Battery arrangement with integrated temperature control unit

Abstract

Battery arrangement (1) comprising a plurality of battery cells (11) arranged in at least two superimposed planes (2 ,3): at least one first temperature control plate (4) in which at least one fluid channel (5; 51, 52, 53, 54) is formed, wherein the first temperature control plate (4) is arranged between the first battery cell level (2) and the second battery cell level (3) and is in thermal contact with the same sides of the battery cells (11) of the first and second battery cell levels (2, 3); at least two second temperature control plates (6), wherein at least one fluid channel (61, 62, 63) is formed in each second temperature control plate (6) and wherein at least one second temperature control plate (6) is arranged in each of the two battery cell levels (2, 3), wherein each second temperature control plate (6) is in thermal contact with several battery cells (11) of the corresponding battery cell level (2, 3); a fluid inlet (8) which is coupled to a first end of the at least one fluid channel (5; 51, 52, 53, 54) formed in the first temperature control plate (4) and to a first end of the at least one fluid channel (61, 62, 63) formed in each of the second temperature control plates (6); and a fluid outlet (10) which is coupled to a second end of the at least one fluid channel (5; 51, 52, 53, 54) formed in the first temperature control plate (4) and to a second end of the at least one fluid channel (61, 62, 63) formed in each of the second temperature control plates (6); wherein the at least one fluid channel (5; 51, 52, 53, 54) formed in the first temperature control plate (4) and the at least one fluid channel (61, 62, 63) formed in the second temperature control plates (6) are separate fluid channels from each other.

Description

[0001] The present invention relates to a battery arrangement with an integrated temperature control device.

[0002] With the advent of electromobility, battery technology has simultaneously become a focus of technological development. While the car battery plays a rather minor role in vehicles with combustion engines, the "electric tank," known as the traction battery, is of paramount importance in electric vehicles, as it significantly influences their range and represents a crucial factor in the mass adoption of electric vehicles.

[0003] Modern electrical machines, which use electromagnetic induction to convert electrical power into mechanical power (electric motor) and vice versa (generator, in recuperation mode), can deliver considerable power outputs of several hundred kW per unit and generally belong to drive systems with very high power densities (kW per liter of installation space). This high power output is accompanied by high current flows from the traction battery, which, among other things, lead to heating of the traction battery. High current flows also occur during the charging process, which leads to heat generation, particularly at rapid charging stations. These stations generate high charging currents of several hundred amperes at a charging voltage of 800 V. In both cases, this waste heat must be dissipated to prevent premature aging of the traction battery and, in the worst case, possible damage from overheating.

[0004] From document DE 10 2006 059 989 A1, a battery arrangement consisting of several individual cells is known. The individual cells are in thermal contact with a base plate, and the thermal contact between the individual cells and the base plate is established via cooling elements arranged in the interstices of the densest packing of the individual cells. The outer contour of the cooling elements has a tribunal symmetry and contacts the individual cells on their cylindrical outer surfaces. Furthermore, the base plate is cooled by a flowing cooling medium.

[0005] Document DE 10 2012 111 970 A1 discloses a battery assembly comprising a battery with a plurality of battery cells, each with two terminals, i.e., pole contacts, and a terminal plate. One terminal of each of the battery cells is arranged on the terminal plate in a form-fitting and / or force-fitting manner, thereby electrically interconnecting the battery cells. A perforated plate is arranged above the terminal plate, through whose holes a cooling medium can be injected.

[0006] Document CN 204 732 500 U discloses a liquid-cooled battery module for electric vehicles with a built-in liquid cooling module, which has a plurality of U-shaped liquid cooling tubes distributed on both sides of the built-in liquid cooling plate and inserted between adjacent individual cells of the battery module.

[0007] Document CN 107 293 824 B discloses a liquid cooling device for a power battery, the device comprising a liquid cooling plate and a liquid cooling tube arranged vertically thereon, which is attached to a side wall of the battery cells. The liquid cooling tube is provided with a hollow liquid cooling tube cavity filled with a cooling liquid and connected to a water path in the liquid cooling plate.

[0008] Against the background of the prior art, it is an object of the present invention to provide a battery arrangement which has a simply constructed and efficient cooling device.

[0009] To achieve the above-mentioned object, a battery arrangement having the features of independent claim 1 is provided. Further embodiments can be found in the dependent claims.

[0010] According to the invention, a battery assembly is provided with a plurality of battery cells arranged in at least two superimposed levels. The battery assembly has at least one first temperature control plate in which at least one fluid channel is formed. The first temperature control plate is arranged between the first battery cell level and the second battery cell level and is in thermal contact with the same (front) sides of the battery cells of the first and second battery cell levels.The battery assembly further comprises at least two second temperature control plates, which, as explained below, may in some cases correspond to corrugated plates (wave plates), wherein at least one fluid channel is formed in each second temperature control plate, and wherein at least one second temperature control plate is arranged in each of the two battery cell levels, and wherein each second temperature control plate is in thermal contact with a plurality of battery cells of the associated battery cell level. The battery assembly further comprises a fluid inlet coupled to a first end of the at least one fluid channel formed in the first temperature control plate and to a first end of the at least one fluid channel formed in each of the second temperature control plates.Furthermore, the battery assembly has a fluid outlet coupled to a second end of the at least one fluid channel formed in the first temperature control plate and to a second end of the at least one fluid channel formed in each of the second temperature control plates. The at least one fluid channel formed in the first temperature control plate and the at least one fluid channel formed in the second temperature control plates are separate fluid channels.

[0011] The battery arrangement described here consists of a plurality of battery cells, for example lithium-ion cells, which can be arranged in two or more levels. The total number of battery cells forms a battery, wherein the battery cells can be interconnected in a manner known from the prior art. Within a level, the battery cells are generally arranged next to one another, i.e. they all have the same orientation. Depending on the base area of ​​the battery cells, these can be arranged in rows next to one another within a level. In particular, if the base area of ​​the battery cells is round, the next row can be offset from the previous row by half a dimension of the battery cell, alternating to the right and to the left, which results in a very compact arrangement of the battery cells within the level.In principle, the battery arrangement can have a cuboid or cube-shaped form, whereby the height of the battery arrangement corresponds to the dimension along the stacking direction of the individual levels on top of each other.

[0012] The battery cells can be inserted into the first temperature control plate, which can function as a base plate, or fixed / fastened therein with the same (end) sides. In this respect, the first and second levels can have essentially the same structure with regard to the battery arrangement, but can be mirror-inverted relative to each other with regard to the first temperature control plate.

[0013] Both the fluid inlet and the fluid outlet can be in the form of a line through which a fluid (temperature control medium) can be transported to or from the battery arrangement. Both the fluid inlet and the fluid outlet can each be coupled to a distributor structure by means of which the fluid is distributed between the fluid inlet and the fluid channels of the first temperature control plate and the fluid channels of the second temperature control plates, or the fluid channels are combined to form the fluid outlet. In other words, the distributor structures can be used to distribute the fluid supplied via a line, in particular to the various fluid channels, in particular the fluid channels formed in the two levels within the second temperature control plates. The distributor structure can essentially be a connector having an inlet and numerous outlets.The second cooling plates can be coupled to the distribution structures, for example, by crimping, so that a fluid connection exists between the at least one fluid channel formed therein and the distribution structure. Typically, several second temperature control plates can be arranged in each plane of the battery arrangement.

[0014] In order to achieve an improved thermal connection between the battery cells to be tempered and the temperature control plates, thermal paste (gap filler) can be arranged between these components.

[0015] The fluid channels described in the context of this invention, which are provided in the temperature control plates, can be used to temperature-control the battery cells and are collectively referred to as a temperature control device. Consequently, depending on the temperature of a temperature control medium provided and flowing through the fluid channels, e.g., a cooling liquid, heat energy can either be added to or removed from the battery cells. In other words, the battery arrangement according to the invention is equipped with a temperature control device that can be used to cool and heat the battery cells as needed.

[0016] In the battery arrangement according to the invention, the temperature of the battery cells is controlled not only via the side of the battery cells, for example via their end faces, with which they are in thermal contact with the first temperature control plate, but also via the outside of the battery cells, which is in contact with the second temperature control plate. When using round battery cells, these are consequently partially enclosed by the second temperature control plate(s) and thus temperature-controlled in the radial direction via the outer surface and, at the same time, by the first temperature control plate in the axial direction via the end face. This makes it possible to avoid strong temperature gradients in the battery cells to be temperature-controlled, and the temperature control can be carried out in a more uniform manner overall. The battery arrangement described here is particularly suitable for temperature-controlling uniform battery cells or other battery stacks.In principle, the number of second temperature control plates provided in a battery arrangement can be adjusted as required so that the battery cells are in contact with only one second temperature control plate from one side or are in contact with a total of two second temperature control plates from two, usually diametrically opposite, sides.

[0017] According to further embodiments of the battery assembly, the fluid inlet and the fluid outlet can be arranged on different, preferably opposite, sides of the battery assembly. As a result, the distributor structures on the fluid inlet and fluid outlet sides can have a similar structure and each extend across the entire side of the battery assembly. Furthermore, such a configuration of the battery assembly naturally results in a fluid flow through the fluid channels, extending through the entire battery assembly. The use of similarly or identically constructed distributor structures also makes it possible to reduce the overall variety of components required to provide the battery assembly according to the invention.

[0018] According to further embodiments of the battery assembly, the fluid inlet and the fluid outlet can be arranged on the same side of the battery assembly. The fluid inlet can be arranged at the level of or in the first plane, and the fluid outlet can be arranged at the level of or in the second plane, or vice versa.

[0019] According to further embodiments of the battery arrangement, the at least one channel formed in the first temperature control plate can have at least one preferably arcuate deflection region in which the channel is deflected by 180°. The deflection region can be a meander. During operation of the temperature control device integrated within the battery arrangement, the direction of the fluid flow is opposite in the sections of the fluid channel separated from the deflection region. By linking several fluid channel sections by deflection regions, the at least one fluid channel in the first temperature control plate can run through it in a serpentine (meandering) manner. With an odd number of deflection regions, the fluid channel ends (i.e. channel inlet and channel outlet) generally open on the same side of the battery arrangement, whereas with an even number of deflection regions they open on different, preferably closely opposite sides.The course of the at least one fluid channel in the first temperature control plate can further be such that the fluid channel is arranged in a single plane. In other words, during operation of the temperature control device, the fluid flow through the at least one fluid channel within the first temperature control plate takes place in a single plane, so that a fluid pump provided in the fluid circuit does not have to perform any lifting work.

[0020] According to further embodiments of the battery arrangement, the at least one channel formed in the at least one second temperature control plate can have at least one preferably arcuate deflection region in which the channel is deflected by 180°. In principle, all of the provisions relating to the at least one fluid channel formed in the first temperature control plate also apply to the at least one fluid channel formed in the at least one second temperature control plate. In contrast to the first temperature control plate, the second temperature control plates are generally arranged perpendicular to the first temperature control plate, so that the channel sections linked by the deflection regions are arranged one above the other, rather than next to one another.With a meandering design of the at least one fluid channel in the second temperature control plate, there is a height difference between the two ends of the fluid channel, which may have to be overcome by a fluid pump arranged in the fluid circuit. In a preferred embodiment of the battery arrangement, a meandering fluid channel in a second temperature control plate has three fluid channel regions that are connected to one another by two deflection regions. The inlet of the fluid channel can, for example, be arranged in the upper region of the battery arrangement, while the outlet is arranged in the lower region of the battery arrangement, on the opposite side. A reverse arrangement can also be realized within the scope of the invention.

[0021] According to further embodiments of the battery assembly, each fluid channel formed in a first and / or second temperature control plate can have a structured, preferably ribbed, surface. Such structuring, which is essentially comparable to cooling fins on conventional heat sinks, serves to increase the contact surface between the fluid flowing in the fluid channel during operation of the battery assembly and the channel or the material of the fluid channel. This allows for more efficient energy transport between the fluid and the fluid channel.

[0022] According to further embodiments of the battery arrangement, each of the second temperature control plates can be shaped such that its side surfaces are at least partially adapted to the shape of the battery cells with which the respective second temperature control plate is in thermal contact. The shape of the second temperature control plate can therefore at least partially correspond to a negative shape with respect to the shape of the battery cells in contact with it. In general, within the scope of the present invention, the shape of the second temperature control plates can be geometrically designed to match the base body to be temperature controlled, usually the battery cell. This makes it possible to achieve optimal thermal contact between a second temperature control plate and the battery cells in thermal contact with it. As already mentioned, thermal paste can be used to further improve the thermal contact.The second temperature control plate can be manufactured, for example, by soldering, welding of die-cast parts or by means of an additive manufacturing process (3D printing).

[0023] In an exemplary embodiment of the battery arrangement, the battery cells can have a round base, i.e., a substantially cylindrical basic shape. The second temperature control plates can correspondingly have a corrugated or wavy shape. In this case, the curvature of the cylindrical shell of the battery cells can correspond to the curvature of the region of the second temperature control plate that abuts the battery cell.

[0024] According to further embodiments of the battery assembly, the second temperature control plates can be arranged substantially perpendicular to the first temperature control plate. In particular, the second temperature control plates can be arranged perpendicularly on or at the first temperature control plate. For example, the second cooling plates can be arranged in a T-shape on the first temperature control plate, for example, plugged into or onto it.

[0025] According to further embodiments of the battery arrangement, the battery cells can be those with single-sided polarity, wherein the battery cells are preferably designed as round cells. This allows the other side, for example the opposite side, on which no pole contacts are arranged, to be flat and provide the largest possible surface area that can be in thermal contact with the first temperature control plate.

[0026] In the context of this description, the term thermal contacting or bringing two objects into thermal contact can be understood to mean that both objects are brought so close to each other that the heat exchange occurs primarily directly between the surfaces of the two objects and not, or only to a very small or negligible extent, through thermal radiation.

[0027] The features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the present invention.

[0028] Further advantages and embodiments of the invention will become apparent from the description and the accompanying drawings. Fig. 1 shows a side view of an embodiment of the battery arrangement according to the invention. Fig. 2 shows a perspective cross-sectional view of an exemplary second temperature control plate. Fig. 3 shows a simplified schematic plan view of an arrangement of battery cells arranged on the first temperature control plate. Fig. 4 shows a top view of an exemplary first temperature control plate. Fig. 5 shows a perspective view of the battery assembly equipped with battery cells from Fig. 1.

[0029] Fig. 1 shows a side view of an embodiment of the battery assembly 1 according to the invention. In the example shown, this has a first level 2 and a second level 3 in which the battery cells 11 are arranged. In Fig. 1, only a single battery cell 11 is shown in the middle compartment of the second level 3 for better clarity. The compartments into which the battery cells 11 are inserted are each laterally surrounded by the second temperature control plates 6. The battery cells 11 inserted into these compartments are each in thermal contact with two temperature control plates 6. The battery arrangement 1 furthermore has a first temperature control plate 4 with which the inserted battery cells 11 are also in thermal contact. While the battery cells 11 are temperature-controlled via their end faces by means of the first temperature control plate 4, they are temperature-controlled via their outer surfaces by means of the second temperature control plates 6. As a rule, the battery cells 11 in the first level 2 are arranged rotated by 180° with regard to their orientation relative to the battery cells 11 in the second level 3.Consequently, in the case of battery cells 11 with unilateral polarity, the battery terminals of the battery cells face the top side of the battery assembly 1 (here, the top side of the sheet), while in the case of battery cells 11 of the second level 3, they face the bottom side of the battery assembly 1 (here, the bottom side of the sheet). Therefore, in this example, the battery cells 11 are arranged with similar surfaces on the first temperature control plate 4, or are inserted into it, or are fixed to it.

[0030] During operation, the cooling fluid is supplied via the inlet 8 and distributed by means of the first distribution structure 7 to the fluid channels arranged in the first temperature control plate 4 and in the second temperature control plates 6. Accordingly, the inlet 8 is coupled to the inlets of the fluid channels via the first distribution structure 7 arranged on the underside of the battery assembly 1. Fig. The arrows in Figure 1 indicate the flow path of the fluid supplied through the inlet 8. The fluid is drawn from the Fig. 1, the fluid is introduced into the fluid channels in the first temperature control plate 4 and in the second temperature control plates 6 and flows through them. The fluid then leaves the fluid channels and is collected and directed to the outlet 10 of the battery assembly 1 by means of the second distributor structure 9, which is arranged on the top side of the battery assembly 1. The first distributor structure 7 and the second distributor structure 9 are arranged on opposite sides of the battery assembly 1.

[0031] In Fig. Figure 2 illustrates a perspective cross-sectional view of an exemplary second temperature control plate 6. Firstly, it can be seen that the second temperature control plate 6 has a corrugated or wavy shape, which is adapted to the geometry of the battery cells 11, assumed to be cylindrical in this case, with which it is in thermal contact within the corresponding plane. Furthermore, it is shown that three fluid channels 61, 62, 63 are provided within the temperature control plate 6. For the design of the fluid channels 61, 62, 63 within the second temperature control plate 6, there are, based on the Fig. 2 shows two practical possibilities. According to a first possibility, the fluid channels 61, 62, 63 shown can all form a continuous fluid channel, wherein they are connected to one another in the edge regions of the temperature control plate by means of deflection regions. Referring to the Fig. 1, the fluid can be introduced into the lower fluid channel 63, guided at a first end of the second temperature control plate 6 by means of a deflection region into the middle fluid channel 62, introduced at a second end of the second temperature control plate 6 by means of a further deflection region into the upper fluid channel 61 and then flow out of the meandering fluid channel into the second distributor structure 9 at the first end of the second temperature control plate 6. According to a second possibility, at least two of the three in Fig. 2, the fluid channels 61, 62, 63 shown in FIG. 2 can be separated from each other, so that one or all of the fluid channels - except for the undulation imposed by the wave-like design of the second temperature control plate 6 - run straight from one to the other end of the second temperature control plate 6. Regardless of the specific design of the fluid flow within the second temperature control plate 6, the width of the Fig. 2 shown fluid channels 61, 62, 63 (corresponds to the smaller of the two dimensions of the cross section of the fluid channel 61, 62,63) are, for example, in the range of 1 mm.

[0032] Fig. 3 shows a simplified schematic plan view of a section of an arrangement of battery cells 11 arranged on the first temperature control plate 4 of the battery arrangement 1 according to the invention. Here, the battery cells 11 are designed as round cells and arranged in rows offset from one another in order to obtain an arrangement with a higher packing density. Furthermore, three second temperature control plates 6 are shown, the undulating shape of which is adapted to the geometry of the battery cells 11. Each of the battery cells 11 is in thermal contact with a second temperature control plate 6 on two sides. In other exemplary embodiments, every second temperature control plate 6 can be omitted, so that each battery cell 11 is only thermally contacted with a second temperature control plate 6 from one side.

[0033] Fig. 4 shows a plan view of an exemplary first tempering plate 4, as shown for example in the Fig. 1 shown embodiment of the battery arrangement according to the invention. In the first temperature control plate 4, a total of four separate fluid channels 51, 52, 53, 54 are formed. The Fig. The arrows shown in Figure 4 indicate the flow direction of the fluid during operation of the temperature control device of the battery arrangement 1. The inlets of the four fluid channels 51, 52, 53, 54 are coupled to the first distributor structure 7, and the four outlets of the four fluid channels 51, 52, 53, 54 are coupled to the second distributor structure 9. Each of the four fluid channels 51, 52, 53, 54 has a serpentine or meandering course, which is achieved with the aid of two deflection regions 55 per fluid channel 51, 52, 53, 54. Due to the meandering structure of the fluid channels 51, 52, 53, 54 and their number, the fluid channel density within the first temperature control plate 4 can be designed to suit the needs of the system to be temperature-controlled, in this case the battery cells 11. As shown, an area can easily be cut out at the lower right corner of the first temperature control plate 4 by indenting the lowest deflection area of ​​the lowest fluid channel 54.In analogy to the description of the course of the fluid channels within the in . Fig. 2 illustrated second tempering plate 6, it is pointed out that the Fig. The interior of the first temperature control plate 4 shown in Figure 4 represents only one of many possible examples. In general, the number of fluid channels 51, 52, 53, 54, the position of their ends, their geometric dimensions, the number and / or position of the reversal regions 55, to name a few design parameters, can be adjusted as needed.

[0034] Fig. 5 shows a perspective view of the battery arrangement 1 equipped with battery cells 11 from Fig. 1, where compared with the Fig. 1 shows the rear side of the battery arrangement 1. The uppermost plate covering the battery cells 11 of the first level 2 from above represents the contact level of the battery cells 11. A corresponding contact level is also provided on the underside of the battery arrangement 1 for electrically contacting the battery cells 11 of the second level 3. The further Fig. 5 elements provided with reference numerals have already been described in detail with reference to the previous figures.

Claims

[1] Battery arrangement (1) with a plurality of battery cells (11) arranged in at least two levels (2, 3) arranged one above the other, comprising: at least one first temperature control plate (4) in which at least one fluid channel (5; 51, 52, 53, 54) is formed, wherein the first temperature control plate (4) is arranged between the first battery cell level (2) and the second battery cell level (3) and is in thermal contact with the same sides of the battery cells (11) of the first and second battery cell levels (2, 3); at least two second temperature control plates (6), wherein at least one fluid channel (61, 62, 63) is formed in each second temperature control plate (6) and wherein at least one second temperature control plate (6) is arranged in each of the two battery cell levels (2, 3), wherein each second temperature control plate (6) is in thermal contact with a plurality of battery cells (11) of the associated battery cell level (2, 3); a fluid inlet (8) which is coupled to a first end of the at least one fluid channel (5; 51, 52, 53, 54) formed in the first temperature control plate (4) and to a first end of the at least one fluid channel (61, 62, 63) formed in the second temperature control plates (6); and a fluid outlet (10) which is coupled to a second end of the at least one fluid channel (5; 51, 52, 53, 54) formed in the first temperature control plate (4) and to a second end of the at least one fluid channel (61, 62, 63) formed in the second temperature control plates (6); wherein the at least one fluid channel (5; 51, 52, 53, 54) formed in the first temperature control plate (4) and the at least one fluid channel (61, 62, 63) formed in the second temperature control plates (6) are separate fluid channels. [2] Battery arrangement (1) according to claim 1, wherein the fluid inlet (8) and the fluid outlet (10) are arranged on different, preferably on opposite sides of the battery arrangement (1). [3] Battery assembly (1) according to claim 1, wherein the fluid inlet (8) and the fluid outlet (10) are arranged on the same side of the battery assembly (1). [4] Battery arrangement (1) according to one of claims 1 to 3, wherein the at least one fluid channel (5; 51, 52, 53, 54) formed in the first temperature control plate (4) has at least one preferably arcuate deflection region (55) in which the fluid channel (5; 51, 52, 53, 54) is deflected by 180°. [5] Battery arrangement (1) according to one of claims 1 to 4, wherein the at least one fluid channel (61, 62, 63) formed in the at least one second temperature control plate (6) has at least one preferably arcuate deflection region in which the fluid channel (61, 62, 63) is deflected by 180°. [6] Battery arrangement (1) according to claim 5, wherein each fluid channel (5; 51, 52, 53, 54; 61, 62, 63) formed in a first and / or in a second temperature control plate (4, 6) has a structured, preferably grooved, surface. [7] Battery arrangement (1) according to one of claims 1 to 6, wherein each of the second temperature control plates (6) is shaped such that its side surfaces are at least partially adapted to the shape of the battery cells (11) with which the respective second temperature control plate (6) is in contact. [8] Battery arrangement (1) according to one of claims 1 to 7, wherein the second temperature control plates (6) are arranged substantially perpendicular to the first temperature control plate (4). [9] Battery arrangement (1) according to one of claims 1 to 8, wherein the battery cells (11) are those with one-sided polarity, wherein the battery cells (11) are preferably designed as round cells.

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