Battery setup and procedure

Abstract

Battery device (1) for a vehicle (100) that is at least partially electrically powered, comprising a plurality of battery modules (102) each comprising at least one battery cell (103) and at least one receiving device (2) for receiving the battery modules (102), wherein each battery module (102) is connected to the receiving device (2) in at least one contact area (12) for heat conduction, characterized by that at least one heat-conducting element (3) is arranged on at least one battery module (102), which extends into the contact area (12) and beyond this into at least one free area (22) of the battery module (102), and that at least one elastic deformation element (4) is arranged in the free area (22) for pressing the heat-conducting element (3) against the battery module (102). and that the heat-conducting element (3) is arranged on at least one self-adhesive support layer (5). and that the heat conducting element (3) and the deformation element (4) are arranged between the support layer (5) and the battery module (102) and that the support layer (5) and the heat conducting element (3) and the deformation element (4) are joined together in a flexible composite mat (6) and that the deformation element (4) is arranged between the support layer (5) and the heat conducting element (3).

Description

[0001] The present invention relates to a battery device for an at least partially electrically operated vehicle according to the preamble of claim 1 and a method for producing such a battery device according to claim 12.

[0002] The batteries of electric or hybrid vehicles often have battery cells grouped together to form battery modules. Cooling the battery modules is often particularly important, as both the retrieval of stored energy and charging generate considerable heat. Optimal battery temperature control is therefore crucial for reliable and consistent operation.

[0003] Various cooling options for battery modules within a battery have become known in the prior art. Cooling channels are often used for this purpose, which are arranged between the battery modules and run alongside them. However, this leads to a very high consumption of installation space, which is very limited, especially in motor vehicles. Therefore, the cooling channels are often only connected to the battery modules in specific areas. This has the disadvantage, however, that the cooling effect is limited and the battery modules are only cooled in certain places.

[0004] A generic battery device is known from DE 10 2013 021 312 A1,

[0005] In contrast, the object of the present invention is to improve the temperature control of battery modules in a battery device for an at least partially electrically powered vehicle.

[0006] This object is achieved by a battery device having the features of claim 1 and a method for manufacturing the same according to claim 12. Preferred developments are the subject of the dependent claims. Further advantages and features of the present invention will become apparent from the general description and the description of the exemplary embodiment.

[0007] The battery device according to the invention is provided for an at least partially electrically powered vehicle and in particular for an electric vehicle and / or a hybrid vehicle. The battery device according to the invention comprises a plurality of battery modules, each having at least one battery cell. The battery device has at least one receiving device for receiving the battery modules. At least one battery module of the plurality of battery modules is connected to the receiving device in at least one contact region. The contact region is suitable and designed for heat conduction between the battery module and the receiving device. At least one heat-conducting element is arranged on at least one battery module of the plurality of battery modules. The heat-conducting element is partially arranged in the contact region.The heat-conducting element extends partially beyond the contact area into at least one free area of ​​the battery module. At least one elastic deformation element is arranged in the free area. The deformation element is suitable and designed to press the heat-conducting element against the battery module. The heat-conducting element is arranged on at least one self-adhesive carrier layer. The heat-conducting element and the deformation element are arranged between the carrier layer and the battery module. The carrier layer, the heat-conducting element, and the deformation element are joined together in a flexible composite mat. The deformation element is arranged between the carrier layer and the heat-conducting element.

[0008] The battery device according to the invention has many advantages. A significant advantage is that at least one heat-conducting element is provided, which is arranged in the contact area and beyond. The arrangement in the contact area results in particularly good heat transfer from the battery module to the receiving device. Thus, the heat from the battery element can be dissipated particularly efficiently and, for example, dissipated to a cooling device connected to the receiving device. By arranging the heat-conducting element outside the contact area as well, the thermal connection of the battery module is considerably improved. This allows the heat to be dissipated even from areas outside the contact area without these areas having to be directly connected to cooling channels or the like. This allows considerable space savings.Another particular advantage of the battery device according to the invention is the elastic deformation element. This presses the heat-conducting element against the battery module in the free area, significantly improving the thermal connection between the heat-conducting element and the battery module. The arrangement of the deformation element outside the contact area has the advantage that the heat conduction in the contact area is not negatively affected by the deformation element.

[0009] The free area is, in particular, an area in which the battery module has no contacts with the receiving device provided for heat conduction. In particular, no direct contact between the battery module and the receiving device is provided in the free area. The battery module is exposed in the free area, in particular except for the connection of the heat-conducting element and the deformation element. In a properly installed state, the free area is preferably arranged on at least one side surface of the battery module. The side surface is preferably provided between a top side and a bottom side of the battery module. The free area is preferably arranged on at least two opposite side surfaces of the battery module. The free area preferably extends spatially between the battery module and a battery component. The battery component is, for example, the receiving device and, in particular, a carrier element.The free area can also be limited by at least one other battery module.

[0010] The contact area is arranged, in particular, on an underside of the battery module provided in the intended installed state. In particular, no deformation element is provided in the contact area. Preferably, the section of the receiving device located in the contact area is cooled, in particular passively and preferably actively, by a cooling device. For example, a cooling channel is arranged in the contact area of ​​the receiving device.

[0011] The deformation element is preferably arranged on the heat-conducting element. In particular, the heat-conducting element extends between the deformation element and the battery module. The deformation element is arranged, in particular, only on a partial region of the heat-conducting element. In particular, the deformation element does not extend beyond the heat-conducting element. The deformation element is made, in particular, from an elastic material. The deformation element is formed, for example, from a rubber material and / or an elastic plastic material. The deformation element can comprise at least one elastic foam body. For example, the deformation element is designed as a rubber mat.

[0012] Preferably, the deformation element rests against at least one battery component, which serves as at least one abutment for pressing the deformation element against the battery module. Such a configuration has the advantage that the heat-conducting element can be pressed particularly well against the battery module, thus significantly improving the thermal connection. Particularly preferably, at least part of the receiving device is provided as an abutment. It is also possible for at least one other battery module to serve as the abutment.

[0013] The heat-conducting element comprises, in particular, at least one flexible heat-conducting mat. The heat-conducting element can also be designed as a flexible heat-conducting mat. In particular, the heat-conducting mat is designed to be flexible. For example, the heat-conducting mat comprises at least one film and / or at least one woven and / or knitted fabric. The heat-conducting mat can also be made from a laminate made of several materials. The heat-conducting mat particularly preferably comprises at least one metallic material. In particular, a metallic material with particularly high thermal conductivity is provided. The heat-conducting mat can comprise a silicone material and / or a glass fabric and / or a graphite material. A ceramic material is also possible. Such heat-conducting mats offer a cost-effective and reliable thermal connection.

[0014] The heat-conducting element is particularly preferably arranged on at least one carrier layer. The heat-conducting element can also comprise at least one carrier layer. The carrier layer is particularly suitable and designed to fasten the heat-conducting element and the deformation element to the battery module. The carrier element is preferably self-adhesive. The carrier element is designed, for example, as a one-sided adhesive film. In this case, the carrier layer extends in particular beyond the heat-conducting mat. The carrier layer is preferably larger than the heat-conducting element. The carrier layer projects beyond the heat-conducting element on at least one side. The carrier element preferably projects beyond the heat-conducting element on at least two opposite sides. The carrier layer projects beyond the heat-conducting element in particular on all sides of the heat-conducting element.Preferably, the heat-conducting element and the deformation element are arranged between the carrier layer and the battery module. Such a carrier layer enables a particularly simple and reliable fixation of the heat-conducting element to the battery module.

[0015] In an alternative embodiment, a plurality of heat-conducting elements are arranged on at least one common carrier layer. A plurality of deformation elements can also be arranged on at least one common carrier layer. In particular, an equal number of deformation elements and heat-conducting elements are arranged on a common carrier layer. For example, two or three or four or more heat-conducting elements and the associated deformation elements are arranged on a common carrier layer. This enables particularly simple attachment of multiple heat-conducting elements and / or deformation elements to a battery module, since only one carrier layer needs to be mounted and, for example, glued. For example, one of such a common carrier layer is attached to opposite side regions of the battery module.

[0016] In a particularly preferred embodiment, the carrier layer, the heat-conducting element, and the deformation element are combined in a composite mat. The deformation element is arranged, in particular, between the carrier layer and the heat-conducting element. Preferably, regions are provided where the heat-conducting element is arranged directly on the carrier layer. Particularly preferably, the composite mat comprises a heat-conducting element designed as a heat-conducting mat. The composite mat is, in particular, flexible. Such a composite mat is particularly easy to process and enables thermal connection of the battery modules with low manufacturing effort.

[0017] In another particularly preferred embodiment, at least two heat-conducting elements are arranged on the battery module. Each heat-conducting element comprises at least one deformation element. The heat-conducting elements are preferably arranged on opposite sides of the battery module. In particular, the heat-conducting elements extend from the opposite sides to an underside of the battery module. It is also possible to provide three, four, or a plurality of heat-conducting elements. For example, a heat-conducting element can be arranged on several or even on each side of the battery module. Such embodiments offer a cost-effective yet effective improvement in thermal application.

[0018] It is possible for the contact area to be equipped with at least one heat-conducting element. In particular, the contact area is equipped continuously with at least one heat-conducting element. The heat-conducting element can also be arranged only in sections in the contact area. Two or three or a plurality of heat-conducting elements can also be arranged in the contact area. The heat-conducting element is designed in particular as a separate heat-conducting element with its own carrier layer. In this case, the heat-conducting element is preferably equipped without a deformation element in the contact area. Such developments enable a particularly good and, in particular, homogeneous thermal connection of the battery module to an underlying receiving device or carrier plate. A further advantage is that such an arrangement of the heat-conducting element also enables tolerance compensation in the contact area, thereby further improving the thermal connection of the battery module.Separate heat conduction elements with their own support layers without deformation elements can also be provided in other sections of the battery module for thermal connection.

[0019] In another advantageous embodiment, the heat-conducting element extends beyond the contact area and beyond it into at least two free areas of the battery module. For example, such a heat-conducting element connects two or more opposing free areas of a battery module. A common carrier layer can be provided, on which the continuous heat-conducting element and / or the associated deformation elements are arranged. For example, one or more deformation elements are provided on the heat-conducting element or the carrier layer for each of the two opposing free areas.

[0020] It is also possible for the contact area to comprise at least one section in which the battery module is directly connected to the receiving device for heat conduction. Preferably, no heat-conducting element is provided in this section. Such a section is advantageous, for example, where the battery module is mounted directly on a cooled component.

[0021] The receiving device comprises in particular at least one carrier plate. The carrier plate is preferably suitable and designed for fastening the battery modules. In particular, several rows of battery modules are arranged on the carrier plate. The contact area is provided in particular between an underside of the battery module and the carrier plate. It is possible for at least a section of a cooling device to be arranged beneath the carrier plate. For example, at least one cooling channel runs beneath the carrier plate. It is also possible for a cooling plate to be arranged beneath the carrier plate. The carrier plate can also be designed as a cooling plate itself. The battery modules are preferably screwed onto the carrier plate. This has the advantage that the battery modules are pressed particularly well against the carrier plate in the contact area.This also presses the heat-conducting mat onto the carrier plate, thus improving the thermal connection.

[0022] The receiving device comprises at least one support element. The support element is preferably arranged on the support plate. The support element runs in particular at least partially between the battery modules. Preferably, the support element is suitable and designed to serve as an abutment for the deformation element. Preferably, the receiving device comprises a plurality of support elements. For example, cross members and / or longitudinal members are provided. The support elements are designed, for example, as struts and / or profiles. It is possible for the support elements to comprise at least one cooling channel. Preferably, the support elements are fastened to the support plate in particular by their underside. It is particularly preferred for the deformation element to be arranged between the support element and the battery module.Such designs not only achieve particularly good thermal connection but also high stability and rigidity of the battery device.

[0023] It is possible for the deformation element to have a thickness that is greater than the distance between the battery module and the support element in the free area. In this case, without the influence of an external force, the deformation element is particularly oversized compared to the distance between the battery module and the support element. Preferably, the deformation element is arranged between the support element and the battery module in the intended installed state and compressed at least in some areas. This allows tolerances to be compensated particularly well and prevents air spaces that delay heat dissipation.

[0024] The method according to the invention serves to produce a battery device for an at least partially electrically powered vehicle. The battery device comprises at least a plurality of battery modules, each with at least one battery cell. At least one receiving device is provided to which the battery modules are fastened. At least one battery module is connected to the receiving device in at least one contact region for heat conduction. At least one heat-conducting element is arranged on at least one battery module. The heat-conducting element extends into the contact region and beyond this into at least one free region of the battery module. At least one elastic deformation element is arranged in the free region. The deformation element presses the heat-conducting element against the battery module.The method according to the invention comprises the following manufacturing steps: fixing the heat-conducting element and / or the deformation element to the battery module by means of at least one flexible carrier layer, compressing the deformation element, pressing the heat-conducting element onto the battery module and / or onto the receiving device, fastening the battery module to the receiving device.

[0025] The method according to the invention has the advantage that a particularly good thermal connection of the battery modules is achieved with correspondingly low manufacturing effort. Particularly preferably, the heat-conducting element and the deformation element are assembled into a composite mat with a carrier layer that is adhesive on at least one side. The composite mat is, in particular, prefabricated. The composite mat is preferably applied with the area without the deformation element to a side of the battery module intended for the contact area, and in particular to an underside. The composite mat is then preferably placed laterally around the battery module so that the deformation element is arranged in the side area of ​​the battery module. The composite mat is subsequently fixed by adhesive.

[0026] In preferred embodiments, the method comprises fixing the heat-conducting element and / or the deformation element to the battery module by means of at least one flexible support layer. The deformation element is preferably compressed during assembly of the battery modules. In this case, the heat-conducting element is pressed, in particular, against the battery module. The heat-conducting element is also pressed, in particular, against the receiving device and / or a support element. The battery modules are fastened to the receiving device and, in particular, screwed. Screwing has the advantage that the heat-conducting element can be pressed particularly well against the battery module.

[0027] Further advantages and features of the present invention will become apparent from the embodiment which will be explained below with reference to the accompanying figures.

[0028] The figures show: Fig. 1 a schematic bottom view of a vehicle with a battery device according to the invention; Fig. 2 a schematic perspective view of a section of a battery device; Fig. 3 an enlargement of section A from the Fig. 2; Fig. 4 a battery module in a perspective view; and Fig. 5 a composite mat in a sectioned perspective view.

[0029] The Fig. Figure 1 shows the underside of an at least partially electrically powered vehicle 100 with a battery device 1 according to the invention. The vehicle 100 is embodied here as an electric vehicle. The vehicle 100 can also be a hybrid vehicle.

[0030] The battery device 1 supplies an electric drive 105 with energy and is embodied here as an underbody battery, which is arranged, for example, between the sill areas 101 of the vehicle 100. The battery device 1 is operatively connected to power electronics 104. The battery device 1 can also include other components, such as a control device and / or a charger. A cooling device 7 is provided to optimally control the temperature of the battery device 1 during operation and charging processes.

[0031] The battery device 1 comprises a plurality of battery modules 102, each having a plurality of battery cells 103. For clarity, only one cell has been shown as an example. The battery modules 102 are arranged in a receiving device 2. The receiving device 2 here comprises a carrier plate 42 on which transversely and longitudinally extending carrier elements 52 are arranged. The battery modules 102 are arranged in several rows between the carrier elements 52.

[0032] The Fig. 2-5 show an embodiment of a battery device 1 according to the invention. The battery device 1 is manufactured according to the method according to the invention.

[0033] The battery device 1 comprises a receiving device 2 with a carrier plate 42 and carrier elements 52 fastened thereon. A cooling device 7 designed as a cooling plate 17 is provided below the carrier plate 42. At least one cooling medium preferably flows through the cooling plate 17. In particular, a liquid cooling medium is provided. The cooling plate 17 can comprise one or more cooling channels. The battery modules 102 are arranged between the carrier elements 52. The battery modules 102 each have two mounting elements 8 designed as screw connections 18 on their end faces. The battery modules 102 are screwed onto the carrier plate 42 by means of these mounting elements.

[0034] For better thermal connection, two heat-conducting elements 3 are arranged on each of the battery modules 102. The heat-conducting elements 3 are designed here as a flexible heat-conducting mat 13. The heat-conducting elements 3 run in the contact area 12, in which the battery module 102 is thermally connected to the carrier plate 42. A section 120 of the contact area 12 is equipped without a heat-conducting element 3. Here, the underside 112 of the battery modules 102 is directly connected to the carrier plate 42.

[0035] From the contact area 12, the heat-conducting elements 3 extend to a free area 22 provided along the long sides 122. This achieves a thermal connection of the otherwise exposed long sides 122 of the battery modules 102 to the carrier plate 42. To improve the thermal connection of the heat-conducting elements 3 to the battery modules 102 along the long sides 122, a deformation element 4 is arranged in each free area 22.

[0036] The deformation element 4 is elastic and designed, for example, as a rubber mat. The deformation element 4 rests on the support elements 52 designed as abutments 14. This compresses the deformation element 4, pressing the heat-conducting element 3 particularly firmly against the battery modules 102.

[0037] Before assembly, the deformation element has a thickness 24, which is greater than the distance 220 between the support element 52 and the longitudinal side 122 of the battery module 102. As a result, the deformation element 4 has an excess dimension compared to the distance 220 present at the free area 22. The deformation element 4 is thus compressed and therefore ensures improved thermal connection of the heat-conducting element, even in the free area 22 of the battery module 102.

[0038] The heat-conducting element 3 and the deformation element 4 are formed here together with a carrier layer 5 as a composite mat 6. The carrier layer 5 is formed here as a single-sided adhesive carrier film 15. The carrier layer 5 is cut to size so that it is larger than the heat-conducting element 3 and protrudes, in particular, at the edges. The deformation element 4 is then applied to the heat-conducting element 3. The cut of the deformation element 4 is adapted to the size of the long sides 122 of the battery modules 102.

[0039] The prefabricated composite mat 6 is then applied to the battery module 102 from the underside 112. The area of ​​the composite mat 6 without the deformation element 4 is applied to the module underside. The composite mat 6 is then folded over the battery module 102 and applied along the long sides 122. The composite mat is then affixed to the battery module 102 using the self-adhesive carrier film 15.

[0040] The battery modules 102 with the attached composite mat 6 are now placed from above onto the carrier plate 42. Due to the excess dimension, the deformation element 4 is pressed together between the battery modules 102 and the carrier elements 52 when the battery modules 102 are inserted. The resulting force ensures that the areas of the heat-conducting element 3 that rest against the battery module 102 in the free area 22 are pressed against the module. This has the advantage that the side surfaces of the battery modules 102 can also be used to dissipate heat downwards into the area of ​​the cooling device 7. The battery modules 102 are then screwed to the carrier plate 42. This presses the heat-conducting element 3 into the contact area 12 beneath the battery module 102 with the carrier plate 42. This also results in a particularly good thermal connection here.

[0041] The battery device described here offers a particularly advantageous thermal connection of the battery modules 102 to a receiving device 2 or to a cooling device 7 located underneath. A particular advantage is that, in addition to the underside 112, the side surfaces 122 of the battery modules 102 are also used for cooling. Furthermore, the thermal connection presented here can be manufactured and assembled very cost-effectively. A further advantage is that tolerances between the side surfaces of the battery module 102 and the support elements 52 are compensated for by the deformation element. The battery device presented here also requires only a small amount of installation space, since no additional cooling channels need to run along the sides of the battery modules 102. Another particular advantage is that existing battery structures are used to press the heat-conducting elements 3 onto the battery modules 102.

Claims

[1] Battery device (1) for an at least partially electrically operated vehicle (100) with a plurality of battery modules (102) each having at least one battery cell (103) and with at least one receiving device (2) for receiving the battery modules (102), wherein each battery module (102) is connected to the receiving device (2) in at least one contact area (12) for heat conduction, characterized by , that at least one heat-conducting element (3) is arranged on at least one battery module (102), which extends into the contact area (12) and beyond this into at least one free area (22) of the battery module (102), and that in the free area (22) at least one elastic deformation element (4) is arranged for pressing the heat-conducting element (3) onto the battery module (102) and that the heat-conducting element (3) is arranged on at least one self-adhesive carrier layer (5) and that the heat-conducting element (3) and the deformation element (4) are arranged between the carrier layer (5) and the battery module (102), and that the carrier layer (5) and the heat-conducting element (3) and the deformation element (4) are joined together in a flexible composite mat (6), and that the deformation element (4) is arranged between the carrier layer (5) and the heat-conducting element (3). [2] Battery device (1) according to claim 1, wherein the deformation element (4) bears against at least one battery component serving as an abutment (14). [3] Battery device (1) according to one of the preceding claims, wherein the heat-conducting element (3) comprises at least one flexible heat-conducting mat (13). [4] Battery device (1) according to one of the preceding claims, wherein a plurality of heat-conducting elements (3) and / or a plurality of deformation elements (4) are arranged on a common carrier layer (5). [5] Battery device (1) according to one of the preceding claims, wherein at least two heat-conducting elements (3) with heat-conducting elements (3) each having at least one deformation element (4) are arranged on the battery module (102). [6] Battery device (1) according to one of the preceding claims, wherein the contact region (12) is equipped with at least one heat-conducting element (3). [7] Battery device (1) according to one of the preceding claims, wherein the heat-conducting element (3) extends over the contact region (12) and beyond this into at least two free regions (22) of the battery module (102). [8] Battery device (1) according to one of the preceding claims, wherein the contact region (12) comprises at least one section (120) without a heat-conducting element (3), in which the battery module (102) is directly connected to the receiving device (2) for heat conduction. [9] Battery device (1) according to one of the preceding claims, wherein the receiving device (2) comprises at least one carrier plate (42) on which the battery modules (102) are fastened. [10] Battery device (1) according to the preceding claim, wherein the receiving device (2) comprises at least one carrier element (52) arranged on the carrier plate (42) and extending at least partially between the battery modules (102), and wherein the carrier element (52) serves as an abutment (14) for the deformation element (4). [11] Battery device (1) according to the preceding claim, wherein the deformation element (4) has a thickness (24) which is greater than the distance (220) between the free area (22) of the battery module (102) and the carrier element (52), so that the deformation element (4) has an excess without the action of an external force. [12] Method for producing a battery device (1) for an at least partially electrically operated vehicle (100) with a plurality of battery modules (102) each having at least one battery cell (103) and with at least one receiving device (2) on which the battery modules (102) are received, wherein a battery module (102) is connected to the receiving device (2) in at least one contact area (12) for heat conduction, characterized by , that at least one heat-conducting element (3) is arranged on at least one battery module (102), which extends into the contact area (12) and beyond this into at least one free area (22) of the battery module (102), and that in the free area (22) at least one elastic deformation element (4) is arranged for pressing the heat-conducting element (3) onto the battery module (102) and that the following manufacturing steps take place: Fixing the heat-conducting element (3) and / or the deformation element (4) by at least one flexible carrier layer (5) to the battery module (102), Compressing the deformation element (4), pressing the heat-conducting element (3) onto the battery module (102) and / or onto the receiving device (2), fastening the battery module (102) to the receiving device (2).

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