Battery device and method for manufacturing a battery device

Abstract

Battery device (1) for a motor vehicle that is at least partially electrically powered, comprising at least one metallic heat sink (2) for temperature control of at least one battery cell (3), wherein at least one cooling channel system (4) through which a coolant can flow runs in the heat sink (2) and wherein the heat sink (2) is manufactured by at least one molding process, characterized in that the heat sink (2) and a battery housing (6) for housing a plurality of battery modules (13) each with a plurality of battery cells (3) are integrally connected and that the cooling channel system (4) is manufactured by the molding process using at least one core (5) removed after molding, so that the cooling channel system (4) is formed together with the heat sink (2) and the battery housing (6).

Description

The present invention relates to a battery device for an at least partially electrically driven motor vehicle and to a method for producing such a battery device. The battery device comprises at least one metallic cooling body for tempering at least one battery cell. At least one cooling channel system runs in the cooling body, through which a coolant can flow. The heat sink is produced by at least one casting process.Reliable temperature management is of great importance for the function and durability of the battery of an electric vehicle or hybrid vehicle. Frequently, such batteries are equipped with a cooling body with cooling channels through which a cooling liquid flows and thus cool or even heat the battery cells. In order to connect the regions to be temperature-controlled as well as possible to the cooling body, the cooling channels often have a complex or branched course. However, it is generally very complicated and cost-intensive to work such a path into the heat sink.From DE 10 2010 056 204 A1, a battery with a plate-shaped temperature control element is therefore known, in which the channels are formed by correspondingly bent tubes. The tubes are then cast around in order to produce the temperature control element. However, the geometry of the channels is limited due to the design and sealing of the channels is sometimes expensive.DE 10 2013 018 413 A1 discloses a battery device of the generic type in which pressurized glasses for bracing battery cells also provide a cooling body. The printing glasses can be produced by die casting or injection molding or sand casting. The channels in the pressure glasses can be introduced at least partially during casting. Two pressurized glasses are arranged opposite one another on the end face of a stack of battery cells and are braced with one another. The edge cells are cooled via channels in the pressurized glasses. For cooling the remaining cells, a cooling plate arranged below the battery cells and formed in two pieces is provided. The cooling plate has cooling channels which are formed between a lower plate and a cover plate and must be fluidically connected to the channels of the pressurized glasses.In contrast, it is the object of the present invention to provide a battery device with an effective cooling which is at the same time inexpensive and economically producible.This object is achieved by a battery device having the features of claim 1 and by a method having the features of claim 8. Further advantages and features of the present invention are evident from the general description and the description of the exemplary embodiment.The battery device according to the invention is provided for an at least partially electrically driven motor vehicle and in particular for an electric automobile and / or hybrid automobile. The battery device comprises at least one metallic cooling body for tempering at least one battery cell. The battery cell can be arranged in a battery module. At least one cooling channel system through which a coolant can flow runs into the cooling body. The heat sink is produced by at least one casting process. In this case, the heat sink and a battery housing for enclosing a plurality of battery modules, each having a plurality of battery cells, are integrally connected to one another. In this case, the cooling channel system is produced by the casting process by means of at least one core removed and / or destroyed after the casting. As a result, the cooling channel system is initially formed together with the cooling body and the battery housing.The battery device according to the invention offers many advantages. A considerable advantage is offered by the cooling channel system cast together with the cooling body. As a result, the battery device has a particularly effective cooling which is at the same time particularly inexpensive and economically producible. The use of one or more cores offers particularly high degrees of freedom for the geometry of the cooling channel system. In addition, such a cooling channel system can be sealed off particularly reliably. The invention therefore offers considerable advantages over other cooling bodies produced by the die casting process and, for example, those with inserted tubes.The core preferably comprises at least one sand core and / or salt core or is designed as such. Heat sinks can thus also be produced reliably and economically with complicated cooling channels. The core may also be made of another suitable core material for removable cores for casting processes. In particular, the core is suitable and configured only for a single use. In particular, the core is destroyed by the removal after the die casting. The core can be formed as a single core. The core may also be formed as a core package having a plurality of core parts.The cooling channel system has in particular at least one injection-molded undercut and preferably a plurality of such undercuts. In particular, the core can only be removed by destruction due to the undercut after the die casting. This offers considerable advantages over cooling channel systems without an undercut, for example in the manner of continuous casting profiles, or over drilled or built channels. With the invention, geometries with undercuts can be implemented particularly advantageously.The cooling channel system comprises in particular at least sectionally radially closed cooling channels with a curved and preferably meandering course. Such a course forms the undercuts. In particular, the cooling channels are at least partially in flow communication with one another. The cooling channels can also be formed separately from one another.The cooling body is preferably formed as a one-piece cast-mold component and particularly preferably as a sand casting or as a die casting or as a permanent-mold casting. The heat sink can also comprise at least one such cast-molded component. Such a cast-molded component can be produced in an inexpensive manner and at the same time offers many advantages with regard to the cooling effect and the mechanical strength and thus also advantages for the protection of the battery cells. The heat sink can also be designed as another molded part produced according to the invention.The casting process is in particular a sand casting and / or die casting and / or permanent mold casting. In particular, the cooling channel system is initially formed together with the cooling body in a sand casting process and / or die casting process and / or permanent mold casting process. In particular, the cooling body and the cooling channel system are formed only by the common die casting component. The casting process is in particular not an injection molding process.In particular, the cooling channel system is produced by the molding of the cooling body. In particular, the cooling channel system is produced during the molding or casting of the cooling body. In particular, a common molding of the cooling body and the cooling channel system takes place. In particular, the cooling body is connected to the cooling channel system in one piece of material. In particular, the cooling channel system comprises channel walls which are provided by the material of the cooling body. In particular, the cooling channel system consists only of recesses in the material of the cooling body.The cooling channel system is arranged in particular completely within the cast-molded component and preferably completely within a wall of the cast-molded component. In particular, the cooling channel system is completely surrounded by the die casting component with the exception of openings for the supply and / or discharge of the coolant. In particular, the radial transformations of the cooling channel system are provided by the die casting component.In all configurations, it is particularly preferred that the cooling body is manufactured from a metal material and in particular from at least one metal or at least one metal alloy. In all configurations, it is preferred that the casting process is a metal casting process or the casting is a metal casting.It is advantageous and preferred that the cooling body comprises at least one cooling plate or is designed as such. Such a cooling plate offers many advantages with regard to production and cooling effect. The heat sink can also have other shapes.According to the invention, the cooling body is part of a battery housing. In particular, the cooling body is at least partially and preferably completely integrated into the battery housing. The battery housing serves in particular for enclosing a multiplicity of battery cells. According to the invention, the battery housing is designed to enclose a plurality of battery modules each having a plurality of battery cells. The heat sink can also be part of a module housing, which is arranged in particular within a battery housing. In addition to an advantageous cooling effect, this also simultaneously offers an inexpensive production of a particularly secure battery housing. According to the invention, the cooling body and the battery housing are integrally connected to one another.The heat sink preferably provides at least one wall portion of the battery housing. The heat sink can also provide at least one wall section of a module housing.In an advantageous development, the cooling body provides at least one cover and / or at least one base and / or at least one side wall of the battery housing. The side wall extends in particular between the cover and the base.It is according to the invention and advantageous that the cooling body and the battery housing are produced by at least one common casting process. According to the invention, the cooling channel system is molded together with the cooling body and the battery housing. Thus, in only a single step, the battery housing together with the cooling body and the cooling channel system can be rough-formed. Such a battery housing can be equipped at least in sections with at least one access opening. It is possible for the battery housing to be closable by at least one further part and, for example, a cover or the like after the battery cells or battery modules have been assembled.The method according to the invention serves to produce a battery device according to the invention as has been described above. In this case, the cooling body and the cooling channel system are produced by at least one casting process. In this case, the cooling duct system is produced by means of at least one core which is removed and / or destroyed after the die casting and is initially formed together with the cooling body and the battery housing.The method according to the invention also achieves the object set above in a particularly advantageous manner. In particular, the method is configured such that the battery device described above can also be produced in its developments. In particular, the battery device is suitable and designed to be produced according to the method according to the invention.According to the invention, at least one metallic heat sink is produced by at least one casting process. According to the invention, a cooling channel system with a plurality of cooling channels runs in the cooling body through which a coolant can flow. According to the invention, the cooling channel system is also produced by the casting process. In this case, the cooling channel system is produced by the casting process by means of at least one core removed and / or destroyed after the casting. According to the invention, the cooling channel system is initially formed together with the cooling body and the battery housing. In particular, the cooling channel system is cast simultaneously with the cooling body.The cooling channel system comprises in particular a plurality of cooling channels or is provided by a plurality of cooling channels. The cooling channel system may comprise connection channels and / or feed openings or the like. In particular, the cooling channel system is suitable and designed for a liquid coolant. The cooling channel system can be fluidically connectable to at least one further cooling channel system of a further cooling body. In the context of the present invention, the term cooling is preferably used in the sense of temperature control, so that this is also understood to mean heating or heating.The battery device is designed in particular as a high-voltage battery. The battery device is in particular a traction battery for driving an electric vehicle and / or hybrid vehicle. It is possible that the battery cells are grouped within battery modules. In particular, the battery device comprises a plurality of battery modules each having a plurality of battery cells. The battery modules can each have at least one module housing. It is possible for the cooling body to be part of a module housing.Further advantages and features of the present invention result from the exemplary embodiments which are explained below with reference to the attached figures.The figures show: FIG. 1 shows a highly schematic illustration of a battery device according to the invention in a sectional front view; and FIG. 2 shows a highly schematic detailed illustration of a further battery device according to the invention in a sectional front view.FIG. 1 shows a battery device 1 according to the invention, which is designed here as a high-voltage battery for an at least partially electrically driven vehicle and, for example, for an electric vehicle or hybrid vehicle and is produced according to the method according to the invention.The battery device 1 comprises a battery housing 6, which is only partially shown here and which provides a receiving space for receiving a plurality of battery modules 13 and, if required, also further battery components. Battery cells 3 are grouped in the battery modules 13. Here, only one of the battery cells 3 is outlined by way of example. The battery housing 6 here comprises a cover 16 and a base 26 and side walls 36 running between the cover 16 and the base 26.The battery device 1 comprises a metallic cooling body 2, in which a cooling channel system 4 having a plurality of cooling channels 24 is integrated. During operation, a coolant flows through the cooling channel system 4, so that the battery modules 13 and the battery cells 3 accommodated therein are cooled. If necessary, the battery modules 13 and battery cells 3 can thus also be heated.The cooling body 2 is produced by a casting process and is formed here as a one-piece casting component 12 and, for example, a sand casting, die casting or permanent mold casting.The cooling channel system 4 is cast together with the cooling body 2. For this purpose, a core 5 that is no longer visible here is used during the casting process. The core 5 depicts the geometry of the cooling channel system 4. In the battery device shown here, a sand core 15 or a salt core 25 is used, for example. The core 5 used may be, for example, a single core or provided by a core package having a plurality of core parts. After the die casting, the core 5 is then removed and destroyed in the process.In order to achieve particularly effective cooling, the cooling channel system 4 is equipped here with meandering cooling channels 24, which form a die casting undercut 14. Such a cooling channel system 4 can be produced particularly well with the method presented here.The cooling body 2 is here part of the battery housing 6. Thus, in addition to the cooling function, the cooling body 2 simultaneously offers a protective enclosure of the battery modules 13. Alternatively or additionally, the base 26 or one or more side walls 36 or also other wall sections of the battery housing 6 can also be provided by the cooling body 2.The battery housing 6 shown here is produced together with the cooling body 2 during the casting process. The receiving space for the battery modules 13 is then formed, for example, by a corresponding core 5. Thus, the cooling body 2, the battery housing 6 and the cooling channel system 4 arranged therein can be produced simultaneously and with little outlay and additionally in a particularly stable manner. In order to be able to arrange the battery modules 13 and other battery components in the receiving space, the battery housing 6 is then equipped with at least one opening. Alternatively or additionally to the arrangement of the cooling channel system 4 shown here, the cooling channel system 4 can also be arranged in the region of the base 26 or the side walls 36.FIG. 2 shows a detailed view of an embodiment of the battery device 1 described above. Here, the cooling body 2 is designed as a cooling plate 22. The cooling plate 22 can then be inserted, for example, into a battery housing 6, not shown in detail here, in order to dissipate heat from the battery modules 13 or battery cells 3. Additionally or alternatively, the cooling plate 22 can also be arranged at other locations inside or outside the battery housing 6.The invention presented here has the advantage that the cooling body 2 and the cooling channel system 4 and also the battery housing 6 are realized in a single component and produced in a single die casting. Through the use of sand cores or salt cores or the like, integrally produced cooling channels 24 with complex geometries can be implemented. The lost molds or cores 5 achieve a high freedom from geometric forming. In addition, sealing problems are effectively counteracted. The battery device 1 can be designed to be particularly compact and light and at the same time particularly stable and secure. For this purpose, the invention requires particularly few components or production steps and, for example, only a single die casting. With the invention, any desired geometries within a casting wall can be represented. The invention significantly reduces the assembly effort of the battery and at the same time achieves a particularly good cooling performance.

Claims

Battery device (1) for an at least partially electrically driven motor vehicle, comprising at least one metallic cooling body (2) for tempering at least one battery cell (3), wherein at least one cooling duct system (4) through which a coolant can flow runs in the cooling body (2), and wherein the cooling body (2) is produced by at least one casting process, characterized in that the cooling body (2) and a battery housing (6) for enclosing a plurality of battery modules (13) are connected to one another in one piece in each case by a plurality of battery cells (3), and in that the cooling duct system (4) is produced by the casting process by means of at least one core (5) removed after the casting process, such that the cooling duct system (4) is initially formed together with the cooling body (2) and the battery housing (6).Battery device (1) according to the preceding claim, wherein the core (5) comprises at least one sand core (15) and / or salt core (25) or is designed as such.Battery device (1) according to one of the preceding claims, wherein the cooling duct system (4) has at least one die-casting undercut (14).Battery device (1) according to one of the preceding claims, wherein the cooling body (2) is a one-piece cast-in-mould component (12) and preferably a sand casting or a die casting or a mould casting.Battery device (1) according to one of the preceding claims, wherein the cooling body (2) comprises at least one cooling plate (22) or is designed as such.Battery device (1) according to one of the preceding claims, wherein the cooling body (2) provides at least one wall section of the battery housing (6).Battery device (1) according to one of the preceding claims, wherein the cooling body (2) provides a cover (16) or a base (26) or a side wall (36) of the battery housing (6).Method for producing a battery device (1) according to one of the preceding claims, wherein the battery device (1) is provided for an at least partially electrically driven motor vehicle and comprises at least one metallic cooling body (2) for tempering at least one battery cell (3) and wherein at least one cooling duct system (4) through which a coolant can flow runs in the cooling body (2), wherein the cooling body (2) and a battery housing (6) for enclosing a plurality of battery modules (13) are connected to one another in one piece in each case with a plurality of battery cells (3), wherein the cooling body (2) and the cooling duct system (4) are produced by at least one casting process and wherein the cooling duct system (4) is produced by means of at least one core (5) which is removed and / or destroyed after the casting process and is rough-formed together with the cooling body (2) and the battery housing (6).

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