Battery modular system for a motor vehicle

Abstract

Battery modular system (3) for a motor vehicle (1), comprising a plurality of battery blocks (4.1, 4.2, 4.3) and an electronic module (5) for contacting and control, wherein the electronic module (5) is arranged in a vertical direction (z) of the motor vehicle (1) in a suitably installed state above at least one battery block (4.1, 4.2), wherein the electronic module (5) comprises a module housing (5') which has at least two spatially separated connection areas (7), each of which has high-voltage and signal connectors (8, 9) for connection with corresponding elements (7', 8', 9') of the at least one battery block (4.1, 4.2, 4.3).3) comprising, characterized in that the module housing (5') provides at least three connection areas (7), wherein at least two of the connection areas (7) are formed on one side of the module housing (5') and at least one of the connection areas (7) is formed on a side of the module housing (5') opposite this one side, wherein the at least two connection areas are located on the lower side of the module housing (5') in the intended installed state of the module housing (5'), wherein the at least one connection area (7) on the opposite side is located on the upper side of the module housing (5').

Description

[0001] The invention relates to a modular battery system for a motor vehicle according to the type defined in the preamble of claim 1.

[0002] DE 10 2020 005 603 A1 describes a traction battery for a motor vehicle and a method for manufacturing the motor vehicle. For a space-efficient arrangement, the traction battery is divided into several battery blocks, which can be arranged at different locations within the vehicle structure. Such a battery is also referred to as a distributed battery. The document then describes various options for arranging the individual battery blocks in the vehicle, for example, under vehicle seats. The arrangement can also be longitudinal, i.e., in or against the direction of travel of the vehicle, and / or divided transversely across the vehicle, leaving space between the battery blocks for a transmission tunnel, a drive shaft, or similar.

[0003] The problem with such distributed batteries is always that the individual elements must be arranged and wired accordingly. The cited document describes an electronic module mounted on each battery housing, which contains electrical and electronic elements for contacting and / or controlling the battery. These electronic modules must also be connected accordingly, for example, to a central control system.

[0004] For further prior art, reference can also be made to DE 10 2020 109 055 A1, which shows a modular system for a traction battery of a motor vehicle. This document accordingly states that it has proven advantageous if larger battery blocks of such a modular battery system, which ultimately also represents a distributed battery within the meaning of the previous document, have the same energy content.

[0005] The object of the present invention is to provide an improved modular battery system according to the preamble of claim 1, in which the structure can be further simplified and made very flexible with regard to scalability.

[0006] According to the invention, this object is achieved by a modular battery system for a motor vehicle having the features in claim 1, and in particular in the characterizing part of claim 1. Advantageous embodiments and further developments of the motor vehicle according to the invention emerge from the dependent claims.

[0007] In the modular battery system according to the invention, similar to the prior art mentioned above, it is provided that a modular battery system is used which comprises at least one battery block and an electronic module for detection and control. The electronic module is arranged above the at least one battery block in a vertical direction of the vehicle, which is also referred to as the z-direction or z-axis or vertical axis of the vehicle.

[0008] According to the invention, the vehicle is provided with the electronics module comprising a module housing having two spatially separated connection areas, each comprising high-voltage and signal connectors for connection to the at least one battery block. Such an electronics module with at least two spatially separated connection areas makes it possible to connect several battery blocks to a single electronics module if required. Cables to the vehicle's electric drive system can then run from the single electronics module, for example. Depending on the vehicle design, one or more battery blocks can be connected easily and efficiently to the single electronics module. This ensures very good scalability of the system, since a different number of battery blocks can be used in the battery kit depending on the power and size of the vehicle.

[0009] According to an exceptionally advantageous development of the motor vehicle according to the invention, it can now further be provided that the connection areas are arranged on the same side of the module housing. In the arrangement described in claim 1 in the direction of the vertical axis above the at least one battery block, a particularly advantageous development of this embodiment can provide for the arrangement on the lower side of the module housing in the intended installed state. The at least one battery block or, in particular, several of the battery blocks can thus be arranged, for example, in the underbody, in particular in a sandwich construction of an underbody of the vehicle.The electronic module, with its module housing and connection areas, is then placed on these batteries, allowing the battery block connectors to interact with the corresponding connectors on the battery blocks to establish electrical contact extremely easily and efficiently. For example, the same electronic module can be used for a different number of battery blocks, so that only some of the connection areas are connected to the battery blocks and others are not.

[0010] According to an extremely advantageous and alternative development of the modular battery system according to the invention, it can also be provided that the connection areas are arranged on opposite sides of the module housing. This can preferably be designed such that the opposite sides with the connection areas form the lower and upper sides of the battery block when installed as intended. One battery block can then be arranged below the electronics module, for example, as described above, and another can be positioned above it. For example, it is conceivable to arrange one battery block in the floor area of ​​the vehicle and to place another battery block onto the electronics module from above, for example if there is installation space available under a driver's seat in a corresponding booster seat in the area of ​​the base, which space can also be used for a battery.

[0011] Another exceptionally advantageous embodiment of the modular battery system according to the invention can also provide for these two possibilities to be combined. The module housing then has at least three connection areas, with at least two of the connection areas being formed on one side and at least one of the connection areas being formed on the side opposite this one side. This enables the use of two or more battery blocks in the floor area of ​​the vehicle and one or more battery blocks, for example, under the front or rear seats of the vehicle.

[0012] Accordingly, it can be provided that the at least one connection area is arranged on top of the module housing in the intended installed state of the electronic module, and the at least two others are arranged accordingly at the bottom.

[0013] As already mentioned several times, according to a very advantageous embodiment, the electronic module located above the at least one battery block in the direction of the vertical axis of the motor vehicle is arranged at least partially below at least one seat of the motor vehicle. Particularly preferably, this can be one of the front seats of the motor vehicle, so that the one electronic module is arranged relatively far forward in the direction of travel of the motor vehicle, so that it can be connected to the electric drive system, which is typically arranged in the front area, with correspondingly short cables.

[0014] Further advantageous embodiments of the modular battery system according to the invention also emerge from the exemplary embodiments which are illustrated in more detail below with reference to the figures.

[0015] Showing: Fig. 1 is a schematic sketch of a vehicle in an embodiment according to the invention; Fig. 2 a schematic sketch of a modular battery system with two battery blocks in an exploded view; Fig. 3 a representation according to Fig. 2 in assembled condition together with the electric drive system and a cardan shaft; Fig. 4 two exemplary battery blocks analogous to the illustration in Fig. 2 and Fig. 3 during assembly with a subframe; Fig. 5 a modular battery system according to Fig. 2 to 3 with a shortened length; Fig. 6 an alternative design of a modular battery system with four battery blocks; Fig. 7 shows an alternative embodiment of a modular battery system with an alternative electronic module in an exploded view; Fig. 8 an alternative design of a modular battery system analogous to the representation in Fig. 7 in assembled condition with an alternative number of battery blocks; Fig. 9 a side view of a possible arrangement of a battery modular system according to one of the Fig. 2 to 6 in a motor vehicle; and Fig. 10 a representation analogous to that in Fig. 9 for the arrangement of a modular battery system according to one of the Fig. 7 or Fig. 8 in the motor vehicle.

[0016] In the presentation of the Fig. 1 shows a motor vehicle 1 in a very schematic way. In the exemplary embodiment shown here, an electric drive system 2 of the motor vehicle 1 is intended to supply electrical power to drive the front axle. The power could just as well be supplied to the rear axle or to both axles simultaneously. The electrical power to drive the electric drive system 2 comes from a modular battery system 3, which in the exemplary embodiment shown here comprises a battery block designated 4 and an electronics module 5. The electronics module 5 is designed to electrically contact the battery block 4 and to control the same. For this purpose, it comprises high-voltage connections for electrically contacting the high-voltage lines of the battery block 4 as well as signal lines which are electrically connected to corresponding measuring lines and control lines of the battery block 4 via suitable plug connections.The electronic module 5 can also include the charger for the battery pack 4. This is designed as a so-called high-voltage battery, i.e., it has a voltage of more than 60 V DC according to the common definition in ECE-R 100.

[0017] In the presentation of the Fig. 2, the modular battery system 3 can be seen again in an exploded view in a possible embodiment. The structure here consists of two battery blocks 4.1 and 4.2 as well as the electronic module 5, which is only represented by its module housing 5'. Two lines 6 extend from the module housing 5', which provide the electrical connection to the electric drive system 2, as shown in Fig. 1. The electronic module 5 with its module housing 5' has on its underside in the illustration of the Fig. 2, i.e. the underside in the direction of the vertical axis of the vehicle 1, which in the illustration of the Fig. 1, designated z, has connection areas 7, which comprise high-voltage connectors 8 and signal connectors 9, in order to connect these elements to the corresponding high-voltage connectors 8' and signal connectors 9' of the corresponding connection areas 7' of the two battery blocks 4.1 and 4.2. For this purpose, the electronic module 5 with its module housing 5' is simply placed on the battery blocks 4.1 and 4.2 and typically firmly connected to the battery blocks 4.1, 4.2 by clamping, screwing, or the like.

[0018] Ultimately, this creates the Fig. 3 consists of the two battery blocks 4.1, 4.2 and the electronic module 5 with its module housing 5'. The battery blocks 4.1, 4.2 run with their length L in the so-called longitudinal direction of the vehicle, i.e. parallel or antiparallel to the direction of travel. The longitudinal direction is shown in the illustration of the Fig. 1 and labeled x. In the transverse direction, which is perpendicular to the longitudinal direction x and the vertical axis z, and which in the representation of the Fig. 1 is designated by y, the two battery blocks 4.1 and 4.2 are spaced apart from each other, as already shown in the illustration of the Fig. 2. This gap between the two battery blocks 4.1 and 4.2 in the transverse direction y of the motor vehicle 1 now allows, in particular, a hybrid drive system 2 comprising an internal combustion engine and an electric drive, which is integrated, for example, in a vehicle transmission, as shown in the illustration of Fig. 3, which transmits power to the rear axle via a cardan shaft 10, for example, in order to drive the wheels of this rear axle accordingly via a differential (not shown here). The modular design of the battery kit system 3 enables such an arrangement without any problems. The arrangement according to the invention is advantageous, for example, in vans, which only have a low loading floor and a rear axle differential on the rear axle, compared to vehicles with an electric motor arranged on the rear axle. The drive system 2 can be either a purely electric drive system or a hybrid drive system, comprising an internal combustion engine and an additional electric motor drive. In motor vehicles that do not have a cardan shaft 10, the gap could accordingly be omitted, so that, for example, both of the battery blocks 4.1 and 4.2 could be made a little wider.

[0019] The representation in the Fig. 4 addresses the structure of the Fig. 2 and Fig. 3 again. Here, too, the two battery blocks 4.1 and 4.2 can be seen, which are electrically and control-connected via the electronics module 5 with its module housing 5'. For installation, for example, in the area of ​​the underbody of the motor vehicle 1, these components are arranged in a mounting frame designated 11. The module housing 5' of the electronics module 5 can be connected to the battery blocks 4.1 and 4.2, for example, with screws (the screw holes are indicated here). Each of the battery blocks 4.1 and 4.2 has a flange 16 with corresponding mounting holes, which enable fixation to the vehicle 1. The entire structure, with the electronics module 5 attached and connected to the battery blocks 4.1 and 4.2, can now be positioned in the subframe 11. This subframe can be temporarily screwed to the vehicle 1 using its own screw holes.The modular battery system 3 is now held in its intended position and can be fastened, for example, from above to the flanges 16 that extend at least partially around the battery blocks 4.1 and 4.2. Subsequently, the subframe 11 can be removed again by loosening its screw connection to the vehicle 1, thus enabling installation, for example, with an insertion direction from below into the vehicle 1.

[0020] In the presentation of the Fig. 5 is now a representation analogous to that in the Fig. 2 and Fig. 3. In contrast to the representation in Fig. 3, the representation of the electric drive system 2 and the cardan shaft 10 has been omitted here. Rather, it is intended to show that, in comparison to the representations in the Fig. 2 and Fig. 3 the length I of the two battery blocks is smaller than the length L in the previously described embodiments. The modular battery system 3 thus allows the use of correspondingly shorter battery blocks 4.1, 4.2, for example, when less electrical storage capacity is required, or when less installation space is available in the longitudinal direction x due to a shorter wheelbase of the motor vehicle 1. Of course, it would also be conceivable here to connect a battery block with the length L and a battery block with the length I to one another using an electronic module 5, thus combining them.

[0021] Another alternative is the representation of the Fig. 6. Here, four individual battery blocks 4.1, 4.2, 4.3 and 4.4 are provided. They all have the same length L, purely as an example, but could also have different lengths. Here, too, a gap in the transverse direction y of the motor vehicle 1 is provided between the two battery blocks 4.1 and 4.2 on one side and the two battery blocks 4.3 and 4.4 on the other side, so that here, too, comparable to the illustration of the Fig. 3, there would be space for a drive shaft 10, a transmission tunnel, or the like. If this gap is not necessary, it would also be conceivable to provide only a single battery block 4, which, combined with the electronics module 5, occupies the entire installation space.

[0022] In the presentation of the Fig. 7, another alternative design can be seen. Two battery blocks 4.1 and 4.2 are connected via the electronic module 5 with its module housing 5', analogous to the illustrations in the Fig. 3 and Fig. 5 is already electrically contacted and connected to the control system. The module housing 5' of the electronics module 5 now has a further connection area 7 on its upper side in the z-direction. This is raised or surrounded by a raised frame 17; preferably, a further raised area 18 is located opposite on the same side. A third battery block 4.2 can now be placed from above onto the electronics module 5 or its module housing 5' and can be contacted via the connection area 7. This leads to a structure in which the electronics module 5 in turn connects several battery blocks, here three battery blocks 4.1, 4.2 and 4.3, electrically and with regard to control and battery management, and in particular charging. This structure can be used in particular when additional installation space is available above the electronics module 5 in the height direction z of the motor vehicle 1.

[0023] The representation in Fig. 8 shows a similar structure to that shown in the exploded view of the Fig. 7, in the assembled state. Here, too, a battery block is mounted on the electronic module 5, which is designated here as 4.2, since the battery block below the electronic module 5 is designed as a single large battery block 4.1. As an alternative to the two illustrations in the Fig. 7 and Fig. 8 it would of course also be conceivable to install the battery blocks 4 below the electronic module 5, for example in the Fig. 5 and Fig. 6. It would also be conceivable to use a battery block 4.3 or 4.2 arranged in the transverse direction y in the illustrations of Fig. 7 and Fig. 8 above the electronic module 5 by two or more battery blocks 4 running in the transverse direction y or longitudinal direction x.

[0024] Finally, based on the Fig. 9 and Fig. 10 will explain how a basic arrangement in the underbody 12 of the vehicle 1, as already indicated above, can look like. In the illustration of the Fig. 9 shows a structure which, for example, Fig. 5 is intended to show the modular battery system 3 shown. This is mounted essentially in the longitudinal direction x in the underbody 12 of the motor vehicle 1, indicated as a sandwich construction. The battery blocks 4.1, 4.2, which are arranged one behind the other in the direction shown, so that only the battery block 4.2 can be seen here, are located directly in the area of ​​the underbody. The electronics module 5 or its module housing 5' protrudes upwards in the direction z beyond the upper end of the sandwich floor 12. This area lies below a vehicle seat 13, which can in particular be one of the front seats of the vehicle 1. This is designed via a frame 14 with a base 15 with a comparatively small extension in the vertical direction z, wherein the installation space for the electronics module 5 is created within this base 15, the module housing 5' of which can preferably be adapted to the available installation space within the base.

[0025] In the presentation of the Fig. An analogous structure can be seen in Figure 10. It differs mainly in the greater length L of the battery blocks 4.1, 4.2 and can be used, for example, analogously to the illustration in Fig. 7. The base 15 under the vehicle seat 13 is designed accordingly larger and dispenses with the seat frame 14. Such structures are often used in light commercial vehicles, which are also colloquially referred to as delivery vans. Within the base 15, a larger available construction volume is then created, so that in addition to the electronic module 5, another battery block, here the battery block 4.3, in a representation analogous to the one in Fig. 7, can be accommodated. This allows the overall battery capacity to be increased in the sense of a distributed battery according to the prior art mentioned above, whereby the advantage of a single electronic module 5 for contacting all battery blocks, which are also collectively designated by the reference numeral 4, can also be achieved here.

[0026] The assembly process can be carried out in both described embodiments both with and without a battery block 4.3 arranged above the electronic module 5 in the Fig. 3 through one or more shell windows, preferably from below into the motor vehicle 1. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 102020005603 A1

[0002] DE 102020109055 A1

[0004]

Claims

[1] Battery modular system (3) for a motor vehicle (1), which has at least one battery block (4) and an electronic module (5) for contacting and controlling, wherein the electronic module (5) is arranged in a vertical direction (z) of the motor vehicle (1) in a properly installed state above the at least one battery block (4), characterized by that the electronic module (5) comprises a module housing (5') which has at least two spatially separated connection areas (7), which each comprise high-voltage and signal plugs (8, 9) for connection to corresponding elements (7', 8', 9') of the at least one battery block (4). [2] Battery modular system (3) according to claim 1, characterized by that the connection areas (7) are arranged on the same side of the module housing (5'), wherein the side with the connection areas (7) is the lower side of the module housing (5') in the intended installed state. [3] Battery modular system (3) according to claim 1, characterized by that the connection areas (7) are arranged on opposite sides of the module housing (5'), wherein the opposite sides with the connection areas (7) are the upper and lower sides of the module housing (5') in the intended installed state. [4] Battery modular system (3) according to claim 1, characterized byin that the module housing (5') provides at least three connection areas (7), wherein at least two of the connection areas (7) are formed on one side of the module housing (5') and at least one of the connection areas (7) is formed on a side of the module housing (5') opposite this one side, wherein the at least two connection areas are located on the lower side of the module housing (5') in the properly installed state of the module housing (5'), wherein the at least one connection area (7) is located on the opposite side on the upper side of the module housing (5'). [5] Battery modular system (3) according to claim 4, characterized by that the connection area located on the upper side of the module housing (5') in the intended installed state is raised or surrounded by a raised frame. [6] Battery modular system (3) according to at least one of claims 1 to 5, characterized bythat the part with the electronic module (5) which lies above the at least one battery block (4) in the vertical direction (z) of the motor vehicle (1) in the intended installed state is intended to be arranged at least partially below at least one vehicle seat (13). [7] Battery modular system (3) according to claim 6, characterized by that the vehicle seat (13) is one of the front seats. [8] Battery modular system (3) according to at least one of claims 1 to 5, characterized by that the electronic module (5) has at least one charger for the battery blocks (4).

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