Device and method for signal line shielding in the cable housing of a high-voltage battery

Abstract

Device for signal line shielding on a high-voltage battery, wherein the high-voltage battery has a plurality of battery modules (101) arranged in series, each battery module (101) having two terminal connections (114) and a plurality of interconnected energy storage cells (302), wherein the respective terminal connections (114) of each battery module (101) are connected to a respective high-voltage line (113) at a module housing opening, wherein the device has a hollow and media-tight line housing (103) with connections to the respective module housing opening, wherein the line housing (103) is designed to conduct a dielectric coolant in its cavity and to be arranged in a media-tight manner enclosing all module housing openings along the battery modules (101) arranged in series, wherein the line housing (103) has a plurality of high-voltage lines (113) in its cavity,at least one signal line (204) and a signal line shield (115), wherein the signal line shield (115) is arranged between the high-voltage lines (113) and the at least one signal line (204), thus dividing the line housing (103) into a first region, which comprises the high-voltage lines (113) and the coolant flowing through it, and a second region, which comprises the at least one signal line (204), wherein the signal line shield (115) is designed to ensure electromagnetic compatibility between the high-voltage lines (113) running adjacently within the line housing (103) and the at least one signal line (204), and wherein a respective shielded output line (116) of the at least one signal line (204) is led from the second region to the respective module housing opening and is connected there to a respective battery module controller.

Description

[0001] The present invention relates to a device for signal line shielding in a cable housing of a high-voltage battery, wherein both high-voltage lines and signal lines run within the cable housing. Furthermore, a method is claimed by which the device is arranged in the cable housing.

[0002] In the battery systems of electric vehicles, high-voltage (HV) electrical cables are arranged for charging or discharging energy storage cells or energy storage cell stacks. Signal cables also run there for monitoring temperatures, charge levels, and much more. Since electromagnetic interference waves emanate from high-voltage cables in particular, which can corrupt the signals transmitted in the signal cables, high-voltage cables and signal cables are positioned at a large distance from each other. The greater the spatial distance between them, the less mutual interference.In the prior art, this is also implemented by having the HV lines run inside a battery system housing, but the signal lines arranged outside, which makes expensive interfaces necessary to guide each signal line to its respective connection destination within the battery housing, especially when the battery housing is flowed through by a cooling liquid.

[0003] During charging or discharging of energy storage cells in an electric vehicle's traction battery, heat is generated, which can damage the battery. Therefore, to ensure a long service life of the energy storage cells, the battery must be cooled. Heat dissipation is particularly effective when done as close to the source as possible, for example, by flushing the energy storage cells with a coolant, rather than indirectly via thermal contact between the battery and cooling plates.

[0004] European document EP 3 110 239 B1 discloses a communication system in which command signals are transmitted via a specially shielded cable. The shielded cable is connected to a high-voltage system.

[0005] The Chinese publication CN 215834273 U also describes a special electrical connection cable that contains both HV lines and a signal line. The connection cable incorporates a separation structure designed to prevent interference between the HV lines and the signal line.

[0006] GB 2508140 A discloses a cable housing for an electrical distribution system, which can be connected, among other things, to a main battery of an electric vehicle. Both HV cables and signal cables, as well as a shield, are arranged in the cable housing. The shield divides the cable housing into separate housing areas, with the HV cables and signal lines arranged in different housing areas. Cooling lines can also be arranged in the housing area with the HV cables, so that the HV cables and the cooling lines are in thermal contact.

[0007] The publication DE 10 2015 118 921 A1 discloses a multilayer cable comprising at least three flat cables running essentially parallel to each other. The flat cables are intended to be connected to respective poles of DC voltage sources and can each be electrically insulated from the other flat cables of the multilayer cable.

[0008] Against this background, it is an object of the present invention to provide a device for signal line shielding on a high-voltage battery, wherein the battery modules of the high-voltage battery, including the high-voltage lines connected to them, are surrounded by a coolant. High-voltage lines and signal lines should run as close to one another as possible in the high-voltage battery to avoid space-consuming and costly separate line housings. Furthermore, a method should be provided by which the device is arranged in the line housing.

[0009] To achieve the above-mentioned object, a device for signal line shielding on a high-voltage battery with the features of claim 1 is proposed, wherein the high-voltage battery has a plurality of battery modules arranged in series. Each battery module has two terminal connections and a plurality of interconnected energy storage cells. In each battery module, the respective terminal connections are connected to a respective high-voltage line at a module housing opening. The device has a hollow and media-tight line housing with connections to the respective module housing opening, wherein the line housing is designed to conduct a dielectric coolant in its cavity and to be arranged in a media-tight manner enclosing all module housing openings along the battery modules arranged in series.The cable housing has a plurality of high-voltage cables, at least one signal line, and a signal line shield in its cavity. The signal line shield is arranged between the high-voltage cables and the at least one signal line. The cable housing is thus divided into a first region, which comprises the high-voltage cables and the coolant flowing through it, and a second region, which comprises the at least one signal line. The signal line shield is designed to ensure electromagnetic compatibility (EMC) between the high-voltage cables running adjacently within the cable housing and the at least one signal line. A respective shielded output of the at least one signal line is led from the second region of the cable housing to the respective module housing opening and connected there to a respective battery module controller.

[0010] It is known from the prior art to provide two separate areas within a cable routing system, in order to route signal lines in one area and HV lines in the correspondingly separate area. Furthermore, the device according to the invention advantageously provides for a flow around the HV lines with coolant within the cable housing, wherein the signal line shielding provided according to the invention shields the flow-through area with the HV lines from the at least one signal line.

[0011] The device according to the invention allows the HV cables and the at least one signal cable to be positioned close to each other and parallel within the cable housing, saving space. Because all cables run inside the cable housing, there are no additional costs for sealed connectors.

[0012] The at least one signal line can, for example, transmit data for monitoring the state of charge (SoC), temperature monitoring of the energy storage cells, service life of the battery module (State of Health, SoH), etc., between the respective battery module controller and a central controller of the HV battery.

[0013] The signal shielding is formed by a shielding plate, for example, made of a steel sheet or an aluminum sheet. The respective material thickness is designed accordingly so that, according to the invention, electromagnetic compatibility between the high-voltage lines running adjacently within the cable housing and the at least one signal line is ensured. Thus, the inventive division of the cable housing into two areas allows voltages of up to approximately 1000 V to be applied to electronic components and / or the high-voltage lines in the first area, while simultaneously allowing electronic components and / or the at least one signal line to operate smoothly with voltages of up to approximately 60 V in the second area.

[0014] In one embodiment of the device according to the invention, the high-voltage lines are formed by busbars and are directly surrounded by dielectric coolant. The predominantly elongated line housing has connections to a coolant circuit at at least one head end for the coolant, as well as electrical connections for the busbars for supplying power to, for example, a traction motor of an electric vehicle. The battery modules, for example, are lined up along their width along the predominantly elongated course of the line housing. A longitudinal extension of a battery module can, for example, extend below a passenger compartment from a left to a right side of the electric vehicle, so that the battery modules are lined up in the longitudinal direction of the vehicle. The module housing openings, which are enclosed in a media-tight manner by the line housing according to the invention, are then located approximately in the center of the vehicle in the transverse direction of the vehicle.This means that the cable housing, with its predominantly elongated shape, also has a main extension direction in the longitudinal direction of the vehicle.

[0015] In a further embodiment of the device according to the invention, the signal line shielding has a contact area with the line housing that is conductive at least in a partial section.

[0016] In yet another embodiment of the device according to the invention, the cable housing has a lower shell and an upper shell. The lower shell and upper shell are joined together, for example, with screws along a wing flange. The lower shell and upper shell can each be formed individually or both together from an electrically conductive material, with the two being electrically conductively connected to one another along the wing flange in the latter case. The signal line shielding is advantageously pulled into this contact area between the lower shell and upper shell, at least in sections, along the wing flange. The signal line shielding is thus electrically conductively connected to the lower shell and / or upper shell—depending on their design, with a conductive material—at least in sections.

[0017] In a further embodiment of the device according to the invention, an electrically conductive foam is arranged at least in a partial section of the contact area between the signal line shielding and the cable housing. It is conceivable that the electrically conductive foam, which is applied to the signal line shielding in the contact area, is pressed against at least one of the two shells by the joint between the lower shell and upper shell, thereby establishing electrical contact between the signal line shielding and the lower shell and / or upper shell. Alternatively, the signal line shielding can be glued, riveted, or screwed to the lower shell and / or upper shell in an electrically conductive manner, at least in sections.

[0018] In a further embodiment of the device according to the invention, the module housing openings, which are enclosed in a media-tight manner by the cable housing, are additionally designed to conduct dielectric coolant. This enables direct flow around the cells, advantageously using the same dielectric coolant, so that only one coolant circuit is necessary.

[0019] Furthermore, a method for arranging signal line shielding on a high-voltage battery with the features of claim 7 is claimed, wherein the high-voltage battery has a plurality of battery modules arranged in series. Each battery module has two terminal connections and a plurality of interconnected energy storage cells. In each battery module, the respective terminal connections are connected to a respective high-voltage line at a module housing opening. A hollow and media-tight line housing with connections to the respective module housing opening is arranged on the high-voltage battery. The line housing is designed to conduct a dielectric coolant in its cavity and to enclose all module housing openings along the lined-up battery modules in a media-tight manner.A plurality of high-voltage lines and at least one signal line are arranged in the cavity of the cable housing, with signal line shielding, which ensures electromagnetic compatibility between the high-voltage lines running adjacently within the cable housing and the at least one signal line, being arranged between the high-voltage lines and the at least one signal line. The cable housing is thus divided into a first region, which comprises the high-voltage lines and the coolant flowing through them, and a second region, which comprises the at least one signal line. From the second region, a respective shielded output of the at least one signal line is led to the respective module housing opening and connected there to a respective battery module controller.

[0020] In one embodiment of the method according to the invention, the high-voltage lines are formed by busbars and are directly surrounded by the dielectric coolant.

[0021] In a further embodiment of the method according to the invention, a contact area which is conductive at least in a partial section is formed between the signal line shielding and the line housing.

[0022] In yet another embodiment of the method according to the invention, the cable housing is formed by a lower shell and an upper shell.

[0023] In a further embodiment of the method according to the invention, an electrically conductive foam is arranged at least in a partial section of the contact area between the signal shielding and the cable housing.

[0024] Further advantages and embodiments of the invention will become apparent from the description and the accompanying drawings.

[0025] In a further embodiment of the method according to the invention, the module housing openings, which are enclosed in a media-tight manner by the cable housing, are designed to conduct dielectric coolant. This enables direct cell flow with the dielectric coolant.

[0026] It is understood that 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.

[0027] The figures are described coherently and comprehensively, and the same components are assigned the same reference symbols. Fig. 1 shows a perspective view and a section of an embodiment of the device according to the invention. Fig. 2 shows a perspective sectional view of a centrally running signal line shield in the embodiment of the device according to the invention. Fig. 3 shows a perspective sectional view of a laterally extending signal line shield in the embodiment of the device according to the invention.

[0028] In Fig. 1 shows a perspective view 100 and a section 110 of an embodiment of the device according to the invention. A plurality of battery modules 101 are arranged between a holding frame 102, which can be located, for example, below the passenger compartment between a left and a right side of the vehicle. The battery modules 101, when connected together, form a high-voltage (HV) battery. A cable housing 103 according to the invention is arranged on the respective module housing openings located centrally on an upper side of the battery modules 101. The cable housing 103 is, for example, a so-called media route, which includes or forms all the cables necessary for the control, cooling, and power connection of the battery modules 101. Electrical connections and coolant connections (not visible), for example, are located at a head end 104 of the cable housing 103.For a section 110, an upper shell of the cable housing 103, which is fastened along a wing flange 112 on a lower shell 112, was removed so that the inventive arrangement of a signal line shield 115 or a shielding plate in the lower shell 111 is visible. Centrally located in relation to the width of the battery module 101 viewed in the section 110 is a module housing opening from which two pole connections 114 protrude as a double column. A respective busbar running in the cable housing 103 is connected to each pole connection 114 as an HV line 113. In the area of the module housing opening, two shielded output lines 116 of a signal line running beneath the shielding plate are led to the module housing opening. The dot-dashed lines 120 and 130 represent sections for the illustrations in . Fig. 2 and Fig. 3.

[0029] In Fig. 2 shows a perspective sectional view 200 of a centrally extending signal line shield 115 in the embodiment of the device according to the invention. A part of the cable housing is viewed which lies outside a connection area of the battery modules. Since no module housing opening needs to be taken into account here, the signal line shield 115 can run in the center of the lower shell 111. The upper shell 201 is connected to the lower shell 111 by means of screws 203. A respective seal 202 runs along the wing flange 112 on both sides, which makes a cavity of the cable housing media-tight. In the cavity, the busbars run in a first area as HV lines 113, around which coolant (not shown) flows. The shielding plate of the signal line shield 115 creates a second area in which the signal lines 204 run.

[0030] In Fig. 3 shows a perspective sectional view 300 of a laterally extending signal line shield 115 in the embodiment of the device according to the invention. The area of a module housing opening is viewed, from which the two terminal connections 114 protrude into the cable housing. The shielding plate of the signal line shield 115 runs along a left side and is clamped, together with a conductive foam 303, between the lower shell and upper shell for screwing to the wing flange. A shielded output line 116 of a signal line 204 running beneath the shielding plate is led from the signal line shield 115 to the module housing opening and connected there to a battery module controller or its connection. The terminal connections 114 are connected to the HV lines 113 and establish contact with the energy storage cells 302 in a connection area 301 within the battery module. List of reference symbols 100 Perspective view of high-voltage battery system 101 battery modules 102 holding frames 103 cable housing 104 Head end of the line housing with bottom coolant connection 110 Top view of section of cable housing with hidden upper shell 111 Cable housing lower shell 112 wing flange 113 Busbar as HV cable 114 battery module terminal connections 115 Signal line shielding 116 Shielded branch signal line / battery module 120 cut for display Fig. 2 130 cut for display Fig. 3 200 Cable routing outside the connection area of the battery modules 201 Cable housing upper shell 202 Seal 203 screw connection 204 Signal line 300 Battery module connection area 301 Connection area pole connections / energy storage cells 302 Energy storage cell 303 Compressed conductive foam

Claims

[1] Device for signal line shielding on a high-voltage battery, wherein the high-voltage battery has a plurality of battery modules (101) arranged in series, in which each battery module (101) has two terminal connections (114) and a plurality of interconnected energy storage cells (302), wherein in each battery module (101) the respective terminal connections (114) are connected to a respective high-voltage line (113) at a module housing opening, wherein the device has a hollow and media-tight line housing (103) with connections to the respective module housing opening, wherein the line housing (103) is designed to conduct a dielectric coolant in its cavity and to be arranged in a media-tight manner enclosing all module housing openings along the battery modules (101) arranged in series, wherein the line housing (103) has a plurality of high-voltage lines (113) in its cavity,at least one signal line (204) and a signal line shield (115), wherein the signal line shield (115) is arranged between the high-voltage lines (113) and the at least one signal line (204), thus dividing the line housing (103) into a first region, which comprises the high-voltage lines (113) and the coolant flowing through it, and a second region, which comprises the at least one signal line (204), wherein the signal line shield (115) is designed to ensure electromagnetic compatibility between the high-voltage lines (113) running adjacently within the line housing (103) and the at least one signal line (204), and wherein a respective shielded output line (116) of the at least one signal line (204) is led from the second region to the respective module housing opening and is connected there to a respective battery module controller. [2] Device according to claim 1, wherein the high-voltage lines (113) are formed by busbars and are directly surrounded by the coolant. [3] Device according to one of the preceding claims, wherein the signal line shield (115) has a contact area with the line housing (103) which is conductive at least in a partial section. [4] Device according to one of the preceding claims, wherein the cable housing (103) has a lower shell (111) and an upper shell (201). [5] Device according to claim 3 or 4, wherein an electrically conductive foam (303) is arranged at least in a partial section of the contact area between the signal line shield (115) and the line housing (103). [6] Device according to one of the preceding claims, wherein the module housing openings enclosed in a media-tight manner by the line housing (103) are additionally designed to pass dielectric coolant through in order to allow direct cell flow. [7] Method for arranging a signal line shield on a high-voltage battery, wherein a hollow and media-tight cable housing (103) with connections to respective module housing openings is arranged on the high-voltage battery, wherein the cable housing (103) carries a dielectric coolant in its cavity and encloses all module housing openings in a media-tight manner along battery modules (101) arranged next to one another, wherein in the cavity of the cable housing (103) a plurality of high-voltage lines (113) and at least one signal line (204) are arranged, wherein a signal line shield (115), which ensures electromagnetic compatibility between the high-voltage lines (113) running adjacently within the line housing (103) and the at least one signal line (204), is arranged between the high-voltage lines (113) and the at least one signal line (204), and thus the line housing (103) is divided into a first region, which comprises the high-voltage lines (113) and the coolant flowing through, and a second region, which comprises the at least one signal line (204), and wherein a respective shielded output line (116) of the at least one signal line (204) is led from the second region to the respective module housing opening and is connected there to a respective battery module controller. [8] Method according to claim 7, wherein the high-voltage lines (113) are formed by busbars and are directly surrounded by the coolant. [9] Method according to claim 7 or 8, wherein a contact region which is conductive at least in a partial section is formed between the signal line shielding (115) and the line housing (103). [10] Method according to one of claims 7 to 9, wherein the cable housing (103) is formed by a lower shell (111) and an upper shell (201). [11] Method according to one of claims 9 or 10, wherein an electrically conductive foam (303) is arranged at least in a partial section of the contact area between the signal line shield (115) and the line housing (103). [12] Method according to one of claims 7 to 11, wherein the module housing openings enclosed in a media-tight manner by the line housing (103) are designed to pass dielectric coolant through in order to allow direct cell flow.

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