Electrical box with cooling system for battery cells and control units

Abstract

The present invention relates to an electrical box (10) for a battery pack (30) and control units (20), comprising a housing (15) containing battery cells (32) and at least one control unit (20), and a cooling system (35) for the battery cells (32), comprising at least one cooling channel (37) and a coolant (39), characterized in that the one cooling system (35) is used for cooling both the battery cells (32) and the control unit(s) (20). In addition, the invention relates to a use of the electrical box (10) according to the invention for a battery pack (30) and at least one control unit (20), and to a method for cooling battery cells (32) and control unit(s) (20) in an electrical box (10) according to the invention.

Description

Technical area

[0001] The present invention relates to an electrical box for a battery pack and control units, comprising a housing containing battery cells and at least one control unit, and a cooling system for the battery cells, comprising at least one cooling channel and a coolant, characterized in that the cooling system is used for cooling both the battery cells and the control unit(s). Furthermore, the invention relates to a use of the electrical box according to the invention for a battery pack and at least one control unit, as well as a method for cooling battery cells and control unit(s) in an electrical box according to the invention. State of the art

[0002] The electronics for battery management, charging, and / or energy conversion are usually located next to the high-voltage battery, especially in vehicles. The electronics are provided with their own cooling system to cool the sometimes high power dissipation.

[0003] DE 10 2021 201 922 A1 discloses a housing element of a battery, which is connected to another housing element to form a common interior space for accommodating a plurality of battery cells of a battery module. The housing element forms a temperature control structure on a first side, and a cover element is connected to the housing element in such a way that the cover element defines a flow channel through which temperature control fluid can flow in a fluid-tight manner. The temperature control structure is designed so that the temperature control fluid can flow around it, and a first element of a battery controller is also arranged on the cover element in a thermally conductive manner. Furthermore, a plurality of vortex elements rise in the flow channel. A vortex element is a geometric structure that converts a laminar flow of temperature control fluid into a turbulent flow, at least in certain regions.It can be cylindrical, conical, pyramidal, or any other geometric shape. This allows the flow to be redirected more precisely and, at the same time, significantly increases the heat transfer surface. The vortex elements are advantageously not connected to the cover element.

[0004] DE 10 2021 209 308 A1 relates to a cooling device for cooling the power electronics of a battery system with a plurality of battery cells. The cooling device comprises a cooling channel with coolant. The power electronics can be connected to the cooling channel ceiling in a heat-transfer manner on a side of the cooling channel ceiling facing away from the cooling channel. The cooling channel ceiling has a base area and at least one elevation forming a ventilation space on the side facing the cooling channel. Disclosure of the invention

[0005] According to the invention, an electrical box for a battery pack and control units is proposed, comprising a housing containing battery cells and at least one control unit, and a cooling system for the battery cells, comprising at least one cooling channel and a coolant. The electrical box according to the invention is characterized in that the one cooling system is used for cooling both the battery cells and the control unit(s). In this case, an underside of a housing of the control unit(s) adjoins the surface of the at least one cooling channel, and the at least one control unit is cooled by a geometric structure as a heat sink on the underside of the housing of the control unit(s), which is immersed in the cooling channel of the cooling system for the battery cells, wherein the housing is sealed off from the coolant.

[0006] The electrical box is understood as a component that combines and functionally connects various electrical components, thus enabling a high level of integration. A particularly high level of integration is achieved with the electrical box according to the invention by using a single cooling system to cool both the battery cells and the control units. This saves space as well as reduces material and weight, while still ensuring the desired temperature control of all components.

[0007] The cooling system uses substances that are typically used for cooling batteries and are familiar to experts. Water-based coolants are particularly preferred.

[0008] Geometric structures serving as heat sinks are also known in the art and can be designed in a variety of geometries. For example, they can be in the form of pins, fins, columns, cylinders, cones, and / or similar bodies. Pin-type heat sinks are preferred. The contact between the cooling channel and the coolant on the underside of the housing and the geometric structures serving as heat sinks is designed to create a fluid-tight connection. The housing is thus sealed from the coolant, preventing penetration into the housing or parts of the housing. Seals prevent this. The interior of the housing from being completely separated from the coolant.

[0009] In an advantageous embodiment of the electrical box according to the invention, the housing of the control unit(s) is made entirely or partially of plastic. For example, the cover of the housing and / or the side wall of the housing can be made entirely or partially of plastic. The plastic used is, in particular, thermoplastics such as polyamide (PA), polycarbonate (PC), polyethylene (PE), polypropylene (PP), polystyrene (PS), acrylonitrile butadiene styrene (ABS), polybutylene terephthalate (PBT), and similar materials.

[0010] In a further advantageous embodiment of the electrical box according to the invention, standard seals are used to seal between the housing and the cooling channel. Such seals are known to those skilled in the art and include various types—such as static, dynamic, and mechanical seals—as well as various materials, such as silicone, rubber, or plastics.

[0011] In a further advantageous embodiment of the electrical box according to the invention, a seal-free connection is used between the cover and the side walls when closing the housing. This is made possible by the seal between the housing and the coolant, creating contact without additional openings, thus preventing coolant from penetrating the housing. The seal-free connection can thus be established by simply placing it on top, pressing it together, clicking it together, or similarly.

[0012] The invention also relates to the use of an electrical box according to the invention for a battery pack and at least one control unit. The use of the electrical box is particularly advantageous for use in electric or partially electric vehicles, including in particular cars, trucks, buses, commercial vehicles, and two-wheelers, due to the high degree of integration of the battery pack and control unit(s).

[0013] The invention also relates to a method for cooling battery cells and control unit(s) in an electrical box according to the invention, wherein a cooling system is used for cooling both the battery cells and the control unit(s). The coolant of the cooling system is directed along the components to be cooled according to the desired temperature profile and the required temperatures or cooling capacities.

[0014] Furthermore, the invention proposes an electrical box for a battery pack and for control units, comprising a housing containing battery cells and at least one control unit, preferably at least two control units, and a cooling system for the battery cells, comprising at least one cooling channel and a coolant. The electrical box according to the invention is also characterized in that the cooling system is used for cooling both the battery cells and the control unit(s).In this case, an underside of a housing of the control unit(s) connects to the surface of the cooling channel with openings, and at least one control unit is cooled by a second cooling channel branched off from the cooling channel of the cooling system, and / or at least one control unit is cooled by a geometric structure as a heat sink on the underside of the housing of the control unit(s), which is immersed in the cooling channel of the cooling system for the battery cells.

[0015] The electrical box is understood as a component that combines and functionally connects various electrical components, thus enabling a high level of integration. A particularly high level of integration is achieved with the electrical box according to the invention by using a single cooling system to cool both the battery cells and the control units. This saves space as well as reduces material and weight, while still ensuring the desired temperature control of all components.

[0016] Substances typically used in the field for cooling batteries and known to experts are used as coolants in the cooling system. Water-based coolants are particularly preferred. The branched second cooling channel, which leads from the (first) cooling channel of the cooling system to a control unit, can differ in diameter from the first cooling channel, in particular to a smaller diameter, but can also be identical. This applies individually to all branched channels, which are not fixed in diameter relative to one another but can be coordinated with one another. The associated properties of fluids and their flow behavior that must be observed and observed are known to experts.

[0017] Geometric structures are also known in the field as heat sinks and can be designed in various geometries. For example, they can be in the form of pins, fins, columns, cylinders, cones, and / or similar bodies. Pin heat sinks are preferred. The contact between the cooling channel and the coolant with the selected cooling components of the control unit(s) (second cooling channel and / or geometric structures as heat sinks) is achieved via openings on the underside of the housing. These openings allow direct contact of the coolant with the control units and are sealed from other components and the rest of the housing's interior.

[0018] In an advantageous embodiment of the electrical box according to the invention, the enclosure contains at least two control units. These are located together in the control unit housing and can be individually selected or even replaced. Depending on their function and activities, the control units can have different levels of power and heat loss and thus also different cooling requirements.

[0019] In a further advantageous embodiment of the electrical box according to the invention, at least one control unit is cooled by a second cooling channel branched off from the cooling channel of the cooling system and at least one control unit is cooled by a geometric structure as a heat sink on the underside of the housing of the control unit(s), which is immersed in the cooling channel of the cooling system for the battery cells.

[0020] In a further advantageous embodiment of the electrical box according to the invention, one of several control units remains uncooled. This design allows the different cooling requirements of the individual control units to be met, so that, on the one hand, an optimal temperature is set by the cooling, while, on the other, the process is energy and material efficient.

[0021] Furthermore, the invention relates to the use of an electrical box according to the invention for a battery pack and at least one control unit. The use of the electrical box is particularly advantageous for use in electric or partially electric vehicles, including in particular cars, trucks, buses, commercial vehicles, and two-wheelers, due to the high degree of integration of the battery pack and control unit(s).

[0022] The invention also relates to a method for cooling battery cells and control unit(s) in an electrical box according to the invention, wherein a cooling system is used for cooling both the battery cells and the control unit(s). The coolant of the cooling system is directed along the components to be cooled according to the desired temperature profile and the required temperatures or cooling capacities. Advantages of the invention

[0023] With the electrical box according to the invention, a single cooling system is used for both cooling battery cells and cooling control units. This makes it particularly efficient and easy to combine and functionally connect various electrical components, creating a high level of component integration. High integration allows for space and material savings, thus reducing costs, and also facilitates handling of the electrical box and its components. Furthermore, a high power density is achieved, which offers advantages in applications and during installation of the electrical box, such as greater compactness, better storage, the possibility of portable applications, and similar benefits.

[0024] Furthermore, the electrical box according to the invention is advantageous when passing on, for example to suppliers, because it is a self-contained and functional unit containing all components. Neither the individual assembly of components nor the individual connection and connection of the components is required for installation of the electrical box.

[0025] The electrical box according to the invention is not limited to one or two control units, but is also suitable for a larger number of control units. These do not require a separate housing each; instead, all control units can be accommodated in one housing within the electrical box. This also reduces material and cost requirements. It is possible to replace or repair control units individually. Likewise, if necessary, all control units can be replaced as a whole. Such a replacement is made quick and easy by opening the housing cover of the electrical box. In addition, the electrical box according to the invention advantageously also allows for the simple replacement of individual or all battery cells, so that repair, replacement, or renewal is easily possible.The described design allows the existing control unit of the electrical box to be accessed at any time, making it easy to read data during maintenance, etc. All components of the electrical box are individually recyclable.

[0026] Contact with the battery cell cooling system for cooling the control units is made on the underside of the housing, either via openings leading to the selected cooling components (second cooling channel, geometric structures as heat sinks) or directly via geometric structures as heat sinks on the housing. This advantageously allows the cooling required for the respective components to be selected and adapted. If cooling without openings in the housing is selected, the housing itself is sealed directly to the coolant. This can be achieved using standard seals, without any additional knowledge required by specialists. This completely separates the control unit housing from the coolant. Another advantage is that sealing the cover on the control unit housing is then not necessary. It is also possible to manufacture the housing entirely or partially from plastic.This can simplify the manufacturing process on the one hand and save weight and material costs on the other. Short description of the drawings

[0027] Embodiments of the invention are explained in more detail with reference to the drawings and the following description.

[0028] They show: Fig. 1 the schematic structure of an electrical box in cross-section with two control units and a shared cooling system using a geometric structure as a heat sink, Fig. 2 the schematic structure of an electrical box in cross-section with two control units and a shared cooling system by means of openings for a second cooling channel and a geometric structure as a heat sink, Fig. 3 the schematic structure of an electrical box in cross-section with two control units and a shared cooling system by means of openings for the geometric structure as a heat sink, Fig. 4 the schematic structure of an electrical box in cross section with two control units and a shared cooling system by means of openings for a second cooling channel, and Fig. 5 the layered structure of an electrical box according to the invention with four levels as an exploded view. Embodiments of the invention

[0029] In the following description of the embodiments of the invention, identical or similar elements are designated by the same reference numerals, whereby a repeated description of these elements is omitted in individual cases. The figures only schematically illustrate the subject matter of the invention.

[0030] Fig. 1 shows the schematic structure of an electrical box 10 according to the invention in cross-section with two control units 20 and for a battery pack 30 (not shown) and a shared cooling system 35 using geometric structures as heat sinks 27, here pin heat sinks. The housing 15 contains the aforementioned components. Electrical connections 21 represent links between the control units 20 and to the outside. One cooling system 35 forms a circuit 36 ​​and is used in the electrical box 10 according to the invention for cooling both the battery cells 32 (not shown) and the two control units 20. The underside 24 of the housing 22 of the control units 20 directly adjoins the surface 38 of the cooling channel 37. At these connection points, geometric structures as heat sinks 27, here pin heat sinks, are attached, which are immersed in the coolant 39 of the cooling channel 37.The geometric structures serving as heat sinks 27 are depicted here as cylinders slightly varying in height and diameter, but they can also have other different shapes and sizes. The control units 20 located above are cooled via the geometric structures serving as heat sinks 27. For this purpose, the control units 20 are also thermally connected to the underside 24 of the housing 22. This can be achieved via special connections known to those skilled in the art, e.g., via so-called Thermal Interface Material (TIM) (see control unit 20, left). Alternatively, the control unit 20 can be attached to the housing 22, for example, by means of a solder joint for mechanical and thermal connection (see control unit 20, right). In the area of ​​the geometric structures serving as heat sinks 27, the housing 22 is sealed from the coolant 39 with seals 25. The housing 22 itself comprises, in addition to the underside 24, side walls 28 and a cover 23.Due to the sealing between the coolant 39 and the interior of the housing 22 of the control units 20, in the illustrated embodiment, a connection without a seal 26 is selected for the cover 23 of the housing 22, which connects the cover 23 and the side walls 28. The housing 22 can be made entirely or partially of plastic.

[0031] The Fig. 2 to 4 show the schematic structure of an electrical box 10 in cross-section with two control units 20 as well as for a battery pack 30 (not shown) and a shared cooling system 35 via openings 41. The housing 15 contains each of the aforementioned components. Electrical connections 21 represent links between the control units 20 and to the outside. One cooling system 35 forms a circuit 36 ​​and is used in the electrical box 10 according to the invention for cooling both the battery cells 32 (not shown) and the two control units 20. An underside 24 of a housing 22 of the control units 20 connects to the surface 38 of the cooling channel 37 via openings 41, with the openings 41 forming the transition between the cooling system 35 and the selected cooling components (second cooling channel 43, geometric structures as heat sink 27).

[0032] In Fig. 2, two openings 41 serve on the one hand a second cooling channel 43 and on the other hand geometric structures as heat sinks 27, here pin heat sinks, in Fig. 3 both openings 41 serve geometric structures as heat sinks 27, here pin heat sinks, and in Fig. 4 there is an opening 41 for a second cooling channel 43.

[0033] The cooling components are attached directly to the control units 20 and can thus directly regulate the temperature via the cooling system 35. For this purpose, the geometric structures as heat sinks 27, here pin heat sinks, are immersed in the coolant 39 at the surface 38 of the cooling channel 37. The pin heat sinks are shown here as cylinders slightly varying in height and diameter, but they can have other different shapes and sizes. The second cooling channel 43 as a cooling component is branched off from the first cooling channel 37 in such a way that the coolant 39 of the cooling system 35 flows through it. The opening 41 to the cooling system 35 is in the illustrated embodiment ( Fig. 2 and Fig. 4) with valves 42 as connecting pieces. The length, shape, and diameter can vary and be adapted to the respective cooling requirements.

[0034] The housing 22 is sealed with seals 25 in the area of ​​the openings 41 to the further interior of the housing 22. The housing 22 itself comprises, in addition to the underside 24, side walls 28 and a cover 23. This cover 23 is also provided with seals 25 and is thus sealed to the side walls 28.

[0035] Fig.5 shows the layered structure of an electrical box 10 according to the invention with four levels as an exploded view. The outer sides of the illustrated components form the housing 15 of the electrical box 10. The lower layer forms the cooling system 35 for the battery pack 30. The cooling system 35 comprises a cooling channel 37 for a coolant 39 and is designed as a circuit 36. Furthermore, seals 25 are located on this layer leading to the layer above. This forms a housing 22 with side walls 28, the underside 24 of which connects to the cooling system 35 and provides space for one or more control units 20. The control units 20 are mounted such that they are also cooled by the cooling system 35. Spaces for battery cells 32 are also provided. Seals 25 are attached to each of the layers above and below for connection. The top layer is the cover 23, which is connected to the housing 22.

[0036] The invention is not limited to the embodiments described here and the aspects highlighted therein. Rather, numerous modifications are possible within the scope of the claims, which are within the scope of expert practice. QUOTES CONTAINED IN THE DESCRIPTION

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

[0000] DE 10 2021 201 922 A1

[0003] DE 10 2021 209 308 A1

[0004]

Claims

[1] Electrical box (10) for a battery pack (30) and control units (20) comprising - a housing (15) containing battery cells (32) and at least one control unit (20), and - a cooling system (35) for the battery cells (32) comprising at least one cooling channel (37) and a coolant (39), characterized by that the one cooling system (35) is used for cooling both the battery cells (32) and the control unit(s) (20), wherein - a bottom side (24) of a housing (22) of the control unit(s) (20) connects to the surface (38) of the at least one cooling channel (37), and - the at least one control unit (20) is cooled by a geometric structure as a heat sink (27) on the underside (24) of the housing (22) of the control unit(s) (20), which is immersed in the cooling channel (37) of the cooling system (35) for the battery cells (32), wherein the housing (22) is sealed off from the coolant (39). [2] Electrical box (10) according to claim 1, characterized by that the housing (22) of the control unit(s) (20) is made entirely or partially of polymer material. [3] Electrical box (10) according to one of claims 1 or 2, characterized by that standard seals (25) are used to seal between the housing (22) and the cooling channel (37). [4] Electrical box (10) according to one of claims 1 to 3, characterized by that when closing the housing (22) a seal-free connection (26) is used between the cover (23) and the side walls (28). [5] Use of an electrical box (10) according to one of claims 1 to 4 for a battery pack (30) and at least one control unit (20). [6] Method for cooling battery cells (32) and control unit(s) (20) in an electrical box (10) according to one of claims 1 to 4, characterized bythat a cooling system (35) is used for cooling both the battery cells (32) and the control unit(s) (20). [7] Electrical box (10) for a battery pack (30) and control units (20) comprising - a housing (15) containing battery cells (32) and at least one control unit (20), preferably at least two control units (20), and - a cooling system (35) for the battery cells (32) comprising at least one cooling channel (37) and a coolant (39), characterized by that the one cooling system (35) is used for cooling both the battery cells (32) and the control unit(s) (20), wherein - a bottom side (24) of a housing (22) of the control unit(s) (20) having openings (41) is connected to the surface (38) of the at least one cooling channel (37), and wherein - at least one control unit (20) is cooled by a second cooling channel (43) branched off from the cooling channel (37) of the cooling system (35) and / or - at least one control unit (20) is cooled by a geometric structure as a heat sink (27) on the underside (24) of the housing (22) of the control unit(s) (20), which is immersed in the cooling channel (37) of the cooling system (35) for the battery cells (32). [8] Electrical box (10) according to claim 7, characterized by that the housing (15) contains at least two control units (20). [9] Electrical box (10) according to one of claims 7 or 8, characterized bythat at least one control unit (20) is cooled by a second cooling channel (43) branched off from the cooling channel (37) of the cooling system (35) and at least one control unit (20) is cooled by a geometric structure as a heat sink (27) on the underside (24) of the housing (22) of the control unit(s) (20), which is immersed in the cooling channel (37) of the cooling system (35) for the battery cells (32). [10] Electrical box (10) according to one of claims 7 to 9, characterized by that one of several control units (20) remains uncooled. [11] Use of an electrical box (10) according to one of claims 7 to 10 for a battery pack (30) and at least one control unit (20). [12] Method for cooling battery cells (32) and control units (20) in an electrical box (10) according to one of claims 7 to 10, characterized bythat a cooling system (35) is used for cooling both the battery cells (32) and the control unit(s) (20).

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