Thermally conductive padding and battery module with thermally conductive padding

Abstract

Thermally conductive padding (200) for dissipating heat from a component (310) to be cooled in a battery-powered vehicle, wherein the thermally conductive padding (200) comprises the following: a thermally conductive bag (210) filled with a malleable, thermally conductive medium (202); wherein the thermally conductive bag (210) is designed for insertion between the component (310) to be cooled and a component (301) acting as a heat sink; wherein the thermally conductive bag (210) has a malleable surface which is designed to adapt to the respective surface structures of the component (310) to be cooled and the component (301) acting as a heat sink when the thermally conductive bag (210) is inserted between the component (310) to be cooled and the component (301) acting as a heat sink, so that air gaps in the respective surface structures are filled by the thermally conductive bag (210) and heat can be dissipated via the thermally conductive bag (210) from the component (310) to be cooled to the component (301) acting as a heat sink, wherein the malleable, thermally conductive medium (202) comprises a thermally conductive paste consisting of two or more material components (101, 102) which harden upon mixing.

Description

Technical field

[0001] The present invention relates to the field of cooling components in battery-powered vehicles, in particular in battery modules of battery-powered vehicles. In particular, the invention relates to a thermally conductive pad for dissipating heat from a component to be cooled in a battery-powered vehicle and to a battery module with such a thermally conductive pad, which is in particular adaptively and individually formable. State of the art

[0002] In the field of electromobility, high temperatures are generated during driving and charging, which generally need to be dissipated. There are many ways to do this. Well-known methods include so-called "gapped pads" that are glued on, applications with thermal paste (with a fixed amount or adaptive), or oil-cooled systems. However, all these known methods have significant drawbacks that complicate their application.

[0003] Specifically, the Gappad solution suffers from poor tolerance compensation, particularly when the Gappad is clamped between two components. Automation of this Gappad solution is only possible to a limited extent. Clamping the Gappad can result in high assembly forces or insufficient contact, leading to low efficiency, poor assembly, and potentially component damage. Therefore, the Gappad solution is only conditionally suitable for electromobility applications.

[0004] When applying thermal pastes, a general marking method is not optimal for all tolerance levels. Adaptive markings are cycle-time dependent and require specialized equipment, resulting in high costs and investment. Assembly forces are high for two-component solutions, increasing particularly after long application or cycle times; this also applies to one-component gap fillers.

[0005] The main disadvantage of oil-cooled systems, or immersion cooling, lies in the complexity related to leak tightness. Leak tightness remains the primary problem here.

[0006] German patent application DE 10 2011 075 820 A1 discloses a traction battery with a plastic housing that encloses an arrangement of electrochemical cells and a temperature control device. During operation, a fluid flows through the temperature control device.

[0007] The publication DE 10 2020 104 501 A1 discloses an air displacer for a traction battery of a motor vehicle, which, when installed in a battery housing of the traction battery, is designed to fill a free volume in the battery housing and thus displace air in the battery housing in the event of heat development inside the housing. Description of the invention

[0008] One object of the invention is therefore to create an advantageous concept for the safe and efficient cooling of components of the battery-powered vehicle which are exposed to strong heating during driving and charging, in which the disadvantages described above do not occur.

[0009] The problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the description, and the accompanying figures.

[0010] One idea of ​​the invention is based on using a thermally conductive pad for heat dissipation on a component to be cooled, such as a busbar or a battery cell, in a battery-powered vehicle.

[0011] Power lines, and especially busbars in the high-voltage section of battery-powered vehicles, heat up when power is demanded. To keep cross-sections small and thus achieve the best compromise between power demand, material usage, weight, sustainability, and, last but not least, cost, this disclosure presents cooling solutions based on cooling systems that use a thermally conductive medium, such as thermal paste or cooling oils, for direct heat transfer between the relevant components of the parts being cooled and those being cooled (i.e., the parts acting as heat sinks).

[0012] The pad presented in this disclosure is filled with a thermally conductive paste, typically one- or two-component, but also multi-component, and inserted between the components to be cooled and those being cooled. Filling with the thermally conductive paste can be performed manually, semi-automatically, or fully automatically using robotics during the industrialization process. In the event of service, the special techniques and designs presented here can be implemented just as easily and effectively (i.e., service-oriented). The "pad solution" presented here can adapt to the individual tolerances of the component pairings and is therefore highly valuable due to its adaptability, as it is very efficient in heat dissipation. This adaptability is also guaranteed during service. The same principle is applicable to the cooling of cells or cell modules, as described in this disclosure.

[0013] The solution described in this disclosure provides an adaptive, customizable cooling system that can be implemented with comparatively little effort. It offers a clean separation of the components and the pad. Because there is no direct contact between the thermal paste and the components, they are easily separable and therefore easy to handle for disposal and servicing in the workshop, as no additional cleaning processes are necessary. The solution presented here is sustainable due to the separation and the energy savings in the industrialization process. The process is location-independent, making customer-proximity manufacturing economically viable. The process is cost-optimized because it is highly automatable. Thanks to the special "bag design," both 1K and 2K gap filler types can be used effectively.The special "bag design" also enables highly sought-after, service-optimized applications. Cooling oils can also be filled into the bag packs, and thin cushions can be geometrically secured by means of welded bridges between the top and bottom of the bag / cushion.

[0014] This disclosure describes battery-powered vehicles, also known as electric vehicles. In such electric vehicles (BEVs, PHEVs, etc.), the energy for propulsion is drawn from a battery (colloquially called a battery). The battery typically consists of several cells connected in parallel and series. These cells are generally fixed in modules, and these modules are in turn fixed in battery housings. This disclosure presents measures for the efficient cooling of these cells and the busbars they use.

[0015] This disclosure describes battery modules. Battery modules contain a plurality of battery cells. A battery cell is an electrical or galvanic cell and thus an electrochemical energy storage device and energy converter. During discharge, stored chemical energy is converted into electrical energy. This can be used by an electrical load.

[0016] According to a first aspect, the problem described above is solved by a thermally conductive pad for dissipating heat from a component to be cooled, for example in a battery-powered vehicle, wherein the thermally conductive pad comprises the following: a thermally conductive bag filled with a malleable, thermally conductive medium; wherein the thermally conductive bag is designed to be inserted between the component to be cooled and a component acting as a heat sink;wherein the thermally conductive bag has a malleable surface which is designed to adapt to the respective surface structures of the component to be cooled and the component acting as a heat sink when the thermally conductive bag is inserted between the component to be cooled and the component acting as a heat sink, so that air gaps in the respective surface structures are filled by the thermally conductive bag and heat can be dissipated via the thermally conductive bag from the component to be cooled to the component acting as a heat sink, wherein the malleable, thermally conductive medium comprises a thermally conductive paste consisting of two or more material components which harden when mixed.

[0017] Such a thermally conductive pad provides safe and efficient cooling of components of the battery-powered vehicle, which are exposed to high temperatures during driving and charging, without the disadvantages described above of the Gappad solution, the direct application of thermal pastes or oil-cooled systems.

[0018] The thermally conductive pad forms an adaptive, individually adjustable cooling system that can be implemented with relatively little effort. The pad tightly encloses the thermal paste or heat-conducting medium, ensuring that the components and the pad are cleanly separated. Because there is no direct contact between the thermal paste and the components, they are easily separable and therefore easy to handle for disposal and servicing in the workshop, as no additional cleaning processes are necessary.

[0019] Using such a thermally conductive pad allows cycle times in the production of battery systems to be increased, since inserting the pad can be done faster, e.g. by a robot, than the direct application of thermal paste between the respective components, where a robot arm has to travel a certain distance to spray the thermal paste onto the relevant components.

[0020] The component to be cooled could be, for example, a busbar or a battery cell. The component acting as a heat sink could be, for example, the housing of a battery module or the frame or chassis of the vehicle. A component can act as a heat sink if its temperature is lower than the temperature of the component to be cooled.

[0021] According to an exemplary embodiment of the thermally conductive cushion, the thermally conductive bag comprises at least one filling nozzle for filling the malleable, thermally conductive medium; and the thermally conductive bag comprises at least one vent opening for venting the bag when filling it with the malleable, thermally conductive medium.

[0022] The malleable, thermally conductive medium can be efficiently poured into the thermally conductive bag via the filling nozzle. For example, two components of the thermally conductive medium can be added to the bag and mixed before use. After the bag is placed between the component to be cooled and the component acting as a heat sink—that is, once the bag's surface has conformed to the respective surface structures—the thermally conductive medium can then cure. Since the curing time ranges from minutes to hours, the bag can also be pre-filled with the thermally conductive medium and used only when needed for production.

[0023] Of course, a malleable, thermally conductive medium that does not need to harden can also be used.

[0024] The vents allow existing air to be expelled from the bag, so that the bag can be completely filled with the thermally conductive medium.

[0025] According to the invention, the malleable, thermally conductive medium comprises a thermally conductive paste consisting of one, two or more material components.

[0026] The thermally conductive paste, which consists of one, two or more material components, offers the technical advantage that it can harden and permanently adapt to the surface structures once fitted, without slipping or displacement.

[0027] According to an exemplary embodiment of the thermally conductive pad, the thermally conductive pouch comprises a first chamber filled with a first material component of the thermally conductive paste; and the thermally conductive pouch comprises a second chamber filled with a second material component of the thermally conductive paste.

[0028] This offers the technical advantage that the padding can be prefabricated and only mixed when it is inserted between the respective components in the factory, or shortly beforehand, to initiate the hardening process. This, in turn, leads to a reduction in cycle times during production, allowing vehicles to be manufactured faster and more efficiently.

[0029] According to an exemplary embodiment of the thermally conductive cushion, the thermally conductive pouch comprises an intermediate membrane between the first chamber and the second chamber, which is designed to rupture during a massage-like movement of the pouch and to cause a mixing of the two material components, wherein the two material components are designed to harden after mixing.

[0030] This offers the technical advantage that the intermediate membrane ruptures during massage-like movements, such as those performed by a robot in manufacturing, and initiates the curing process. This curing process then takes minutes to hours, ensuring that after manufacturing, the thermally conductive pad is optimally positioned between the component to be cooled and the component acting as a heat sink, e.g., the housing, thus providing very efficient, air-gap-free heat dissipation.

[0031] According to an exemplary embodiment of the thermally conductive cushion, the thermally conductive bag comprises two pull tabs which can each be actuated in opposite directions to each other, wherein the two pull tabs are designed to tear open the intermediate membrane when actuated and to allow a mixing of the two material components.

[0032] The intermediate membrane can be easily torn open via the pull tabs, either manually or by a robot in the manufacturing process, so that the mixing of the material components and thus the start of the curing process can be controlled and take place at the appropriate time.

[0033] According to a second aspect, the problem described above is solved by a battery module for a battery system of a battery-powered vehicle, wherein the battery module comprises: a plurality of battery cells and / or busbars as components to be cooled; a housing acting as a heat sink in which the components to be cooled are housed; and a thermally conductive pad according to the first aspect described above; wherein the thermally conductive pad is inserted between the components to be cooled and the housing and is designed to dissipate heat from the components to be cooled to the housing.

[0034] Such a battery module with a thermally conductive pad offers safe and efficient cooling of the battery module components, which are exposed to high temperatures during driving and charging, without the disadvantages described above for the Gappad solution, the direct application of thermal pastes or oil-cooled systems.

[0035] Using such a battery module with thermally conductive padding increases cycle times in the production of battery systems, as inserting the padding can be done faster, e.g. by a robot, than directly applying thermal paste between the respective components.

[0036] According to an exemplary embodiment of the battery module, the housing includes a lockable housing cover which is designed to press the thermally conductive pad against the components to be cooled when the housing is closed.

[0037] This offers the technical advantage that pressing the pad against the component to be cooled and against the housing cover, which acts as a heat sink, can be achieved simply by closing the housing cover. This allows the surface of the bag to conform to the respective surface structures of the component to be cooled and the housing cover, enabling optimal heat dissipation without disruptive air gaps.

[0038] According to an exemplary embodiment of the battery module, the battery cells and / or busbars are aligned with tolerances in the housing; and the thermally conductive padding is designed to compensate for tolerances between the battery cells and / or busbars with the malleable surface of the thermally conductive bag.

[0039] The battery cells and / or busbars can therefore be arranged unevenly relative to each other; for example, one battery cell or busbar can be positioned higher than the next. These irregularities in the arrangement are compensated for by the padding, which can adapt to the respective surface structures.

[0040] According to an exemplary embodiment of the battery module, a plurality of cooling channels are embedded in the housing, which are designed to absorb the heat transferred from the thermally conductive pad to the housing and to dissipate it externally.

[0041] This offers the technical advantage of improved heat dissipation, where heat transfer to the housing and cooling channels is more efficient via the padding, as no air is trapped in the surfaces which would disrupt the overall heat transfer due to its poor heat transfer properties. Brief character description

[0042] The invention will now be described in more detail with reference to exemplary embodiments and the figures. The figures show: Fig. 1 a schematic representation of a method for producing a thermally conductive pad according to the invention in an exemplary embodiment; Fig. 2 a 3D representation of a thermally conductive pad according to the invention in an exemplary embodiment; Fig. 3 a schematic 3D representation of a battery module according to the invention with an open housing cover for inserting the thermally conductive pad according to an exemplary embodiment; Fig. 4 a schematic sectional view of the battery module according to the invention with the housing cover open for inserting the thermally conductive padding according to an exemplary embodiment; Fig. 5 a schematic sectional view of the battery module according to the invention with closed housing cover, so that the thermally conductive pad is pressed in between the housing cover and the battery cells or busbars, according to an exemplary embodiment; Fig. 6 a schematic sectional view of the battery module according to the invention with closed housing cover and two thermally conductive pads pressed between the housing cover or housing base and the battery cells or busbars, according to an exemplary embodiment; Fig. 7 a schematic sectional view of the battery module according to the invention with closed housing cover, so that the thermally conductive pad is pressed in between the housing cover and the battery cells or busbars, and cooling channels in the housing cover according to an exemplary embodiment; Fig. 8 a 3D representation of a thermally conductive pad according to the invention with two chambers and an intermediate membrane between the chambers according to an exemplary embodiment; Fig. 9 a 3D representation of a thermally conductive pad according to the invention with two chambers and an open intermediate membrane, so that the material components of the two chambers mix, according to an exemplary embodiment; and Fig. 10 a 3D representation of a thermally conductive pad according to the invention with two chambers and an intermediate membrane between the chambers and two pull tabs for tearing open the intermediate membrane according to an exemplary embodiment.

[0043] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently identified by the same reference numerals.

[0044] The following detailed description refers to the accompanying drawings, which form part thereof and illustrate specific embodiments in which the invention can be implemented. It is understood that other embodiments can also be used and structural or logical modifications can be made without deviating from the concept of the present invention. Therefore, the following detailed description is not to be understood as limiting. Furthermore, it is understood that the features of the various embodiments described herein can be combined with one another, unless specifically stated otherwise.

[0045] The aspects and embodiments are described with reference to the drawings, where the same reference numerals generally refer to the same elements. For explanatory purposes, numerous specific details are presented in the following description to provide a thorough understanding of one or more aspects of the invention. However, it may be obvious to a person skilled in the art that one or more aspects or embodiments can be implemented with a lesser degree of specific detail. In other cases, known structures and elements are shown schematically to facilitate the description of one or more aspects or embodiments. It is understood that other embodiments may be used and structural or logical modifications may be made without departing from the concept of the present invention.

[0046] Fig. Figure 1 shows a schematic representation of a method 100 for producing a thermally conductive pad 200 according to an embodiment according to the invention.

[0047] Two material components 101 and 102 are brought together in the filling element 103 to produce a thermal paste and mixed together in a mixing head 104. The two material components 101 and 102 can, for example, be taken from two separate tubes.

[0048] The thermally conductive pad 200 comprises a thermally conductive bag 210 into which the malleable, thermally conductive medium 202, which is produced by mixing the two material components 101, 102 in the mixing head 104, can be poured. The thermally conductive pad 200 corresponds to the thermally conductive pad 200 described in the following figures.

[0049] The mixing head 104 is coupled to a filling support of the bag 210 in order to fill the thermal paste 202, which is produced by mixing the two material components 101, 102, into the bag 210.

[0050] In this example, bag 210 includes two vent openings 203 to expel air from bag 210 during the filling process. Bag 210 is thermally conductive; it can be a highly thermally conductive plastic bag.

[0051] The process 100 can be carried out in an automated industrialization process. Alternatively, it can also be used as a simplified workshop solution for service.

[0052] Fig. Figure 2 shows a 3D representation of a thermally conductive pad 200 according to an embodiment according to the invention.

[0053] The thermally conductive pad 200 serves to dissipate heat from a component that needs cooling, for example in a battery-powered vehicle. This could be, for instance, a busbar or a battery cell, which can heat up considerably under high-voltage loads.

[0054] The thermally conductive pad 200 comprises a thermally conductive pouch 210 filled with a malleable, thermally conductive medium 202. The thermally conductive pouch 210 is designed to be inserted between the component 310 to be cooled and a component 301 acting as a heat sink, for example a housing or a housing cover 301, as described in the following figures.

[0055] The thermally conductive bag 210 has a malleable surface which is designed to adapt to the respective surface structures of the component 310 to be cooled and the component 301 acting as a heat sink when the thermally conductive bag 210 is inserted between the component 310 to be cooled and the component 301 acting as a heat sink, so that air gaps in the respective surface structures are filled by the thermally conductive bag 210 and heat can be dissipated via the thermally conductive bag 210 from the component 310 to be cooled to the component 301 acting as a heat sink.

[0056] It is not necessary to fill all existing air gaps. For improved heat dissipation, it is sufficient to fill most of the existing air gaps caused by the surface structure with the bag containing the heat-conducting medium. In extreme cases, even partially filling an air gap is enough to improve heat dissipation.

[0057] The thermally conductive bag 210 can include one or more filling nozzles 201 for filling the malleable, thermally conductive medium 202, as already described above. Fig. Figure 1 shows the thermally conductive bag 210. It can include one or more vent openings 203 for venting the bag 210 when filling it with the malleable, thermally conductive medium 202, as already described above. Fig. 1 shown.

[0058] The malleable, thermally conductive medium 202 can, for example, comprise a thermally conductive paste, which may consist of one, two, or more material components 101, 102. These can be curable material components that harden when mixed. As long as these material components are not mixed, no curing takes place, and the thermally conductive medium 202 remains malleable to conform to the surface structures of the respective components.

[0059] A material is considered malleable if it is flexible or stretchable in its original state, even though it is no longer malleable once cured. Examples of such malleable materials include two-component materials that are malleable when mixed within a specific time interval and solidify after curing. Even a non-curing material, such as a cooling oil, a coolant, or a non-curing thermal paste, can be malleable when contained within a thermally conductive pouch.

[0060] Alternatively, the malleable, thermally conductive medium 202 can comprise a cooling oil that remains malleable at all times and does not harden. Alternatively, the malleable, thermally conductive medium 202 can also comprise a thermal paste that does not harden.

[0061] Fig. Figure 3 shows a schematic 3D representation of a battery module 300 according to the invention with the housing cover open for inserting the thermally conductive pad 200 according to an exemplary embodiment.

[0062] The battery module 300 can be used in a battery system of a battery-powered vehicle.

[0063] The battery module 300 comprises: a plurality of battery cells and / or busbars as components to be cooled 310; a housing 301, 302 acting as a heat sink in which the components to be cooled 310 are housed; and a thermally conductive pad 200, as described above. Fig. 1 and Fig. 2 described.

[0064] The housing 301, 302 can, for example, be formed as a housing structure made of iron, aluminum, or another metal in sheet metal or cast form. A plastic housing is also possible, for example made of a highly thermally conductive plastic.

[0065] The thermally conductive pad 200 can be inserted between the components 310 to be cooled and the housing 301, 302. The thermally conductive pad 200 is designed to conduct heat from the components 310 to be cooled to the housing 301, 302.

[0066] The housing 301, 302 comprises a lockable housing cover 301, which is designed to press the thermally conductive pad 200 against the components 310 to be cooled when the housing is closed. Fig. 3. The housing cover 301 is still open, allowing the thermally conductive pad 200 to be placed on the components 310 to be cooled. After closing the housing cover 301, as indicated by the two arrows, the housing cover 301 is pressed against the thermally conductive pad 200, causing the surface of the bag 210 to conform to the surface structures of the housing cover 301 and the components 310 to be cooled, which in Fig. 5 is shown in more detail.

[0067] The battery cells and / or busbars 310 can, for example, be aligned with tolerances relative to each other in the housing 301, 302, which in Fig. Figure 3 is not shown. For example, the components 310 may be arranged at different heights relative to each other, so that a flat contact surface is not formed and a Gappad has problems adapting to this uneven surface. Such problems do not occur with the thermally conductive pad 200. This is because the thermally conductive pad 200, with its malleable surface, is designed to compensate for tolerances between the battery cells and / or busbars 310 relative to each other. These tolerances may also consist of minor or major irregularities in the contact surface. The thermally conductive pad 200 can also compensate for misaligned components 310, i.e., when the individual components to be cooled are arranged at different angles to the vertical or have different tilt angles to the horizontal.

[0068] Fig. Figure 4 shows a schematic sectional view of the battery module 300 according to the invention with the housing cover open for inserting the thermally conductive pad 200 according to an exemplary embodiment.

[0069] The illustration shows how the thermally conductive pad 200 can be inserted between the components 310 to be cooled, for example busbars or battery cells, and the housing cover 301 when the housing cover is open.

[0070] In this example, the thermally conductive pad 200 has an elliptical cross-section. However, it can also have other geometric shapes as its cross-section.

[0071] It is important that the thermally conductive bag 210 has a malleable surface designed to adapt to the respective surface structures of the component(s) to be cooled 310 and the component 301 acting as a heat sink when the thermally conductive bag 210 is inserted between the component(s) to be cooled 310 and the component 301 acting as a heat sink. This malleable surface allows the thermally conductive bag 210 to fill air gaps in the respective surface structures, enabling efficient heat transfer from the component to be cooled 310 to the component 301 acting as a heat sink via the thermally conductive bag 210.

[0072] Fig. Figure 5 shows a schematic sectional view of the battery module 300 according to the invention with a closed housing cover, so that the thermally conductive padding 200 is pressed in between the housing cover and the battery cells or busbars, according to an exemplary embodiment.

[0073] The two arrows indicate that the housing cover 301 was closed, so that the thermally conductive pad 200 was pressed between the components 310 to be cooled and the housing cover 301.

[0074] This creates an air-gap-free surface structure both between the housing cover 301 and the thermally conductive pad 200, and between the components 310 to be cooled and the thermally conductive pad 200. The thermally conductive pad 200 even surrounds the upper sides of the components 310 to be cooled, ensuring optimal heat transfer to the housing cover 301.

[0075] Fig. Figure 6 shows a schematic sectional view of the battery module 300 according to the invention with a closed housing cover and two thermally conductive pads 200, which are pressed in between the housing cover or housing base and the battery cells or busbars, according to an exemplary embodiment.

[0076] Here too, the two arrows indicate that the housing cover 301 has been closed, so that the upper thermally conductive pad 200 is pressed between the components 310 to be cooled and the housing cover 301, and the lower thermally conductive pad 200 is pressed between the components 310 to be cooled and the housing base part 302.

[0077] This creates an air-gap-free surface structure both between the housing cover 301 or housing base 302 and the upper or lower thermally conductive pad 200, as well as between the components 310 to be cooled and the upper or lower thermally conductive pad 200. The upper thermally conductive pad 200 surrounds the upper sides of the components 310 to be cooled, while the lower thermally conductive pad 200 surrounds the lower sides of the components 310 to be cooled. This ensures optimal heat transfer to both the housing cover 301 and the housing base 302.

[0078] Additional thermally conductive pads 200 can also be inserted, for example between the respective components 310 to be cooled, which can then be used with or without the lower and upper in Fig. The thermally conductive pads 200 shown in Figure 6 can be connected to the housing cover 301 and the housing base 302 to ensure even better heat dissipation. The thermally conductive pads 200 between the components 310 to be cooled can be shaped differently from the upper and lower thermally conductive pads 200, according to a predetermined distance between the components to be cooled, for example, narrower than the upper and lower thermally conductive pads 200.

[0079] Fig. Figure 7 shows a schematic sectional view of the battery module 300 according to the invention with a closed housing cover, so that the thermally conductive padding 200 is pressed in between the housing cover and the battery cells or busbars, and cooling channels in the housing cover according to an exemplary embodiment.

[0080] In the housing 301, 302 a plurality of cooling channels 303, 304 can be embedded, which are designed to absorb the heat dissipated from the thermally conductive pad 200 to the housing 301, 302 and to dissipate it externally.

[0081] In Fig. The 7 flow channels 303 are designated by "V" and the return channels 304 by "R". The number of flow channels V can be equal to or different from the number of return channels R.

[0082] Here, the heat transfer also takes place to an active cooling system, for example a water-glycol mixture or an oil, etc. This prevents the housing from heating up so much that it can still be used as a heat sink.

[0083] Of course, the cooling channels 303, 304 can also be used in the 2-pad system according to Fig. 6 must be formed.

[0084] Fig. Figure 8 shows a 3D representation of a thermally conductive pad 200 according to the invention with two chambers and an intermediate membrane between the chambers according to an exemplary embodiment.

[0085] The heat-conductive padding 200 in Fig. 8 is a special version of the thermally conductive padding 200 of the Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7, wherein the thermally conductive bag 210 comprises a first chamber 211 which is filled with a first material component 101 of the thermally conductive paste; and wherein the thermally conductive bag 210 comprises a second chamber 212 which is filled with a second material component 102 of the thermally conductive paste.

[0086] In this example, the thermally conductive bag 210 has an intermediate membrane 220 between the first chamber 211 and the second chamber 212, which is designed to rupture during a massage-like movement of the bag 210 and cause the two material components 101, 102 to mix. The two material components 101, 102 can be designed to harden after mixing.

[0087] The intermediate membrane 220 is thin and can be equipped with a pre-perforation between the two chambers 211, 212, so that the intermediate membrane 220 tears open at the pre-perforation during massage-like movement and the two material components 101, 102 can mix.

[0088] The intermediate membrane 220 can, for example, be torn open shortly before the cushion 200 is inserted, so that the two material components 101, 102 can mix and harden in the inserted state.

[0089] Fig. Figure 9 shows a 3D representation of a thermally conductive pad 200 according to the invention with two chambers 211, 212 and an open intermediate membrane 220, so that the material components of the two chambers 211, 212 mix, according to an exemplary embodiment.

[0090] The thermally conductive pad 200 can be inserted in this state between the components 310 to be cooled and the housing 301, 302. The surface of the bag 210, containing the still malleable thermally conductive medium 202, can adapt to the surface structures of the components 310 to be cooled and the housing 301, 302, ensuring air-gap-free heat transfer. During curing, the air-gap-free heat transfer surface is fixed, preventing it from shifting even during vibrations while the vehicle is in operation.

[0091] Fig. Figure 10 shows a 3D representation of a thermally conductive pad 200 according to the invention with two chambers 211, 212 and an intermediate membrane 220 between the chambers and two pull tabs 230 for tearing open the intermediate membrane according to an exemplary embodiment.

[0092] The heat-conductive padding 200 in Fig. 10 is a special version of the thermally conductive padding 200. Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8 to Fig. 9, wherein the thermally conductive bag 210 comprises two pull tabs or handles 230, each of which can be operated in opposite directions to each other.

[0093] The two pull tabs 230 are designed to tear open the intermediate membrane 220 when actuated, thus enabling the mixing of the two material components 101, 102.

[0094] For example, one pull tab 230 can be attached to the top of the bag 210 and the other pull tab 230 to the bottom of the bag 210, as shown in Fig. Figure 10 is shown. Other positions are also possible, for example on two opposite sides. REFERENCE MARK LIST 100 methods for filling a thermally conductive bag with a thermally conductive paste made of two material components 101 first material component or gap filler 102 second material component or gap filler 103 Filling element 104 Mixing head 200 thermally conductive pads 201 Filler neck 202 Thermal paste or malleable, thermally conductive medium 203 Vent opening 210 thermally conductive bags or plastic bags 211, 212 chambers in the thermally conductive bag 220 Intermediate membrane 230 pull tabs or handle elements 300 battery module 301 Housing top or housing cover 302 Lower housing part or housing base 303 Cooling channel, supply 304 Cooling channel, return 310 Component to be cooled or battery cell or busbar

Claims

Thermally conductive pad (200) for dissipating heat from a component (310) to be cooled in a battery-powered vehicle, wherein the thermally conductive pad (200) comprises: a thermally conductive bag (210) filled with a malleable, thermally conductive medium (202); wherein the thermally conductive bag (210) is designed to be inserted between the component (310) to be cooled and a component (301) acting as a heat sink;wherein the thermally conductive bag (210) has a malleable surface which is designed to adapt to the respective surface structures of the component (310) to be cooled and the component (301) acting as a heat sink when the thermally conductive bag (210) is inserted between the component (310) to be cooled and the component (301) acting as a heat sink, so that air gaps in the respective surface structures are filled by the thermally conductive bag (210) and heat can be dissipated via the thermally conductive bag (210) from the component (310) to be cooled to the component (301) acting as a heat sink, wherein the malleable, thermally conductive medium (202) comprises a thermally conductive paste consisting of two or more material components (101, 102) which harden when mixed. Thermally conductive padding (200) according to claim 1, wherein the thermally conductive bag (210) comprises at least one filling nozzle (201) for filling the malleable, thermally conductive medium (202); and wherein the thermally conductive bag (210) comprises at least one venting opening (203) for venting the bag (210) when filling the malleable, thermally conductive medium (202). Thermally conductive pad (200) according to claim 1 or 2, wherein the thermally conductive pouch (210) comprises a first chamber (211) filled with a first material component (101) of the thermally conductive paste; and wherein the thermally conductive pouch (210) comprises a second chamber (212) filled with a second material component (102) of the thermally conductive paste. Thermally conductive pad (200) according to claim 3, wherein the thermally conductive pouch (210) comprises an intermediate membrane (220) between the first chamber (211) and the second chamber (212), which is configured to rupture upon a massage-like movement of the pouch (210) and to cause a mixing of the two material components (101, 102); wherein the two material components (101, 102) are configured to harden after mixing. Thermally conductive padding (200) according to claim 4, wherein the thermally conductive bag (210) comprises two pull tabs (230) which can each be actuated in opposite directions to each other, wherein the two pull tabs (230) are designed to tear open the intermediate membrane (220) when actuated and to allow a mixing of the two material components (101, 102). Battery module (300) for a battery system of a battery-powered vehicle, wherein the battery module (300) comprises: a plurality of battery cells and / or busbars as components to be cooled (310); a housing (301, 302) acting as a heat sink in which the components to be cooled (310) are housed; and a thermally conductive pad (200) according to one of the preceding claims; wherein the thermally conductive pad (200) is inserted between the components to be cooled (310) and the housing (301, 302) and is configured to dissipate heat from the components to be cooled (310) to the housing (301, 302). Battery module (300) according to claim 6, wherein the housing (301, 302) comprises a lockable housing cover (301) which is designed to press the thermally conductive padding (200) against the components (310) to be cooled when the housing (301, 302) is closed. Battery module (300) according to claim 6 or 7, wherein the battery cells and / or busbars in the housing (301, 302) are aligned with tolerances to each other; and wherein the thermally conductive pad (200) is designed to compensate for tolerances between the battery cells and / or busbars to each other with the malleable surface of the thermally conductive bag (210). Battery module (300) according to one of claims 6 to 8, wherein a plurality of cooling channels (303, 304) are embedded in the housing (301, 302) which are designed to absorb the heat transferred from the thermally conductive pad (200) to the housing (301, 302) and to dissipate it externally.

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