame, this will also cause corresponding compression of the airbag, as described above, which can be detected. The detection device can also accordingly include a pressure sensor designed to acquire the pressure present in the airbag. Deformation can advantageously be detected based on the pressure, and optionally, the amount of deformation can also be detected. Embedding the airbag in the corresponding long side of the supporting frame is also possible, although less preferred.

[0039] In some cases, the pressure present in the airbag below a preset pressure threshold can also be used for deformation detection. For example, if the deformation of components acting on the airbag (such as the protective plate and / or the relevant long side of the load-bearing frame) intensifies to the point of causing airbag damage, thereby causing gas to escape from the airbag, this can also be detected by a pressure sensor, and it can be inferred that deformation has occurred, and / or that the airbag may be defective or damaged.

[0040] According to another advantageous design of the invention, the detection element is designed as a first contact element, and the detection device includes a second contact element, wherein the detection device is designed to detect contact between the first contact element and the second contact element, and to detect deformation based on the detection of contact. The second contact element may be arranged on or provided by a component different from the support frame. Several possibilities exist for this. For example, the second contact element may be arranged on or provided by a portion of at least one battery cell. Additionally or alternatively, the contact element may also be arranged on a protective plate, particularly a bottom protective device, which is arranged on the side of the first long side of the support frame opposite the receiving area, or provided by a portion of the protective plate. Thus, in the first case, contact between at least one battery cell and the relevant long side of the support frame can be detected. In the second case, contact between the protective plate and the relevant long side of the support frame can be detected. In both cases, the presence of deformation can be detected by such contact. In the first case, the deformation involves at least the long side of the support frame, and in the second case, at least the deformation of the protective plate. Slight deformation will not consequently lead to contact. Therefore, with this configuration of the detection device, it is possible to distinguish between slight deformations that would not be detected at all and severe deformations that at least cause the relevant parts to come into contact.

[0041] In addition, there are several different feasible methods for detecting such contact. According to an advantageous design, the first contact element and the second contact element are each part of a conductor loop that is electrically closed when contact occurs between the first and second contact elements. Thus, the first contact element is, for example, part of a first conductor loop portion of the conductor loop, and the second contact element is part of a second conductor loop portion of the conductor loop, forming such a conductor loop when the first and second contact elements contact each other. For example, contact can be detected by measuring the current and / or resistance at the ends of the conductor loop. A voltage can be applied to the ends of the conductor loop. As long as there is no current flow in the conductor loop, it is open, that is, the first and second contact elements are not in contact. Once current flow is detected, contact between the first and second contact elements can be considered detected. The contact elements are accordingly made of conductive material. For example, if the cell housing of at least one battery cell is itself made of a metallic material, a portion of it can be used as such a second contact element. The cell housing can be electrically insulated outwards, for example, covered by an electrically insulating layer. In the area where the second contact element is provided, this insulating layer can be exposed. Therefore, a portion of the conductor circuit, particularly the second conductor circuit, is formed by a part of the cell housing itself of at least one cell. However, a separate contact element can also be provided as the second contact element, arranged on the cell or, alternatively, on the protective plate. If the protective plate is designed to be locally conductive, that portion itself can also serve as the second contact element, eliminating the need for a separate contact element.

[0042] According to another advantageous design of the invention, one of the two contact elements is designed as a switch, particularly a piezoelectric switch, and the detection device is designed to detect contact between the first and second contact elements when the switch is actuated by the other of the two contact elements. Contact between the other of the two contact elements and the switch causes the switch to be triggered, which can be detected by the detection device as a corresponding switch signal. For a piezoelectric switch, the deformation of at least a portion of the piezoelectric switch caused by this contact will generate a voltage between the lead elements of the piezoelectric switch, which can be detected by the detection device. Therefore, if such a voltage or a voltage of a predetermined amplitude is detected, deformation can again be inferred. When such contact elements are designed as switches, multiple such switches, particularly piezoelectric switches, can also be provided for each support frame. These switches can be distributed along the length of the support frame in a second direction. This also advantageously achieves reliable deformation detection across the entire or almost the entire length of the support frame.

[0043] In addition, the detection system may include a battery, which in turn includes one or more cell modules. The battery may be designed, for example, as a high-voltage battery. The battery may include a battery casing that includes a support frame for the individual cell modules.

[0044] Furthermore, the present invention also relates to a motor vehicle having a detection system according to the present invention or one of its design schemes.

[0045] The motor vehicle according to the invention is preferably designed as an automobile, particularly as a passenger car or commercial vehicle, or as a bus or motorcycle. The motor vehicle may be designed as an electric vehicle, for example. The battery may be located in the bottom area of ​​the motor vehicle.

[0046] Furthermore, the present invention relates to a method for manufacturing a detection system for detecting deformation, wherein a housing member for a battery cell housing is provided, and a detection device having a detection element by means of which deformation can be detected, wherein the detection element is arranged on or within the housing member. Here, as the housing member, a support frame is provided, the support frame being designed to receive a battery cell array having at least one battery cell, wherein the support frame includes a first long side and a second long side opposite in a first direction, and a first high side and a second high side opposite in a second direction, wherein the first long side and the second long side, as well as the first high side and the second high side, enclose a receiving area for receiving the battery cell array, wherein the detection element is arranged on the first long side and / or the second long side, and / or arranged within the first long side and / or the second long side.

[0047] The advantages described for the detection system and its design according to the present invention also apply to the method according to the present invention.

[0048] The support frame can be provided or constructed using the injection molding process as described above. In particular, the support frame can be injection molded at least partially or completely around the edge of the plate (especially the aforementioned cooling plate) using the injection molding process. Optionally, in the injection molding process, at least a portion of the sensing element can also be embedded in the plastic of the support frame. It is particularly advantageous that the sensing element is designed, for example, as a strain gauge.

[0049] In the process of manufacturing the testing system, batteries comprising multiple support frames, particularly multiple cell modules, can also be manufactured. In manufacturing such batteries or testing systems, multiple support frames and testing elements can therefore be provided, wherein at least one testing element is arranged in and / or on each support frame, particularly on and / or on at least one long side. Furthermore, after arranging the testing elements, the support frames are arranged side-by-side, particularly stacked, in a third-party upward direction. Before arranging or stacking the support frames, cell arrays having at least one cell can be loaded into the respective support frames. In other words, multiple cell modules can be manufactured first, designed such that, before assembling these cell modules, the testing elements have been integrated into or arranged on the relevant long side of the respective support frame. Therefore, after manufacturing or providing multiple cell modules, they can be arranged side-by-side or stacked in a third-party upward direction. Here, the support frames can be secured to each other after stacking, for example, by clips and / or tensioning with tension bands.

[0050] The present invention also includes improvements to the method according to the invention, which have features related to improvements to the detection system according to the invention. Therefore, corresponding improvements to the method according to the invention will not be described herein.

[0051] The detection device, particularly the control device included in the detection device, may have a data processing device or a processor device (processor circuit) configured to detect deformation based on a detection signal provided on the detection device by means of a detection element. For this purpose, the processor device may include at least one microprocessor and / or at least one microcontroller and / or at least one FPGA (Field-Programmable Gate Array) and / or at least one DSP (Digital Signal Processor). As a microprocessor, a CPU (Central Processing Unit), GPU (Graphics Processing Unit), or NPU (Neural Processing Unit) may be used accordingly. Furthermore, the processor device may have program code configured to detect deformation based on the detection signal provided on the detection device by means of a detection element when executed by the processor device. The program code may be stored in the data memory of the processor device. The processor device may be based, for example, on at least one circuit board and / or at least one SoC (System-on-Chip).

[0052] The present invention also includes feature combinations of the described embodiments. Therefore, the present invention also includes implementations having multiple feature combinations of the described embodiments, provided that these implementations are not described as mutually exclusive. Attached Figure Description

[0053] Embodiments of the present invention are described below. The figures show:

[0054] Figure 1 An exploded schematic diagram of a detection system according to an embodiment of the present invention is shown;

[0055] Figure 2 A schematic perspective view of a battery cell array is shown in a detection system according to an embodiment of the present invention;

[0056] Figure 3 A schematic perspective view of a portion of a battery in a detection system according to an embodiment of the present invention is shown;

[0057] Figure 4 A schematic cross-sectional view of a detection system according to an embodiment of the present invention, together with a battery under normal and deformed conditions, is shown.

[0058] Figure 5 A schematic cross-sectional view of a detection system together with strain gauges according to an embodiment of the present invention is shown;

[0059] Figure 6 A schematic cross-sectional view of a detection system according to an embodiment of the present invention, together with a contact circuit, and a battery in normal and deformed conditions, is shown; and

[0060] Figure 7 A schematic cross-sectional view of a detection system, together with an airbag and a piezoelectric switch, is shown according to another embodiment of the present invention. Detailed Implementation

[0061] The embodiments described below are preferred embodiments of the present invention. In the embodiments, the components described are individual, independent features of the present invention, and these features also independently improve the present invention. Therefore, this disclosure should also include feature combinations different from the feature combinations of the illustrated embodiments. Furthermore, the embodiments can also be supplemented by other features among the features already described in the present invention.

[0062] In the accompanying drawings, the same reference numerals denote elements that have the same function.

[0063] Figure 1 A schematic exploded view of a detection system 10 according to an embodiment of the present invention is shown. The detection system 10 includes a detection device 12, which in turn includes a detection element 14, which in this example is designed as a strain gauge 16. Furthermore, the detection device 12 also includes a control device 18, which in this example is coupled to the detection element 14 and designed to evaluate the signals provided by the detection element 14 and detect deformation D based on these signals (see [reference]). Figure 4 ).

[0064] The detection system 10 also includes a housing 20 in the form of a support frame 22. The support frame 22 includes two long sides 24, 26 and two high sides 28, 30. Here, the long sides 24, 26 and the high sides 28, 30 enclose a receiving area 32 for receiving at least one and currently multiple battery cells 36 (see...). Figure 2 The battery cell array 34. Here, the long sides 24, 26 are opposed in the z-direction shown, also referred to previously as the first direction, and correspond to the vehicle height direction relative to the predetermined installation position in the motor vehicle. The high sides 28, 30 are opposed in the x-direction shown, also referred to previously as the second direction. The receiving area 32 in the y-direction shown (also referred to previously as the third direction) is defined by a plate 38 also included in the detection system 10, which in this example is designed as a cooling plate 40. The cooling plate 40 may be designed, for example, as an aluminum profile or generally as a metal profile, or as in this example, as a metal cooling plate 40 that may include two or more housings joined together.

[0065] Furthermore, it is highly advantageous that the supporting frame 22 is not manufactured as a separate component and then joined to the plate 38, but rather that the frame 22 is formed as a plastic frame by overmolding the plate 38. Therefore, the frame 22 can be injection molded onto the edge 38a surrounding the plate 38. In the case where the cooling plate 40 is formed of multiple shells that join together, the edge 38a can be formed by a joint area 42 defining at least two shells of the cooling plate 40 in the y-direction and opposite to the y-direction. Thus, the overmolded frame 22 provides additional sealing to the joint area 42.

[0066] Furthermore, corresponding connecting elements 44 can be formed via the frame 22 for introducing coolant into and discharging coolant from the cooling plate 40. The plate can be designed to have corresponding inlet and outlet openings 46.

[0067] A cell module 48 can be provided by combining the frame 22, particularly with the detection element 14, the plate 38, and especially with the cell array 34 received in the receiving area 32. Battery 50 (see...) Figure 3 The battery cell module 48 can be easily constructed by stacking multiple such battery cell modules 48 on top of each other in the y-direction. Such battery cell module 48 can also be referred to as battery cell electrode 48.

[0068] Here, the detection element 14 is advantageously arranged on at least one long side 24, 26, or at least partially integrated into one of the long side 24, 26. It is assumed below that the detection element 14 is arranged on and / or in the lower long side 24. However, the detection element can also be arranged in the upper long side 26. Furthermore, the detection system 10 may also include detection elements 14 with different configurations, or multiple detection elements 14 with identical configurations arranged at different locations on one or more long side 24, 26. In other words, the embodiments regarding the detection element 14 and its positioning described above and below can be combined with each other in any manner.

[0069] The lower long side 24 has an inner side 24a facing the receiving area 32 and an outer side 24b facing away from the receiving area 32. The detection element 14 can be arranged, for example, on the outer side 24b, or on the inner side 24a, or partially or almost completely embedded in the plastic of the long side 24. This allows the detection element 14 to be advantageously integrated into the frame 22 during the molding process of the frame 22, for example, in an injection molding process. Here, the detection element 14 can be embedded, for example, in addition to the plastic connecting the region 14a and the frame 22.

[0070] Figure 2 A schematic perspective view of a cell array 34 for a detection system 10 according to an embodiment of the present invention is shown. In this example, the cell array 34 includes a plurality of cells 36, which are designed, for example, as prismatic cells. Here, each cell 36 includes two opposing sides 36a with the largest area in the y-direction. Furthermore, each cell 36 also includes two additional opposing sides 36b in the x-direction. A cell electrode 52 is arranged on each side 36b. The cells 36 of the same cell array 34 are positioned relative to each other such that their cell electrodes 52 face each other. When such a cell array 34 is arranged as intended in a receiving area 32, one of the largest sides 36a of the corresponding cell 36 abuts against, for example, a plate 38, for example, bonded to the plate. Thus, the cell array 34 can be advantageously positioned and secured in the receiving area 32. When multiple such battery cell modules 48 are arranged side by side in the y direction, the two largest side surfaces 36a of the corresponding battery cell 36 are respectively adjacent to such a plate 38.

[0071] Figure 3 A schematic perspective view of a portion of a battery 50 as part of a detection system 10, according to an embodiment of the present invention, is shown. Here, the battery 50 includes a plurality of cell modules 48, which can be constructed as previously described. The long sides 24, 26 (of which only the upper long side 26 is currently visible) can form a closing cover for the battery casing 54. The same applies to the lower long side 24.

[0072] Figure 4 A schematic cross-sectional view of a detection system 10 together with a battery 50 according to an embodiment of the present invention is shown. Here, the detection system 10 is... Figure 4 The image above shows the product in its normal, undeformed state. Figure 4 The following diagram illustrates the case where deformation D occurs. The battery 50, and particularly the detection system 10, can be constructed again as previously described. The cell 36 or cell array 34 can be positioned in the receiving area 32 such that the cell 36 has a distance A from the lower long side 24. This allows the detection element 14 (currently redesigned as a strain gauge 16, but could also be designed in other forms as described later) to be integrated not only into the long side 24 as illustrated, but also positioned, for example, on its inner side 24a, and further positioned between the long side 24 and the cell array 34. Furthermore, the strain gauge 16 or other constructed detection element 14 can also be arranged on the outer side 24b of the long side 24.

[0073] Furthermore, the detection system 10 (as shown here) may also include a protective plate 56, particularly a bottom protective device 56. This bottom protective device is arranged below the battery 50 in the z-direction. The bottom protective device 56 has the same spacing in the z-direction as the battery 50, particularly the long side 24 of the frame 22.

[0074] Furthermore, the battery 50 is arranged in an additional overall housing 57, which may include a frame 58 and a cover plate 62. The battery 50 is received in a receiving space 60 of the overall housing 57.

[0075] exist Figure 4 The image below illustrates a bollard impact event that causes the bottom protective device 56 to deform (D) toward the battery 50, particularly resulting in deformation (D) of one or more long sides 24, especially the long side 24 currently shown with integrated strain gauges 16. This deformation (D) can be detected accordingly by a signal provided on the control device 18 via the strain gauges 16. The strain of the strain gauges 16 can be detected and / or quantified, for example, by means of the resistance of the strain gauges 16 acquired by the control device 18.

[0076] Figure 5 A schematic diagram of a detection system 10 according to another embodiment of the invention is shown. This detection system can be constructed in particular as described above. It is intended to particularly illustrate the possibility of positional identification of deformation D by means of a plurality of detection elements 14 arranged on and / or within the respective long sides 24 of corresponding support frames 22 arranged side-by-side in the y-direction.

[0077] Furthermore, two different bollard impact events P1 and P2 are shown. In the first case, bollard P1, with deformation D of the bottom protection device 56 (also labeled 56a for better illustration of this first case), impacts one or more load-bearing frames 22 and their detection elements 14 in the first region Y1 (e.g., relatively centrally). In the second case, bollard P2, with deformation D of the bottom protection device 56 (also labeled 56b for better illustration of this second case), impacts one or more load-bearing frames 22 and their detection elements 14 in the second region Y2. Here, the two regions Y1 and Y2 are located differently in the y-direction.

[0078] Depending on which detection element 14 detected the deformation (which can be obtained based on the signal provided by the detection element 14 on the control device 18), it can also be determined in which regions Y1 and Y2 the deformation D occurred.

[0079] Figure 6 A schematic diagram of a detection system 10 according to another embodiment of the present invention is shown, in particular Figure 6 The above is the normal state. Figure 6 The following is a modified version. The detection system 10 can be constructed as previously described, except for the differences described below. In this example, the first detection element 14 is again arranged on the long side 24, in this example on the outer side 24b of the long side 24. The second detection element 14' is arranged on the side of the protective plate 56 facing the battery 50. The two detection elements 14, 14' are opposite each other in the z-direction. In this example, the detection elements 14, 14' are designed as electrical conductors 64 and form portions 66a, 66b of a conductor loop 66, which can have an open state Z1 and a closed state Z2. Under normal conditions, the conductor loop 66 is open. The end 68 of the conductor loop 66 is again connected to the control device 18, which provides a monitoring voltage here. The control device 18 can thus monitor whether there is a possible current flow in the conductor loop 66. As long as there is no current flow, the detection elements 14, 14' are not in contact. In the case of contact K (such as this in Figure 6 As shown below, the monitoring voltage provided by the control device 18 at the end 68 of the conductor circuit 66 causes current to flow through the conductor circuit 66. Therefore, deformation D can also be detected through this contact K. Alternatively or additionally, similarly, the second detection element 14' can be arranged on the underside of the cell 36 of the cell array 34, or provided by the housing portion of the cell 36 itself. In this case, the first detection element 14 can be additionally or alternatively arranged on the inner side 24a of the long side 24 of the associated support frame 22. The contact between the long side 24 and the cell array 34 can also be detected accordingly.

[0080] Figure 7 A schematic cross-sectional view of a detection system 10 according to another embodiment of the invention is shown. Here, the detection system 10 can also be constructed as previously described, except for the differences described below. This is intended to illustrate two other possible implementations of the detection device 12, and in particular the detection element 14. On one hand, the detection element 14 can also be provided in the form of an airbag 70. This airbag includes a housing 72 that surrounds a gas-filled inner cavity 74. In this example, the airbag 70 is arranged between the cell array 34 and the lower long side 24. However, it can also be arranged between the lower long side 24 and the bottom protective device 56. Using a pressure sensor 76 (which can be configured as part of the detection element 14), the control device 18 can detect that the pressure p in the inner cavity 74 exceeds a predetermined threshold. From this, a deformation D can be inferred.

[0081] According to another example, one or more switches 78, particularly piezoelectric switches 78, are provided on the long side 24 of the frame 22 as detection elements 14. These switches can also be connected to the control device 18. In this example, the switches 78 are arranged on the lower side, i.e., the outer side 24b, of the long side 24. One or more switches 78 are actuated by the deformation D of the bottom protection device 56 when the strength is sufficient, which can be detected by the control device 18, thus detecting the deformation D. Accordingly, one or more such switches 78 can also be arranged on the inner side 24a of the long side 24. If the long side 24 is deformed to sufficient strength in the direction of the cell array 34, causing the switch 78 to be actuated by the cell array 34, then the actuation of the corresponding switch 78 is caused accordingly.

[0082] In general, these examples demonstrate how the present invention can provide measures for monitoring damage occurring in battery cell electrodes. The electrode design provides mechanical protection to the battery cell by completely or almost completely surrounding it. Forces acting on the battery from below are guided around the cell by horizontal and vertical components of the frame. Under excessive loads or the presence of point loads, the "electrode," and especially the frame, can potentially fail. Therefore, it is highly advantageous to detect such deformation on and / or within the electrode, for example, on the underside of the electrode, using suitable sensing devices. Similarly, acceleration, deformation, or other damage patterns can also be identified in this way. Thus, each electrode can be equipped with a sensing device, which allows not only the detection of deformation or damage, but also, in particular, the detection of the degree of damage, and especially, at least precisely down to the frame level, the location of the damage. Based on the detection of deformation, a signal can be output. Several deformation identification possibilities exist. For example, possible deformation can be monitored, for example, on the underside, i.e., the lower long side, using installed strain gauges. Once a value exceeding a preset threshold is obtained, a fault message or risk warning can be issued. According to another variant, a signal can be acquired when excessive deformation occurs via a contact circuit between the cell electrode and the cell. This contact circuit can be located either between the bottom protection device and the electrode, or between the electrode (i.e., the frame) and the cell. According to another variant, a pressure sensor diaphragm positioned below the electrode can acquire force input from below. According to yet another variant, an air bladder can be placed between the cell and the electrode, or between the electrode and the bottom protection device. Internal pressure is monitored when the air bladder is compressed. According to yet another variant, a piezoelectric switch can be incorporated to generate current and output a signal upon actuation.

Claims

1. A detection system (10) for detecting the deformation (D) of a battery, wherein, The detection system (10) includes: - Housing components (20, 22) for the battery casing (54), and - A detection device (12) having detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) arranged on and / or in the housing parts (20, 22), by means of which deformation (D) can be detected. Its features are, - The housing components (20, 22) are designed as a load-bearing frame (22), which is designed to receive a cell array (34) having at least one cell (36). - The load-bearing frame (22) includes a first long side (24) and a second long side (26) opposite each other in the first direction (z), and a first high side (28) and a second high side (30) opposite each other in the second direction (x). - The first long side (24) and the second long side (26), as well as the first high side (28) and the second high side (30), enclose a receiving area (32) for receiving the battery cell array (34). - Wherein, the detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are arranged on the first long side (24) and / or the second long side (26), and / or the detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are arranged in the first long side (24) and / or the second long side (26).

2. The detection system (10) according to claim 1. Its features are, The detection system (10) has a cell module (48), which includes a support frame (22). The cell module (48) has the following features: - Plates (38, 40), particularly cooling plates (40), said plates being arranged on the supporting frame (22) and defining a receiving area (32) in a third direction (y), and / or - A cell array (34) arranged in a receiving area (32), wherein at least one cell (36) faces the plate (38, 40) with one of its largest side surfaces (36a), and in particular abuts against the plate.

3. The detection system (10) according to any one of the preceding claims. Its features are, The detection system (10) includes a battery housing (54) comprising a plurality of load-bearing frames (22) arranged side-by-side in a third direction (y), wherein the detection system (10) includes a plurality of cell modules (48) arranged side-by-side in a third direction (y), wherein detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) of the detection device (12) are arranged on and / or in the first long side (24) and / or the second long side (26) of the plurality of or all of the load-bearing frames (22), the detection device (12) being designed to determine which load-bearing frames (22) are affected by deformation (D) based on which detection elements (14, 14'; 16, 66, 66a, 66b) detect deformation (D) in the event of deformation (D).

4. The detection system (10) according to any one of the preceding claims. Its features are, The detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are arranged on the inner side (24a) of the first long side (24) and / or the second long side (26) facing the receiving area (32) and / or on the outer side (24b) of the first long side (24) and / or the second long side (26) away from the receiving area (32).

5. The detection system (10) according to any one of the preceding claims. Its features are, The sensing elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are designed as strain gauges (16), and in particular, the supporting frame (22) is made of plastic, and the sensing elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are at least partially embedded in the plastic.

6. The detection system (10) according to any one of the preceding claims. Its features are, The detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are designed as pressure sensor membranes, wherein the detection device (12) is designed to acquire the magnitude and / or position of the pressure acting on the pressure sensor membrane.

7. The detection system (10) according to any one of the preceding claims. Its features are, The detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are designed as airbags (70), wherein the detection device (12) is designed to obtain the magnitude of the pressure present in the airbag (70), and / or obtain the magnitude of the pressure present in the airbag (70) when the pressure present in the airbag (70) exceeds and / or falls below a preset pressure threshold.

8. The detection system (10) according to any one of the preceding claims. Its features are, The detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are designed as first contact elements (66a, 78), and the detection device (12) includes second contact elements (66b, 36, 56). - The second contact element is arranged on at least one cell (36) or provided by a portion of at least one cell (36); and / or, - The second contact element is arranged on the protective plate (56), particularly on the bottom protective device (56), or provided by a part of the protective plate (56), which is arranged on the side of the first long side (24) of the supporting frame (22) opposite to the receiving area (32); The detection device (12) is designed to detect the contact (K) between the first contact element (66a, 78) and the second contact element (66b, 36, 56), and in particular, - The first contact element (66a) and the second contact element (66b) are each part of a conductor loop (66), which is electrically closed when the first contact element (66a) contacts the second contact element (66b); and / or, - One of the two contact elements (78; 36, 56) is designed as a switch (78), particularly a piezoelectric switch (78), and the detection device (12) is designed to detect the contact (K) between the first contact element (66a) and the second contact element (66b) when the switch (78) is actuated by the other of the two contact elements (78; 36, 56).

9. A motor vehicle having a detection system (10) according to any one of the preceding claims.

10. A method for manufacturing a detection system (10) for detecting deformation (D), - Provide housing parts (20, 22) for the battery housing (54). - A detection device (12) is provided, which has detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) by means of which deformation (D) can be detected. - Arrange the detection elements (14, 14'; 16, 66, 66a, 66b) on and / or within the housing components (20, 22). Its features are, - As housing components (20, 22), a support frame (22) is provided, the support frame being designed to receive a cell array (34) having at least one cell (36). - The load-bearing frame (22) includes a first long side (24) and a second long side (26) opposite each other in the first direction (z), and a first high side (28) and a second high side (30) opposite each other in the second direction (x). - The first long side (24) and the second long side (26), as well as the first high side (28) and the second high side (30), enclose a receiving area (32) for receiving the battery cell array (34). - Wherein, the detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are arranged on the first long side (24) and / or the second long side (26), and / or the detection elements (14, 14'; 16, 66, 66a, 66b, 70, 78) are arranged in the first long side (24) and / or the second long side (26).

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