Method for producing a tempering element, corresponding tempering element and traction battery for a motor vehicle

Abstract

The invention relates to a method for producing a temperature control element (8), wherein the temperature control element (8) has a temperature control channel arrangement (14) having at least one temperature control channel (16) and is configured between a first layer (11) and a second layer (12) of the temperature control element (8). Provision is made for a core arrangement having at least one expendable core to be adhesively applied to the first layer (11), the second layer (12) to be arranged on and connected to the first layer (11) in such a way that the core arrangement forms the temperature control channel arrangement (14) in the second layer (12) with a closed edge in cross-section, and the core arrangement is removed from the temperature control element (8) when the second layer (12) is connected to the first layer (11). The invention further relates to a temperature control element (8) and a traction battery (1) for a motor vehicle.

Description

[0001] The invention relates to a method for producing a temperature control element, in particular for a traction battery of a motor vehicle, wherein the temperature control element has a temperature control channel arrangement comprising at least one temperature control channel, which is configured between a first layer and a second layer of the temperature control element. The invention further relates to a temperature control element, preferably for a traction battery of a motor vehicle, and to a traction battery for a motor vehicle.

[0002] For example, the prior art document DE 10 2020 212 138 A1 is known. This document describes a method for producing a cooling element as a composite component with a metal part and a thermoplastic part, wherein a surface region of the metal part is structured by laser radiation, and wherein the plastic part is connected to the metal part in the structured surface region, so that at least one cooling channel is delimited by the metal part and the plastic part. Furthermore, a cooling element with a metal part and a plastic part is described, which are connected to one another in a structured surface region of the metal part and which together delimit at least one cooling channel. Furthermore, the use of such a cooling element as a structural component is explained.

[0003] Furthermore, the document DE 10 2020 128 766 A1 discloses a method for forming a composite material component having a sealed interface between two materials, the method comprising: applying a sacrificial material to a surface of a metal automotive component shell; overmolding the substrate and the sacrificial material with an overmolding material such that the overmolding material covers at least a portion of the sacrificial material and at least one surface of the substrate, wherein the overmolding material comprises a polymer, a polymer composite, or a continuous fiber composite material; removing the sacrificial material by deflagration to form a composite material component having a channel between the substrate and the overmolding material; introducing an uncured sealant into the channel; and curing the sealant to form a sealed composite material component.

[0004] In addition, the document DE 10 2019 202 708 A1 discloses a method for producing a housing for power electronics consisting of at least one circuit board and electronic or electrical components with the following steps: introducing structures for producing cooling channels, overmolding the structures with plastic.

[0005] Furthermore, the prior art documents DE 10 2017 221 347 A1, DE 10 2022 123 454 A1, EP 0 286 400 B1, DE 10 2020 121 381 A1 and EP 3 686 952 A1 are known.

[0006] It is an object of the invention to propose a method for producing a tempering element, in particular for a traction battery of a motor vehicle, which has advantages over known methods, in particular enabling a particularly flexible and cost-effective design of the tempering element.

[0007] This is achieved according to the invention with a method for producing a temperature control element having the features of claim 1. It is provided that a core arrangement having at least one lost core is adhesively applied to the first layer, the second layer is arranged on the first layer and connected to it in such a way that the core arrangement forms the temperature control medium channel arrangement in the second layer with a closed edge in cross-section, and the core arrangement is removed from the temperature control element when the second layer is connected to the first layer.

[0008] Advantageous embodiments with useful further developments of the invention are specified in the dependent claims. It should be noted that the exemplary embodiments explained in the description are not limiting; rather, any variations of the features disclosed in the description, the claims, and the figures are feasible.

[0009] The described method is used to manufacture the temperature control element. The temperature control element serves to control the temperature of a technical device, for example, the traction battery. Of course, the temperature control device can also be separate from the technical device or the traction battery, in particular until the temperature control element is mounted on or in the device. The traction battery is preferably a component of the motor vehicle. However, it can also be separate from the vehicle, in particular until it is mounted on or in the motor vehicle.

[0010] The traction battery is intended and designed for the temporary storage of electrical energy for a drive direction of the motor vehicle. The drive device serves to drive the motor vehicle, thus providing a drive torque directed toward driving the motor vehicle. To provide the drive torque, the drive device has at least one drive unit, which is designed as an electric traction machine electrically connected to the traction battery.

[0011] The electrical energy temporarily stored in the traction battery is used, at least temporarily, to drive the motor vehicle, i.e., to provide the drive torque required to drive the motor vehicle by means of the drive device or drive unit. Conversely, it can be provided that electrical energy provided by the drive device is temporarily stored in the traction battery.

[0012] The traction battery has at least one battery module, which has at least one battery cell, i.e., one or more battery cells. The battery cell(s) are preferably prismatic cells or pouch cells. To accommodate the battery module and, to that extent, the battery cell(s), the traction battery has a battery housing. This housing contains a battery module receptacle, which is provided and designed to accommodate the battery module or multiple battery modules.

[0013] During the manufacture of the traction battery, the battery module is inserted into the battery module receptacle. Preferably, not just a single battery module is arranged in the battery housing, but rather multiple battery modules are inserted into the battery housing. In such a configuration, the battery housing has one battery module receptacle designed to accommodate multiple battery modules, or multiple battery module receptacles.

[0014] The battery cell or the battery cells of the battery module each have a cell housing. The cell housing contains the battery cell electrodes and an electrolyte. During operation of the traction battery, heat is generated at least temporarily in the traction battery or the at least one battery cell, which must be dissipated. Conversely, it may be necessary at times to supply heat to the traction battery or the at least one battery cell, in particular to adjust the temperature of the traction battery or the battery cell toward its operating temperature.

[0015] The removal of heat from and / or the supply of heat to the traction battery or battery cell is generally referred to as tempering in this description. Tempering therefore includes either merely the removal of heat, the supply of heat, or the temporary supply of heat and the temporary removal of heat. In each case, tempering is aimed at adjusting the temperature of the traction battery or battery cell.

[0016] The temperature control element described and to be manufactured here is characterized by particularly high flexibility and low manufacturing costs. It features the temperature control channel arrangement, which in turn has at least one temperature control channel. In principle, the temperature control channel arrangement can have any number of temperature control channels, for example, just a single temperature control channel or multiple temperature control channels.

[0017] If the temperature control channel arrangement is mentioned in this description, the above definition applies. If reference is made to the at least one temperature control channel or the temperature control channel, the explanations are always equivalent. Explanations for the at least one temperature control channel are transferable to the temperature control channel, and explanations for the temperature control channel are transferable to the at least one temperature control channel. Furthermore, the explanations are always applicable to multiple temperature control channels, if present, preferably to each of the multiple temperature control channels.

[0018] Preferably, the temperature control channel or each of the temperature control channels can be separately flowed through by a temperature control medium. For this purpose, the temperature control channel has a fluid inlet and a fluid outlet, via which it is preferably fluidically connected to a temperature control circuit of the technical device, preferably the traction battery.

[0019] The temperature control channel arrangement and thus the at least one temperature control channel are arranged between the first layer and the second layer of the temperature control element. This means that, viewed in cross-section, the temperature control channel arrangement is partially delimited by the first layer and partially by the second layer, although, viewed in cross-section, the first layer and the second layer completely and continuously encompass the temperature control channel arrangement. The first layer and the second layer thus bear against one another in a sealing manner or are fastened to one another in a sealing manner, namely away from the temperature control channel arrangement, so that the latter, or the temperature control channel, is fluid-tight when viewed in cross-section.In other words, the first layer and the second layer enclose the temperature control channel between them away from its fluid inlet and its fluid outlet, so that it is designed to be fluid-tight between the fluid inlet and the fluid outlet.

[0020] To produce the temperature control element, the core arrangement is first applied to the first layer. The core arrangement has at least one lost core. The core arrangement is understood to be an arrangement with any number of lost cores; thus, there can be just a single lost core or several lost cores spaced apart from one another. Again, the statements for the at least one lost core are equivalent to the lost core. They are also transferable to each of the several lost cores, if present. Wherever the core arrangement is discussed within the scope of this description, this definition shall always be used.

[0021] The core assembly is applied to the first layer in such a way that the core assembly adheres to the first layer. This means that the core assembly is not simply placed or placed on the first layer; rather, a connection is formed between the core assembly and the first layer, so that the core assembly is attached to the first layer, preferably by a material bond. For example, the core assembly is glued to the first layer, or the core assembly contains a binder, which creates the adhesive bond between the core assembly and the first layer.

[0022] The core arrangement is applied directly to the first layer; for example, a core material of the core arrangement is applied layer by layer to the first layer. This means that the core arrangement, in particular each of the lost cores, is composed of several layers that are applied one after the other. The several layers are arranged one above the other so that the layers are spaced at an increasing distance from the first layer. The core arrangement is preferably applied to the first layer using a 3D printer. This enables a particularly flexible design of the core arrangement and thus also of the temperature control channel arrangement.

[0023] After the core arrangement has been adhesively applied to the first layer, the second layer is arranged on the first layer and connected to it, in particular by a material bond. The arrangement of the second layer on the first layer takes place in such a way that the temperature control channel arrangement is produced by the core arrangement in the second layer, namely by correspondingly shaping the second layer. Thus, while the shape of the first layer is not changed, or at most slightly changed, by the arrangement of the second layer on the first layer, the production of the temperature control channel arrangement in the second layer takes place during the arrangement, in particular due to the arrangement.The shaping of the temperature control channel arrangement in the second layer is also carried out in such a way that the temperature control channel arrangement is closed at its edges in cross-section, i.e., viewed in cross-section, the temperature control channel is continuously and completely encompassed by the first layer and the second layer. This makes it fluid-tight, at least away from its fluid inlet and fluid outlet.

[0024] After the second layer has been arranged on the first layer and bonded together, the core assembly is removed from the temperature control element while the two layers are still bonded together. This means that removing the core assembly does not separate the layers from each other; rather, this connection remains after the layers have been bonded together, particularly during the removal of the core assembly from the temperature control element or its temperature control channel arrangement. This reliably avoids complex post-processing of the temperature control element. Overall, the described procedure results in the advantages already mentioned.

[0025] A further development of the invention provides that the second layer is arranged on the first layer and connected to it by primary shaping or forming. Primary shaping is to be understood as meaning, for example, casting, injection molding or overmolding, foaming or foam filling, press molding or the like. The forming comprises, in particular, pressing or deep drawing the second layer in order to arrange it on the first layer. It can be provided that the two layers are connected to one another directly when the second layer is arranged on the first layer. This is particularly the case with primary shaping, for example casting or injection molding.

[0026] However, it can also be provided that the bonding takes place after the actual arrangement of the second layer on the first layer, for example by thermal treatment of the temperature control element. In this case, it is preferably provided that the temperature control element is heated during or after the arrangement of the second layer on the first layer, namely in such a way that the two layers bond together, in particular with a material bond. Alternatively, it can of course be provided that an adhesive or the like is applied to the first layer before the arrangement of the second layer on the first layer, in particular away from the core arrangement, for example between several cores of the core arrangement. The advantages already mentioned are achieved with the procedure described.

[0027] A further development of the invention provides that the second layer is integrally connected to the first layer at at least one connection point away from the core arrangement. The connection point is understood to be a point at which the two layers are integrally connected or fastened to one another. The connection point preferably extends, after the temperature control element has been manufactured, along the at least one temperature control channel, in particular along the entire temperature control channel. The integral connection is fluid-tight, so that the temperature control channel is reliably sealed against the external environment along its extent between its fluid inlet and its fluid outlet.

[0028] A further development of the invention provides that the first layer has a fastening structure and / or a fastening means at the at least one connection point, via which the second layer is connected to the first layer. The fastening structure is to be understood as at least one projection or a recess of the first layer which projects beyond a base body of the first layer or is produced in it. For example, the first layer or at least the base body of the first layer is flat on its side facing the second layer, in particular completely and continuously. The fastening structure serves to improve the adhesion of the second layer to the first layer. For example, the fastening structure is a surface structure produced by lasering and / or etching, which improves the material connection between the two layers.In addition to or as an alternative to the fastening structure, the fastening agent is present. The fastening agent is preferably a chemical substance that improves the adhesion of the two layers to each other. The fastening agent is preferably present as an adhesion promoter. This also serves to achieve the advantages already mentioned.

[0029] A further development of the invention provides that when the second layer is arranged on the first layer, the second layer is designed in a meandering shape. As a result of the formation of the temperature control channel arrangement in the second layer, the latter thus takes on a meandering shape. In particular, this means that the second layer is reshaped during the formation of the temperature control channel arrangement so that it has different distances from the first layer across its extent. Preferably, a layer thickness of the second layer is constant or at least almost constant in its meandering region. This results in particularly good mechanical properties of the temperature control element.

[0030] A further development of the invention provides that the core arrangement is applied to the first layer by means of 3D printing. In other words, the application is carried out by means of additive manufacturing, in which the core arrangement is applied layer by layer to the first layer. The multiple layers of the core arrangement have different distances from the first layer; in particular, a first of the layers lies directly against the first layer, whereas subsequent layers are only connected to the first layer via the preceding layers. Such production of the core arrangement enables particularly flexible guidance of the temperature control channel arrangement in the temperature control element.

[0031] A further development of the invention provides for the use of a core arrangement made of sand and / or salt, wherein the removal of the sand core arrangement takes place by shaking and the removal of the salt core arrangement takes place by rinsing. In each case, the core arrangement is designed such that it assumes a specific structure or shape during application. The core arrangement is designed such that it automatically or of its own accord maintains this structure during the application of the second layer to the first layer. During the removal of the core arrangement from the tempering element, the structure or shape is dissolved again.

[0032] This can be achieved particularly advantageously by using sand and / or salt as the core material. The sand has the advantage that it is particularly easy to remove, namely by shaking the temperature control element, which occurs in such a way that the structure of the core arrangement is dissolved and the core arrangement divides into individual grains of sand, which are then carried out of the temperature control element, for example, by the influence of gravity and / or by means of an air stream. If salt is used as the core material, a solvent is used to dissolve the structure of the core arrangement. The solvent is chosen such that the salt dissolves as quickly as possible upon contact with the solvent. To remove the core arrangement, the temperature control element or the temperature control medium channel arrangement is rinsed with the solvent, thereby dissolving the structure of the core arrangement.In any case, a particularly rapid and flexible production of the temperature control channel arrangement is implemented.

[0033] A further development of the invention provides that the adhesion of the core arrangement to the first layer is achieved through the use of a binder in the core arrangement. The binder is therefore mixed with the core material. The binder is particularly selected such that when the core material is applied to the first layer of the temperature control element, it assumes the desired structure and forms the core arrangement with a defined geometry. For example, the binder serves to hold the individual sand grains of the core material together to produce the core arrangement and, at the same time, to bond the core arrangement to the first layer. A similar approach can also be used if salt is used as the core material. Due to the use of the binder, no separate means is required to apply the core arrangement adhesively to the first layer, since the adhesion is achieved by the binder.

[0034] A further development of the invention provides that a layer of metal is used as the first layer and a layer of metal and / or a plastic material is used as the second layer. The metal is in particular steel, for example stainless steel, aluminum or copper or an alloy comprising at least one of these metals. If both the first layer and the second layer are made of metal, the same metal is preferably used for both layers. This enables a particularly simple material-to-material bond between the two layers. Of course, however, different metals can also be used, in particular steel or aluminum for the first layer and copper for the second layer.

[0035] Alternatively or additionally, the second layer comprises the plastic material. It can therefore be provided that the second layer consists exclusively of the plastic material or comprises both the metal and the plastic material. In this case, it is particularly preferred to provide the plastic material with a metal coating. This makes it possible to bond the coating of the second layer to the first layer in a material-to-material manner, for example by welding or soldering. It can also be provided to heat the second layer during or after the arrangement of the second layer on the first layer in such a way that the metal coating of the second layer melts and bonds to the first layer in a material-to-material manner. Accordingly, a particularly efficient and cost-effective production of the temperature control element is possible.

[0036] A further development of the invention provides that a plastic or a composite material with a matrix consisting of a plastic and a filler material is used as the plastic material. For example, the second layer consists of the plastic, for example a pure plastic. A thermoplastic or a thermoset can be used as the plastic. A polyolefin, a thermoplastic elastomer, a polyamide or the like is particularly preferably used as the plastic. The composite material has greater strength than the plastic, which is achieved by the filler material. The composite material is composed at least of the matrix and the filler material, in particular exclusively. The matrix is ​​made of plastic, preferably of one of the plastics mentioned above.The filler material can be a fiber material, for example, carbon fibers, glass fibers, ceramic fibers, aramid fibers, steel fibers, or natural fibers. By selecting the appropriate plastic material, the desired properties of the temperature control element can be adjusted.

[0037] A further development of the invention provides that the plastic contains at least one electrically conductive and / or thermally conductive additive. A substance is thus added to the plastic which has a higher electrical conductivity and / or a higher thermal conductivity than a base material of the plastic, for example, the aforementioned thermoplastic or thermoset. Accordingly, the additive improves the electrical or thermal conductivity of the plastic, so that, for example, potential equalization is established via the second layer and electrostatic charging is avoided. With the help of the thermally conductive additive, the efficiency of temperature control using the temperature control element is further improved.

[0038] A further development of the invention provides that the plastic is foamed, in particular for producing a fluid line running through the plastic. The foaming of the plastic takes place, for example, using an appropriate blowing agent. The plastic can also be in the form of or as a component of a multi-component foam, for example, a two-component foam. The foam formed by foaming the plastic is, for example, closed-pore or open-pore. In the latter case, the fluid line is preferably produced by foaming the plastic, wherein the fluid line is formed by fluidically interconnected pores in the plastic.In any case, however, the foam is provided with a closed surface, at least in the direction of the temperature control channel arrangement, so that the closed surface, viewed in cross-section, creates a fluidic separation between the temperature control channel arrangement and the fluid line. This enables a particularly versatile use of the temperature control element.

[0039] A further development of the invention provides that the second layer is produced with a first sub-layer made of a first material and a second sub-layer made of a second material different from the first material. The second layer is therefore composed of several layers or has a multi-layer design. At least it has the first sub-layer and the second sub-layer, preferably exclusively. For example, the first sub-layer directly borders the first layer or is arranged directly on the first layer and connected to it, whereas the second sub-layer only engages the first layer or is held to it via the first sub-layer.

[0040] The two sublayers consist of different materials. It can be provided that the first sublayer is made of the plastic material and the second sublayer is made of the composite material. In this case, the same plastic is preferably used for the plastic material and the matrix of the composite material. This achieves a particularly good bond between the sublayers. It can be provided that the first material is a material that adheres better to the first layer than the second material. This achieves a particularly good sealing effect.

[0041] A further development of the invention provides that the second layer is made flexible, so that the temperature control element expands when a temperature control medium is applied to the temperature control channel. The second layer preferably has greater flexibility than the first layer, and preferably the second layer is elastic. For example, the elastic modulus of the second layer is at most 10 GPa, at most 5 GPa, or at most 1 GPa. The flexibility, in particular the elasticity, of the second layer has the advantage that the temperature control element expands when the temperature control medium is applied to the temperature control channel, so that the temperature control element is pressed against the device to be temperature-controlled, preferably the battery cell.

[0042] A further development of the invention provides that at least one fastening element and / or a holder for a component or a line and / or a connecting piece in fluid communication with the temperature control channel arrangement is formed on the second layer. The molding takes place in particular away from the second layer, for example on a side of the second layer facing away from the first layer. The fastening element serves, for example, to fasten the temperature control element to a housing of the device to be temperature-controlled, for example to the battery housing. Additionally or alternatively, the holder is formed on the second layer. The holder serves to hold the line, for example an electrical line or a fluid line or a component, in particular an electronic component, preferably a sensor.

[0043] Additionally or alternatively, the connecting piece is integrally formed on the second layer. The connecting piece forms, for example, the aforementioned fluid inlet or the fluid outlet of the at least one temperature control channel. In this respect, the temperature control channel or the temperature control channel arrangement is fluidically connected via the connecting piece, preferably via several connecting pieces integrally formed on the second layer, in particular to a temperature control circuit of the motor vehicle. The aforementioned elements are integrally formed before the second layer is arranged on the first layer or during the arrangement of the second layer on the first layer. In either case, the aforementioned advantages are achieved.

[0044] A further development of the invention provides that a third layer is arranged on the side of the second layer facing away from the first layer and is connected to the second layer. Preferably, the third layer is configured analogously to the first layer and is connected to the second layer, so that reference is made to the corresponding statements regarding the first layer in this description. The third layer is arranged at a distance from the first layer; in particular, the first layer and the third layer are located on opposite sides of the second layer and from there adjoin it.

[0045] It can be provided that, during the production of the temperature control element, the temperature control channel arrangement is formed both between the first layer and the second layer, and a further temperature control channel arrangement is formed between the second layer and the third layer. For example, it is provided for this purpose that a core arrangement is adhesively applied to both the first layer and the third layer and that the second layer is then arranged and connected to the first layer and the third layer in such a way that the core arrangement forms the temperature control channel arrangement and the further core arrangement forms the further temperature control channel arrangement in the second layer. Such a design of the temperature control element is particularly advantageous if it is arranged between two battery cells.In this case, the first layer is applied to a first of the battery cells and the third layer is applied to a second of the battery cells, so that both battery cells can be tempered or are tempered simultaneously by means of the tempering element.

[0046] A further development of the invention provides that the first layer and the third layer are arranged at a distance from one another, and the second layer is produced in a space between the first layer and the third layer. The core arrangement is adhesively applied at least to the first layer. Optionally, the further core arrangement is applied to the third layer. The core arrangement of the first layer is located on the side of the first layer facing the third layer, and - optionally - the further core arrangement of the third layer is located on the side of the third layer facing the first layer.

[0047] Preferably, after the application of the core arrangement and / or the further core arrangement, the first layer and the third layer are arranged relative to one another such that the intermediate space is present between them. The core arrangement is preferably arranged at a distance from the third layer and / or the further core arrangement is arranged at a distance from the first layer. If both the core arrangement and the further core arrangement are present, the core arrangement is preferably arranged at a distance from the third layer and the further core arrangement, and the further core arrangement is arranged at a distance from the first layer and the core arrangement. However, it can also be provided that the core arrangement and the further core arrangement bear against one another in certain regions, in particular only in certain regions, so that a flow transition is created between the temperature control medium channel arrangement and the further temperature control medium channel arrangement.

[0048] After arranging the first and third layers, the second layer is created in the space between them, for example, by filling the space with the appropriate material. If the second layer consists of foam, it may be possible to fill the space with foam to create the second layer. The described procedure enables particularly rapid and flexible production of the temperature control element.

[0049] A further development of the invention provides that the at least one temperature control channel is produced with a continuously constant flow cross-section or is provided with at least one flow resistance. In the case of the constant flow cross-section, this is preferably present continuously in the temperature control channel, in particular starting from the fluid inlet to the fluid outlet. Alternatively, the temperature control channel is provided with the flow resistance. The flow resistance is produced, for example, by a constriction of the temperature control channel or by arranging a resistance element in the temperature control channel. With the aid of the flow resistance, turbulence can be generated in the temperature control channel, in particular the turbulence of the temperature control medium flowing through the temperature control channel can be adjusted to a desired turbulence. This improves the heat transfer from or into the temperature control medium.

[0050] A further development of the invention provides that the at least one temperature control channel is manufactured with constant external dimensions or with at least one widening or constriction. The temperature control channel thus has constant external dimensions at least in some regions, in particular throughout, preferably from the fluid inlet to the fluid outlet. Constant external dimensions are understood to mean, in particular, that both a flow cross-section and a flow cross-sectional area of ​​the temperature control channel are constant.

[0051] Alternatively, the temperature control channel is manufactured with a widened or constricted portion. This means that the temperature control channel has locally larger or smaller dimensions, in particular, flow cross-sectional areas. For example, the constriction serves to create the aforementioned flow resistance. The widened or constricted portion can, for example, allow a fluidic orifice, a fluidic throttle, or a fluidic nozzle to be formed in the temperature control channel. The described method for manufacturing the temperature control element thus enables particularly flexible flow guidance in the temperature control channel arrangement.

[0052] A further development of the invention provides that at least one flow resistance is created in the widening and / or the constriction. In other words, the flow resistance overlaps with the widening or the constriction, as seen in the direction of flow. The flow resistance here is understood to be the resistance element which is arranged in the temperature control medium channel or extends into the temperature control medium channel, preferably starting from the second layer. It can be provided that the flow resistance extends from the second layer up to the first layer. However, it can also be provided that it only partially penetrates the temperature control medium channel, starting from the second layer, i.e. is spaced from the first layer. In any case, the already mentioned high flexibility in flow guidance is achieved.

[0053] A further development of the invention provides that, in addition to the at least one flow resistance, at least one further flow resistance is produced in the at least one temperature control medium channel, wherein the at least one flow resistance and the at least one further flow resistance are arranged in series or with a laterally offset from one another. For example, the flow resistance and the further flow resistance are present in the same widening or in the same constriction or in overlap with the same. The flow resistances are arranged at a distance from one another and are positioned, for example, in series or laterally offset from one another. The arrangement in series is to be understood in particular that the flow resistances are arranged one behind the other in the main flow direction of the temperature control medium through the temperature control medium channel or with respect to a longitudinal central axis of the temperature control medium channel.

[0054] In the case of lateral offset, they are arranged offset in a laterally direction with respect to the main flow direction or the longitudinal center axis. Such an arrangement is particularly preferred when several additional flow resistances are present, so that at least three flow resistances are created in the temperature control medium channel. In the case of a series arrangement, the flow resistances lie on an imaginary straight line, whereas in the case of lateral offset, the imaginary straight line only runs through two of the flow resistances and is spaced from another of the flow resistances. For example, this creates a vortex chain as the temperature control medium flows through the temperature control medium channel, which achieves particularly good heat transfer.

[0055] The invention further relates to a temperature control element, preferably for a traction battery of a motor vehicle, in particular manufactured according to the method according to one or more of the preceding claims, wherein the temperature control element has a temperature control channel arrangement comprising at least one temperature control channel, which is configured between a first layer and a second layer of the temperature control element. It is provided that the second layer is arranged on and connected to the first layer in such a way that, in the second layer, the temperature control channel arrangement is formed in the second layer with a closed edge in cross-section by means of a core arrangement which is adhesively applied to the first layer and has at least one lost core.

[0056] The advantages of such a design of the temperature control element and such a manufacturing procedure have already been pointed out. Both the temperature control element and the method for its manufacture can be further developed according to the explanations within the scope of this description, so reference is made to these in this regard.

[0057] The invention further relates to a traction battery for a motor vehicle, comprising a battery cell and a temperature control element for temperature control of the battery cell, in particular a temperature control element according to the explanations in this description, wherein the temperature control element has a temperature control channel arrangement comprising at least one temperature control channel, which is configured between a first layer and a second layer of the temperature control element. It is provided that the second layer is arranged on and connected to the first layer in such a way that, in the second layer, the temperature control channel arrangement is formed in the second layer with a closed edge in cross-section by means of a core arrangement adhesively applied to the first layer and comprising at least one lost core.

[0058] With regard to the advantages and possible advantageous embodiments of the traction battery, reference is again made to the explanations in this description. Naturally, the invention also relates to a method for manufacturing the traction battery. In this method, the battery cell and the temperature control element are arranged adjacent to one another, in particular adjacent to one another.

[0059] A further development of the invention provides that, in addition to the battery cell, there is another battery cell, wherein the battery cell and the other battery cell accommodate the temperature control element between them, so that the temperature control element rests flat against the battery cell on the one hand and flat against the other battery cell on the other. In other words, the temperature control element is arranged between the battery cells and thus acts as an inter-cell temperature control element. Such an arrangement of the temperature control element enables particularly effective temperature control of the battery cells.

[0060] The features and feature combinations described in the description, in particular the features and feature combinations described in the following description of the figures and / or shown in the figures, can be used not only in the respective combination specified, but also in other combinations or on their own, without departing from the scope of the invention. Thus, embodiments are also considered to be encompassed by the invention that are not explicitly shown or explained in the description and / or the figures, but which follow from or can be derived from the explained embodiments.

[0061] The invention will be explained in more detail below with reference to the exemplary embodiments shown in the drawings, without limiting the invention. In the drawings: Fig. 1 a schematic sectional view of a traction battery for a motor vehicle with several battery cells and a temperature control element, Fig. 2 a schematic sectional view of the temperature control element with a temperature control channel arrangement, as well as Fig. 3 a schematic sectional view of a temperature control channel of the temperature control channel arrangement.

[0062] The Fig. Figure 1 shows a purely exemplary and schematic sectional view of a traction battery 1 for a motor vehicle. A battery module 2 of the traction battery 1 is shown, of which two battery cells 3 and 4 are shown for illustration purposes. These cells are arranged between two end plates 5 and 6 of a module housing 7. For example, the end plates 5 and 6 are clamped together, in particular by means of a clamping strap, so that the battery cells 3 and 4 are clamped between the end plates 5 and 6.

[0063] A temperature control element 8 is arranged between the battery cells 3 and 4. This element is designed such that it bears flatly against a cell housing 9 of the battery cell 3 and a cell housing 10 of the battery cell 4. The temperature control element 8 preferably extends, at least in section, over at least 80%, at least 90%, or at least 100% of the battery cells 3 and 4, so that it overlaps and bears against the mutually facing side surfaces of the cell housings 9 and 10 to one of the aforementioned portions. This achieves particularly effective cooling of the battery cells 3 and 4.

[0064] In the embodiment illustrated here by way of example, the temperature control element 8 has a first layer 11, a second layer 12, and a third layer 13. The second layer 12 is configured between the first layer 11 and the third layer 13 such that a temperature control channel arrangement 14 or 15 is present between it and the respective other layer 11 or 13. Each of the temperature control channel arrangements 14 and 15 has at least one temperature control channel 16 or 17, preferably a plurality of temperature control channels 16 or 17, of which only a few are identified here as examples.

[0065] The Fig. 2 shows a schematic sectional view through the temperature control element 8. It can be seen that the second layer 12 is multi-layered and has a first partial layer 18, which is bordered on opposite sides by a second partial layer 19 and a third partial layer 20. The first layer 11 and the third layer 13 consist of a first material, the second layer 12 comprises several materials. Thus, the second partial layer 19 and the third partial layer 20 are preferably made of the same material as the first layer 11 and the third layer 13. The first partial layer 18, however, is made of a different material. Preferably, the first layer 11 and the third layer 13 as well as the second partial layer 19 and the third partial layer 20 are made of metal, for example aluminum or an aluminum alloy. The first partial layer 18, on the other hand, is made of a foam, preferably a foamed plastic.

[0066] The material of the first partial layer 18 is also preferably flexible, particularly preferably elastic. As a result, the temperature control element 8 is also designed to be elastic overall, so that it can be compressed between the battery cells 3 and 4. This ensures reliable surface contact between the temperature control element 8 on the one hand and the battery cells 3 and 4 or their cell housings 9 and 10 on the other.

[0067] The Fig.Figure 3 shows, purely by way of example, a schematic representation of one of the temperature control channels 16 and 17, with only the temperature control channel 16 being discussed below. The temperature control channel 16 extends from a fluid inlet 21 to a fluid outlet 22. Along its length, it has several widened portions 23 in which it widens locally. A flow resistance 24 is created in one of the widened portions 23, namely by arranging a resistance element 25 in the temperature control channel 16. In particular, such a resistance element 25 is arranged in each of the widened portions 23.

[0068] The resistance element 25 extends, for example, from the second layer 12 into the temperature control channel 16, preferably extending as far as the first layer 11. It can have any cross-sectional shape; in the illustrated embodiment, it is oval, or more precisely elliptical. However, it can also be round or polygonal, in particular square. For example, it is round on its front side in the flow direction and flat on its rear side in the flow direction, so that it is partially oval or partially circular. It can also be provided that in at least one of the widened portions 23, preferably in each of the widened portions 23, several resistance elements 25 are present, which have different cross-sectional shapes and / or different dimensions.

[0069] In the illustrated embodiment, the resistance elements 25 are arranged offset in the lateral direction, i.e., they do not lie on an imaginary straight line. However, for example, several of the resistance elements 25 each lie on such a straight line, resulting in a total of several imaginary straight lines that are offset from one another, in particular parallel to one another. With the aid of the flow resistances 24, a flow pattern of the temperature control medium is generated, as indicated by the arrows, which results in a particularly high heat transfer, particularly through recirculation regions and the like.

[0070] Overall, the presented traction battery 1, or rather the temperature control element 8 assigned to the traction battery 1, is characterized by a particularly good cooling effect. Furthermore, the temperature control element 8 can be manufactured cost-effectively and flexibly. For this purpose, the temperature control medium channel arrangements 14 and 15 are produced using core arrangements, each of which has at least one lost core. The core arrangements are arranged so as to be adhesive to the first layer 11 and the third layer 13, and the second layer 12 is subsequently produced between them, for example by foaming a space between the first layer 11 and the third layer 13. For example, the core arrangements of the first layer 11 and the third layer 13 are arranged offset, so that a core of one of the layers 11 and 13 is arranged between two cores of the other of the layers 11 and 13, in particular centrally.This results in a meandering course of the second layer 12. LIST OF REFERENCE SYMBOLS: 1 traction battery 2 battery module 3 battery cells 4 battery cells 5 end plates 6 end plates 7 module housings 8 Tempering element 9 cell housings 10 cell housings 11 1st shift 12 2nd shift 13 3rd layer 14 Tempering agent channel arrangement 15 Tempering agent channel arrangement 16 Tempering agent channel 17 Tempering agent channel 18 1st sub-shift 19 2nd sub-shift 20 3rd sub-shift 21 Fluid inlet 22 Fluid outlet 23 Widening 24 Flow resistance 25 resistance element

Claims

[1] Method for producing a tempering element (8), wherein the tempering element (8) has a tempering channel arrangement (14) having at least one tempering channel (16) which is formed between a first layer (11) and a second layer (12) of the tempering element (8), characterized by that a core arrangement having at least one lost core is adhesively applied to the first layer (11), the second layer (12) is arranged on the first layer (11) and connected to it in such a way that the core arrangement forms the temperature control medium channel arrangement (14) in the second layer (12) with a closed edge in cross-section, and the core arrangement is removed from the temperature control element (8) when the second layer (12) is connected to the first layer (11). [2] Method according to claim 1, characterized by that the second layer (12) is arranged on the first layer (11) and connected to it by primary shaping or reshaping. [3] Method according to one of the preceding claims, characterized by that the application of the core arrangement to the first layer (11) is carried out by means of 3D printing. [4] Method according to one of the preceding claims, characterized by that a core assembly made of sand and / or salt is used, wherein the removal of the core assembly made of sand is carried out by shaking and the removal of the core assembly made of salt is carried out by rinsing. [5] Method according to one of the preceding claims, characterized by that a layer of metal is used as the first layer (11) and a layer of metal and / or a plastic material is used as the second layer (12). [6] Method according to claim 5, characterized by that the plastic material used is a plastic or a composite material with a matrix consisting of a plastic and a filling material. [7] Method according to one of the preceding claims, characterized bythat the second layer (12) is produced with a first partial layer (18) made of a first material and a second partial layer (19) made of a second material different from the first material. [8] Method according to one of the preceding claims, characterized by that a third layer (13) is arranged on the side of the second layer (12) facing away from the first layer (11) and is connected to the second layer (12). [9] Tempering element (8) manufactured according to the method according to one or more of the preceding claims. [10] Traction battery (1) for a motor vehicle, comprising a battery cell (3) and a tempering element (8) for tempering the battery cell (3) according to claim 9.

Images