Cooling plate arrangement with an intermediate layer of plastic and channel-like recesses formed therein, manufacturing process for such a cooling plate arrangement and motor vehicle with such a cooling plate arrangement

Abstract

A cooling plate arrangement (10) for cooling a battery storage device (204) of an at least partially electrically powered motor vehicle (200) is described, wherein the cooling plate arrangement (10) comprises: a first outer cooling plate (12) made of a metal; a second outer cooling plate (14) made of a metal, in particular the same metal; and an intermediate layer (16) made of an intermediate layer material (16m) arranged between the two outer cooling plates (12, 14). The intermediate layer (16) is provided to have at least one channel-like recess (18) which is bounded by the first cooling plate (12) and the second cooling plate (14). Furthermore, a method for manufacturing such a cooling plate arrangement (10) and a motor vehicle with such a cooling plate arrangement (10) are described.

Description

[0001] The invention relates to a cooling plate arrangement for cooling a battery storage device of an at least partially electrically powered motor vehicle, wherein the cooling plate arrangement comprises: a first outer cooling plate made of a metal; a second outer cooling plate made of a metal, in particular the same metal; an intermediate layer made of an intermediate layer material arranged between the two outer cooling plates.

[0002] From DE10 2012 217 367 A1 a cooling plate for battery cell cooling of a battery module is known, which is made up of a first and a second plate element, wherein the first plate element is a plastic plate with recessed cooling channels.

[0003] From DE10 2011 002 415 A1 a cooling plate made of two joined plastic partial plates is known, which have corresponding recesses for forming cooling channels.

[0004] Cooling plate assemblies for battery storage systems are of great importance in the development and manufacture of electrically powered vehicles. In particular, it is desirable to create cooling plate assemblies that can be easily adapted to different battery storage systems or to varying space constraints within a vehicle, especially by means of adaptable geometries or cooling channel layouts.

[0005] The object underlying the invention is seen as being to provide a cooling plate arrangement and a method for its manufacture in order to achieve greater flexibility in the design of cooling channels.

[0006] This problem is solved by a cooling plate arrangement, a method for its manufacture, and a motor vehicle with the features of the respective independent patent claim. Advantageous embodiments with expedient further developments are specified in the dependent patent claims.

[0007] A cooling plate arrangement for cooling a battery storage device of an at least partially electrically powered motor vehicle is proposed, wherein the cooling plate arrangement comprises: a first outer cooling plate made of a metal; a second outer cooling plate made of a metal, in particular the same metal; an intermediate layer made of an intermediate layer material arranged between the two outer cooling plates. It is provided that the intermediate layer has at least one channel-like recess, which is bounded by the first cooling plate and the second cooling plate.

[0008] This makes it possible to provide different profiles or geometries of the channel-like recess or recesses in the intermediate layer, so that the profile or geometry of the channel-like recess can be essentially independent of the cooling plates.

[0009] In cooling plate arrangements, the intermediate layer material can be a plastic, particularly a thermoplastic. Due to the various processing techniques available for plastics, this allows for greater flexibility in the design of channel-like recesses or cooling channels.

[0010] In the cooling plate arrangement, the channel-like recess can form a single, continuous cooling channel for a coolant, extending from an inlet coolant connection to an outlet coolant connection. The channel-like recess can, in particular, meander between the two coolant connections. This allows for the formation of adjacent cooling channel sections in which a coolant flows back and forth along the cooling plates.

[0011] In the cooling plate arrangement, several channel-like recesses can form a cooling channel network for a coolant, with the cooling channel network having an inlet coolant connection and an outlet coolant connection. This allows a coolant to be effectively distributed with respect to the effective cooling surface.

[0012] In the cooling plate arrangement, the coolant connections can be made from the interlayer material, projecting in particular beyond an edge of the cooling plate arrangement. In other words, the coolant connections can be formed integrally with the interlayer. Connecting lines of a coolant circuit can then be attached to these projecting connections.

[0013] In the cooling plate arrangement, the first cooling plate and / or the second cooling plate can each have a substantially flat boundary surface that defines the channel-like recess. In this way, the course and shape of the channel-like recess are essentially determined only by the intermediate layer, which is covered at the top and bottom by a flat boundary surface of the cooling plate.

[0014] Such a symmetrical design offers a particular advantage because it prevents distortions, especially those caused by temperature fluctuations.

[0015] Alternatively or additionally, at least one of the cooling plates can have at least one feature, in particular an embossing, that corresponds to and delimits the channel-like recess of the intermediate layer. For example, a cooling channel can thus have a larger flow cross-section if convex embossings are formed in one of the covering cooling plates (viewed from the outside), the course of which corresponds to the course of the channel-like recesses in the intermediate layer.

[0016] A method for manufacturing a cooling plate arrangement described above is also proposed, comprising the following steps: Provide the first metal cooling plate and the second metal cooling plate; Applying the intermediate layer material to the first cooling plate and / or to the second cooling plate, wherein the at least one channel-like recess is formed completely on one of the cooling plates or partially on both cooling plates, in particular half; Arrange the second cooling plate on top of the first cooling plate so that the channel-like recess in the interlayer material is bordered on both sides by the two cooling plates.

[0017] In this process, the first cooling plate and the second cooling plate can be joined with the intermediate layer material at common contact surfaces by means of material bonding and / or force bonding, in particular by means of mirror welding, friction welding or hot pressing.

[0018] In this process, the intermediate layer material can be applied to the first cooling plate and / or the second cooling plate using 3D printing, or applied to the first cooling plate and / or the second cooling plate using injection molding or plastic casting processes (cast polyamide).

[0019] Furthermore, it is conceivable that the intermediate layer is provided as a pre-cut plastic film or plastic sheet.

[0020] The process may also include at least one step in which one or both metallic cooling plates are processed, for example by means of a laser, structured and / or an adhesion promoter is applied before bonding with the intermediate layer.

[0021] Furthermore, a motor vehicle with at least a partially electric drive and a battery storage unit is proposed, wherein at least one cooling plate arrangement as described above, in particular manufactured according to the described method, is provided on the battery storage unit, wherein the cooling plate arrangement is in fluid communication with a coolant circuit of the motor vehicle.

[0022] Further advantages and details of the invention will become apparent from the following description of embodiments with reference to the figures. These show: Fig. 1. An example of a cooling plate arrangement as a simplified and schematic sectional and top view; Fig. 2 an example of a cooling plate arrangement as a simplified and schematic sectional view and top view; Fig. 3. An example of a cooling plate arrangement as a simplified and schematic sectional view; Fig. 4 a simplified representation of an example of a method for manufacturing a cooling plate arrangement; Fig. 5 a simplified representation of an example of a method for manufacturing a cooling plate arrangement; Fig. 6 A simplified and schematic representation of a motor vehicle with a cooling plate arrangement.

[0023] In Fig. Figure 1 (left) at A) shows a simplified and schematic sectional view of part of a cooling plate arrangement 10. The figure on the right shows the same... Fig. Figure 1 in B) shows a simplified and schematic top view of the cooling plate arrangement 10. The sectional view in A) corresponds approximately to section line AA in the top view in B).

[0024] Cooling plate arrangement 10 is particularly intended to cool a battery storage device (not shown) of a motor vehicle that is at least partially electrically powered.

[0025] The cooling plate arrangement 10 comprises a first outer cooling plate 12 made of a metal and a second outer cooling plate 14, in particular made of the same metal. The metal could be, for example, aluminum, stainless steel, copper, or a metal alloy.

[0026] An intermediate layer 16 made of an intermediate layer material is arranged between the two outer cooling plates 12, 14. The intermediate layer material can be, for example, a plastic, in particular a thermoplastic plastic.

[0027] In the cooling plate arrangement 10, the intermediate layer 16 has at least one channel-like recess 18, which is bounded by the first cooling plate 12 and the second cooling plate 14.

[0028] In the top view on the right in the Fig. In Figure 1 (B), the first cooling plate 12 is at the very bottom and not actually visible. The second cooling plate 14 is shown with diagonal hatching and transparently, allowing a view of the dotted-patterned intermediate layer 16 and the channel-like recess 18 (white). It is clear that the intermediate layer 16 would not normally be visible in such a top view because it is covered on both sides by a cooling plate 12, 14. In other words, the intermediate layer 16 with the channel-like recess 18 is sandwiched between the cooling plates 12, 14.

[0029] From the top view (right in Fig. 1) As can be seen by way of example in the cooling plate arrangement 10, the channel-like recess 18 forms a single, continuous cooling channel for a coolant, extending from an inlet coolant connection 20 to an outlet coolant connection 20. In the example shown, the channel-like recess 18 winds within the surface of the cooling plates 12, 14. In other words, the channel-like recess 18 meanders between the two coolant connections 20, 22.

[0030] In Fig. Figure 2 is another example of a cooling plate arrangement 10 in the same way as in the Fig. 1 shown, i.e., in a partial section A) and a top view B). The only difference to the cooling plate arrangement 10 of the Fig. The purpose of this document is to demonstrate that several channel-like recesses 18 form a cooling channel network for a coolant, wherein the cooling channel network has an inlet coolant connection 20 and an outlet coolant connection 22. The cooling channel network shown here is purely exemplary and schematic and can be configured differently in the implementation of a cooling plate arrangement 10.

[0031] From the Fig. 1 and Fig. 2 it is evident that the coolant connections 20, 22 are made of the intermediate layer material, i.e. in particular of plastic, and in particular they protrude over an edge 10r of the cooling plate arrangement 10.

[0032] Furthermore, the examples of Fig. 1 and Fig. 2. It is evident that the first cooling plate 12 and / or the second cooling plate 14 each have a substantially planar boundary surface 12f, 14f, which defines the channel-like recess 18. This is particularly evident in the sectional views at A) of the Fig. 1 and Fig. 2 shown.

[0033] In Fig. Figure 3 is a simplified sectional view as in the Fig. 1 at A). In this example of the cooling plate arrangement 10, it is illustrated that at least one of the cooling plates, here the second cooling plate 14, has at least one feature 14p, in particular an embossing, which corresponds to the channel-like recess 18 of the intermediate layer 16 and delimits the channel-like recess 18.

[0034] In the Fig. 4 based on similar representations, as in the Fig. 1 a method 500 for manufacturing a cooling plate arrangement 10 simplified representation.

[0035] In this process 500, in step S501, a first cooling plate 12 made of metal and / or a second cooling plate 14 made of metal are provided, which in the Fig. 4 is not explicitly shown.

[0036] According to step S502, intermediate layer material 16m is applied to the first cooling plate 12, whereby in this example the channel-like recess 18 on the first cooling plate is fully formed. In other words, the intermediate layer 16 is applied to the first cooling plate 12 with its full thickness or height.

[0037] In the process, in step S502, the intermediate layer material 16m can be applied to the first cooling plate 12 by means of 3D printing or by means of injection molding.

[0038] The intermediate layer material 16m can also be applied in such a way as to selectively create turbulence of the cooling medium in the channel-like recesses 18. In particular, the cross-sectional area of ​​the channel-like recess or cooling channel (and thus the flow rate of coolant) can be varied to generate turbulent flow.

[0039] Furthermore, it is conceivable that the intermediate layer 16 is provided as a pre-cut plastic film or plastic sheet. The channel-like recess 18 is cut or punched out of the plastic film or plastic sheet, for example by laser cutting or similar methods. Such a production or provision of the intermediate layer 16 is particularly characterized by its potential for automation and thus highly productive manufacturing.

[0040] According to step S503, the second cooling plate 14 is arranged on the first cooling plate 12, such that the channel-like recess 18 in the interlayer material 16m is bounded on both sides by the two cooling plates 12, 14. After this step S503, a cooling plate arrangement 10 can be provided as described in the Fig. 1, Fig. 2 to Fig. 3 has already been shown and described above.

[0041] In process steps S502 and S503, the first cooling plate 12 and the second cooling plate 14 can be joined with the intermediate layer material at common contact surfaces in a material-locking and / or force-locking manner, in particular by means of mirror welding, friction welding or hot pressing.

[0042] In the Fig. Figure 5 illustrates an alternative example of Method 500 using the simplified sectional views shown.

[0043] In this example, according to step S501, the first cooling plate 12 and the second cooling plate 14 are provided.

[0044] According to step S502, the intermediate layer material 16m is applied to the first cooling plate 12 and to the second cooling plate 14, wherein the at least one channel-like recess 18 is formed on both cooling plates 12, 14 partially, in particular halfway. In other words, a portion of the intermediate layer 16 is applied to both cooling plates. The application of the intermediate layer material 16m to the two cooling plates 12, 14 is carried out in a mirror-image fashion.

[0045] According to step S503, the second cooling plate 14, with its portion of the intermediate layer 16, is positioned on top of the first cooling plate 12, with its portion of the intermediate layer 16, so that the channel-like recess 18 in the joined intermediate layer material 16m is bounded on both sides by the two cooling plates 12 and 14. In this example, during step S503, two plastic layers (intermediate material layers 16m) are placed on top of each other during the joining process, which can be effectively bonded together by targeted heating.

[0046] Regarding further options for the procedural steps, please refer to the above description of the Fig. 4 referred to. Such options can also be found in this example of the slightly modified procedure 500 of the Fig. 5 can be applied.

[0047] Even towards the end of the in Fig. In the method 500 shown, a cooling plate arrangement 10 can be provided, as shown in the Fig. 1, Fig. 2 to Fig. 3 has already been shown.

[0048] In the Fig. Figure 6 is a highly simplified and schematic representation of a motor vehicle 200 with at least a partially electric drive 202 and a battery storage unit 204. A cooling plate arrangement 10, as described above, is provided on the battery storage unit 204. The illustration also shows that the cooling plate arrangement 10, in particular its channel-like recess 18 (cooling channel or channels), is in fluid communication with a coolant circuit 206 of the motor vehicle. QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 10 2012 217 367 A1

[0002] DE 10 2011 002 415 A1

[0003]

Claims

[1] Cooling plate arrangement (10) for cooling a battery storage device (204) of a motor vehicle (200) that is at least partially electrically powered, wherein the cooling plate arrangement (10) comprises: a first outer cooling plate (12) made of a metal; a second outer cooling plate (14) made of a metal, in particular the same metal; an intermediate layer (16) made of an intermediate layer material (16m) arranged between the two outer cooling plates (12, 14); characterized by that the intermediate layer (16) has at least one channel-like recess (18) which is bounded by the first cooling plate (12) and the second cooling plate (14). [2] Cooling plate arrangement (10) according to claim 1, characterized by that the intermediate layer material (16m) is a plastic, in particular a thermoplastic plastic. [3] Cooling plate arrangement (10) according to claim 1 or 2, characterized by, that the channel-like recess (18) forms a single, continuous cooling channel for a coolant, extending from an inlet coolant port (20) to an outlet coolant port (22), wherein the channel-like recess (18) in particular meanders between the two coolant ports (20, 22). [4] Cooling plate arrangement (10) according to claim 1 or 2, characterized by , that several channel-like recesses (18) form a cooling channel network for a coolant, wherein the cooling channel network has an inlet coolant connection (20) and an outlet coolant connection (22). [5] Cooling plate arrangement (10) according to claim 3 or 4, characterized by , that the coolant connections (20, 22) are made from the interlayer material (16m), in particular protruding over an edge (10r) of the cooling plate arrangement (10). [6] Cooling plate arrangement (10) according to one of the preceding claims, characterized by , the first cooling plate (12) and / or the second cooling plate (14) each have a substantially planar boundary surface (12f, 14f) that limits the channel-like recess (18) and / or that at least one of the cooling plates (14) has at least one shape (14p), in particular an embossing, which corresponds to the channel-like recess (18) of the intermediate layer (16) and limits the channel-like recess (18). [7] Method (500) for manufacturing a cooling plate arrangement (10) according to any one of the preceding claims, comprising the steps: Providing (S501) the first metal cooling plate (12) and the second metal cooling plate (14); Applying (S502) the interlayer material (16m) to the first cooling plate (12) and / or to the second cooling plate (14), wherein the at least one channel-like recess (18) is formed completely on one of the cooling plates (12) or partially, in particular half, on both cooling plates (12, 14); Arrange (S503) the second cooling plate (14) on the first cooling plate (12) so that the channel-like recess (18) in the intermediate layer material (16m) is bounded on both sides by the two cooling plates. [8] Method (500) according to claim 7, wherein the first cooling plate (12) and the second cooling plate (14) are joined to the intermediate layer material (16m) at common contact surfaces by means of material joining or / and force joining (S502, S503), in particular by means of mirror welding, friction welding or hot pressing. [9] Method (500) according to claim 7 or 8, wherein the intermediate layer material (16m) is applied to the first cooling plate (12) and / or to the second cooling plate (14) by means of 3D printing (S502) or by means of injection molding to the first cooling plate (12) and / or to the second cooling plate (14) (S502). [10] Motor vehicle (200) with at least a partially electric drive (202) and a battery storage unit (204), wherein at least one cooling plate arrangement (10) according to one of claims 1 to 6 is arranged on the battery storage unit (204), wherein the cooling plate arrangement (10) is in fluid communication with a coolant circuit (206) of the motor vehicle (200).

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