Hybrid cell holding structure for battery systems for a motor vehicle

Abstract

The invention relates to a hybrid cell holding structure for a battery system for a motor vehicle. The hybrid cell holding structure comprises an upper cell holding structure, a lower cell holding structure, and at least one spacer, wherein the upper cell holding structure and the lower cell holding structure are arranged parallel to each other and spaced apart. At least two accumulators are arranged between the upper cell holding structure and the lower cell holding structure, wherein the at least two accumulators penetrate the spacer, which is arranged between the upper cell holding structure and the lower cell holding structure, at an angle.The at least two accumulators each comprise a first end face with a first contact area and a second end face with a second contact area, wherein the upper cell holding structure for the at least two accumulators each comprises a through-opening, wherein the through-openings are designed for contacting with a cell contacting system of the first contact area and the second contact area of ​​the at least two accumulators, and the lower cell holding structure for the at least two accumulators each comprises a through-opening, wherein the through-openings are designed for contacting with a cell contacting system of the first contact area and the second contact area of ​​the at least two accumulators.

Description

[0001] The present invention relates to a hybrid cell holding structure for battery systems.

[0002] In modern automotive engineering, the safety of electrical energy storage systems is of paramount importance. Any failure can lead to system failure. Particularly in mobile applications, where battery systems are increasingly integrated into electric vehicles, the requirements for operational safety are extremely high. Technical faults can cause fires or explosions due to thermal overload, endangering both vehicle occupants and bystanders. Furthermore, electrical short circuits caused by mechanical deformation or damage to the battery cells can result in extensive damage to the vehicle's electronics system and, in the worst-case scenario, impair vehicle control.Consequently, the development of support structures that insulate the battery cells both electrically and thermally while ensuring their mechanical integrity under extreme conditions is important for the overall safety architecture of battery-powered systems.

[0003] DE 10 2013 215 975 B4 discloses spacers arranged between battery cells, which preferably consist of a thermoplastic material, a fiber composite material or aluminium.

[0004] The KR 10 2018 0 055 399 A concerns a battery module that includes an elastic frame for fixing battery cells.

[0005] WO 2017 / 169 729 A1 concerns a battery pack formed by housing several battery packs, in which in turn a large number of battery cells are housed in a fixed position of a mounting housing, and in particular a battery pack in which the heat dissipation of a battery cell housed in the battery pack is improved.

[0006] JP 2012-234699A relates to a power or energy storage device which is equipped with a structure for receiving a large number of energy storage elements.

[0007] The solutions for battery cell mountings mentioned in the prior art do not offer sufficient safety in the event of a technical failure of the battery cell, particularly in the area of ​​directly cooled battery systems. It is therefore an object of the invention to provide a mounting structure for battery cells in space-constrained environments, which is designed, among other things, for use in directly cooled fluid systems.

[0008] According to the invention, a hybrid cell holding structure for battery systems according to claim 1 is provided, as well as a motor vehicle with a hybrid cell holding structure for battery systems according to claim 9. Advantageous embodiments can be found in the dependent claims and the description.

[0009] The invention relates to a hybrid cell holding structure for a battery system for a motor vehicle. The hybrid cell holding structure comprises an upper cell holding structure, a lower cell holding structure, and at least one spacer, wherein the upper cell holding structure and the lower cell holding structure are arranged parallel to each other and spaced apart. At least two accumulators are arranged between the upper cell holding structure and the lower cell holding structure, wherein the at least two accumulators penetrate the spacer, which is arranged between the upper cell holding structure and the lower cell holding structure, at an angle.The at least two accumulators each comprise a first end face with a first contact area and a second end face with a second contact area, wherein the upper cell holding structure for the at least two accumulators each comprises a through-opening, wherein the through-openings are designed for contacting with a cell contacting system of the first contact area and the second contact area of ​​the at least two accumulators, and the lower cell holding structure for the at least two accumulators each comprises a through-opening, wherein the through-openings are designed for contacting with a cell contacting system of the first contact area and the second contact area of ​​the at least two accumulators.

[0010] The at least two accumulators can be arranged in the same orientation, i.e., parallel to each other, so that the poles with the same polarity point in the same direction. Alternatively, the at least two accumulators can be arranged in reverse to each other, so that the poles with opposite polarities point in the same direction.

[0011] With more than two accumulators, parallel or series-connected groups of accumulators can be connected via the cell contacting system.

[0012] The first contact area or the second contact area of ​​one of the at least two accumulators is the area in which a positive terminal or a negative terminal of the respective accumulator is located.

[0013] The aforementioned modification results in a three-point mounting between the upper cell support structure, the lower cell support structure, and at least one spacer. The at least two accumulators can each be bonded or potted with a potting compound at their first and / or second contact points to the spacer. In the upper and / or lower cell support structures, the first and / or second contact point of each accumulator (of the at least two accumulators) can be bonded or potted with a potting compound on the negative terminal side. The first and / or second contact point of each accumulator (of the at least two accumulators) on the positive terminal side can be bonded, clamped, or foamed into the upper and / or lower cell support structures.PU foam can be used as the foam material.

[0014] The three-point mounting is designed to prevent the batteries from becoming dislodged under any operating condition. In particular, if one of the at least two batteries fails, the mechanical stability of the cell holding structure should be maintained, as a certain system function is ensured even if one mounting point fails.

[0015] The term "runaway" in relation to batteries is also known as "thermal runaway." Thermal runaway is a dangerous condition in batteries, particularly lithium-ion batteries, and describes an uncontrolled, exothermic chemical reaction that is self-reinforcing and leads to a sudden rise in temperature within the battery.

[0016] This phenomenon is typically triggered by an internal short circuit or by external factors such as overheating, overcharging, mechanical damage, or manufacturing defects. The resulting heat can accelerate the degradation of other battery materials, releasing additional heat and potentially leading to a dangerous chain reaction.

[0017] The spacer can also be used to limit the space between at least two batteries. The term "limit" in this context refers to the spacer's function of controlling or limiting the spatial expansion of one battery relative to the other. Within a battery housing, various factors such as heat, pressure, or mechanical stress can cause batteries to deform or expand. A spacer positioned between two batteries can restrict this expansion and thus prevent them from touching. This helps prevent short circuits, as metallic contact between the batteries can lead to short circuits.By preventing contact, the spacer ensures electrical insulation between the batteries and increases the safety of the battery system. In the event of thermal runaway of a battery, it can expand radially, that is, in the circumferential direction.

[0018] In a housing containing at least two batteries, maintaining proper temperature regulation can be crucial for the performance and lifespan of these batteries. The spacer positioned between the two batteries not only serves to physically separate the cells but can also create cooling cavities.

[0019] The cavities created by the presence of at least one spacer between the at least two accumulators can allow the flow of air or a cooling fluid. This helps to dissipate excess heat generated during the operation of the accumulators.

[0020] If multiple spacers are used, they can be arranged equidistantly from each other. Equidistant spacers offer the advantage of a uniform distribution within the housing, resulting in more efficient cooling of at least two batteries. The uniformity of the spacers means that all batteries are the same distance apart, which can lead to homogeneous air or cooling fluid circulation.

[0021] According to the invention, the upper cell holding structure, the lower cell holding structure and the at least one spacer are each formed from a multilayer material.

[0022] According to the invention, the multilayer material consists of or comprises a glass fiber reinforced thermoplastic.

[0023] The glass fiber reinforced thermoplastic can be designed to withstand high temperatures and / or provide insulation. The glass fibers in the glass fiber reinforced thermoplastic can be configured as long fiber structures.

[0024] Glass fiber reinforced thermoplastics that integrate long fibers can offer several advantages over short-fiber reinforced thermoplastics. By embedding long fibers within the polymer matrix material, significantly improved mechanical properties can be achieved, including higher tensile strength, impact strength, and increased fatigue resistance. This is due to the effective load distribution that long-fiber reinforced structures enable within the material.

[0025] An additional advantage is the increased fracture toughness, which translates into improved energy absorption of the material before fracture occurs. This makes components reinforced with long fibers significantly more resistant to brittle failure behavior and high temperatures.

[0026] Long-fiber-reinforced thermoplastics offer clear advantages in terms of weight savings while maintaining stiffness and strength. They are not only lighter but can also exhibit superior thermal properties, making them more reliable, especially under extreme temperatures. Furthermore, long-fiber-reinforced thermoplastics can offer improved chemical resistance.

[0027] Glass fiber reinforced thermoplastics are materials that combine a base plastic with glass fibers to improve the mechanical and thermal properties of the original plastic. This reinforcement can significantly increase its strength and stiffness, making the material more resistant to mechanical stress. Additionally, it can offer improved dimensional stability and reduced elongation under thermal stress. In a preferred embodiment, long glass fibers can be used to fabricate the upper and / or lower cell support structure entirely from such a glass fiber reinforced thermoplastic.

[0028] The exact properties can be adjusted by the type of thermoplastic used, such as PA, PP, PBT, and / or the type, length and orientation of the glass fibers and / or the ratio of the glass fibers to the thermoplastic, as well as the processing method.

[0029] In an advantageous further development, the multi-layered material includes a potting material.

[0030] Epoxy resins and / or silicones and / or polyurethanes can be used as potting materials.

[0031] Epoxy resins exhibit high thermal conductivity. They offer good adhesion to many substrates and can be modified with fillers such as aluminum oxide, boronitride, or silver, which further improve thermal conductivity.

[0032] Thermally conductive silicones are flexible, which is advantageous when potting components subjected to thermal cycling or vibration. They generally have lower thermal conductivity than epoxy resins, but perform better at higher temperatures and have lower coefficients of thermal expansion.

[0033] Polyurethanes can also be formulated to be thermally conductive and are known for their elasticity and good mechanical properties. They can be less hard than epoxy resins, which makes them preferable in certain applications.

[0034] The selection of the appropriate potting compound depends on several factors, such as the required thermal conductivity, processing temperature, chemical resistance, mechanical properties, and adhesion to the substrate to be potted. Furthermore, factors such as pot life, curing time and temperature, and cost can also play a role.

[0035] In a further advantageous embodiment, the potting material is applied to one side of the upper cell holding structure and the lower cell holding structure facing the at least two accumulators, and / or the potting material is applied to a top and / or a bottom of the at least one spacer.

[0036] In an advantageous embodiment, the at least two accumulators are spaced apart by at least two guide elements, wherein at least one upper guide element is arranged in the upper cell holding structure and extends in the direction of the at least one spacer, and wherein at least one lower guide element is arranged in the lower cell holding structure and extends in the direction of the at least one spacer.

[0037] In a further advantageous embodiment, the at least one spacer runs perpendicular to the at least two accumulators and / or the at least one spacer runs parallel to the upper cell holding structure and / or the lower cell holding structure.

[0038] In a particularly advantageous embodiment, connecting elements can be arranged on the outer surface of both the upper and lower cell holding structures. The outer surface of the upper and lower cell holding structures, respectively, is the side facing away from the at least two accumulators. The connecting elements can be designed as projections or recesses. These projections and recesses can be configured such that another hybrid cell holding structure for battery systems, with its own projections and recesses, can be inserted into it, and the two hybrid cell holding structures for battery systems can be mechanically connected to each other.Alternatively or additionally, the protrusions can be designed as spacers between at least two hybrid cell holding structures for battery systems or other objects such as a housing wall.

[0039] The connecting elements and / or the guide elements can be used to create an adjustable distance between the support structure and the cell contacting system, as well as to accommodate the cell contacting system. This allows the cells to be advantageously cooled with air or a cooling fluid.

[0040] In a further advantageous development, at least one barrier can be inserted between the at least two accumulators. This barrier can be used for the thermal protection of surrounding components. The barrier can also be designed with protrusions and recesses. These may be necessary in the event of a thermal runaway of one of the at least two accumulators.

[0041] The barriers may be made of or comprise a hybrid material, in particular glass fiber reinforced composite materials or thermoplastic composites or draped carbon fiber textile materials used in sandwich construction.

[0042] In a further advantageous embodiment, cooling channels run between the lower cell holding structure, the upper cell holding structure and the at least one spacer between the at least two accumulators, wherein the cooling channels are formed by the position of the at least one spacer as well as by the position of the at least two guide elements and the upper and lower cell holding structures.

[0043] The cooling channels can then be filled with the cooling fluid. Fluids with dielectric properties can be used as cooling fluids. These fluids have good heat transfer properties and the ability to function at a wide range of temperatures without freezing or overheating. This allows for immersion cooling. Furthermore, there is no risk of a short circuit.

[0044] In an advantageous further development, at least two accumulators are designed as cylindrical cells and / or prismatic cells.

[0045] The invention also relates to a motor vehicle comprising a hybrid cell holding structure for a battery system, which is designed according to one of the preceding further developments.

[0046] The invention is described below by way of example only, with reference to the drawings. The drawings show: Fig. 1 a hybrid cell holding structure for battery systems; Fig. 2 a hybrid cell support structure for battery systems in cross-section; and Fig. 3 a hybrid cell support structure for battery systems in cross-section; and

[0047] Fig. Figure 1 shows a hybrid cell holding structure 100 for a battery system for a motor vehicle, comprising an upper cell holding structure 110, a lower cell holding structure 120, and at least one spacer 130. The upper cell holding structure 110 and the lower cell holding structure 120 are arranged parallel to each other and spaced apart, with at least two accumulators 200 arranged between the upper cell holding structure 110 and the lower cell holding structure 200, the at least two accumulators 200 penetrating the spacer 130, which is arranged between the upper cell holding structure 110 and the lower cell holding structure 120, at an angle. The at least two accumulators 200 each comprise a first end face 210 with a first contact area 211 and a second end face 220 with a second contact area 221.The upper cell holding structure 110 comprises a through-opening 140 for each of the at least two accumulators 200, wherein the through-openings 140 are configured for contacting a cell contacting system of the first contact area 211 and the second contact area 221 of the at least two accumulators 200. The lower cell holding structure 120 comprises a through-opening 140 for each of the at least two accumulators 200, wherein the through-openings 140 are configured for contacting a cell contacting system of the first contact area 211 and the second contact area 221 of the at least two accumulators 200.

[0048] In an advantageous embodiment, connecting elements 180 can be arranged on the outer surface of the upper cell holding structure 110 and on the outer surface of a lower cell holding structure 120. The outer surface of the upper cell holding structure 110 and the lower cell holding structure 120, respectively, is the side of the upper cell holding structure 110 and the lower cell holding structure 120 facing away from the at least two accumulators 200. The connecting elements 180 can be designed as projections or recesses. The projections and recesses can be designed such that another hybrid cell holding structure 100 for battery systems can be inserted into it with its projections and recesses, and the two hybrid cell holding structures 100 for battery systems can be mechanically connected to each other.Alternatively or additionally, the protrusions can be designed as spacers between at least two hybrid cell holding structures 100 for battery systems or other objects such as a housing wall. The connecting elements 180 and the guide elements 160 can be used to create an adjustable distance between the cell holding structure 120 and the cell contacting system, as well as to accommodate the cell contacting system. This allows the at least two accumulators 200 to be advantageously cooled with air or a cooling fluid.

[0049] In a further advantageous embodiment, at least one barrier (not shown) can be inserted between the at least two accumulators 200. This barrier can be used for thermal protection of surrounding components, particularly the at least two accumulators 200. The barrier can also be designed with projections and recesses. These may be necessary in the event of a thermal runaway of one of the at least two accumulators 200.

[0050] The barriers may be made of or comprise a hybrid material, in particular glass fiber reinforced composite materials or thermoplastic composites or draped carbon fiber textile materials used in sandwich construction.

[0051] Fig. Figure 2 shows a cross-section of the hybrid cell holding structure 100 for battery systems. The upper cell holding structure 110, the lower cell holding structure 120, and at least one spacer 130 are each made of a multilayer material 150.

[0052] The multilayer material 150 comprises a glass fiber reinforced thermoplastic 151 and a potting material 152 with good conductivity.

[0053] The potting material 152 is applied to one side of the upper cell holding structure 110 and the lower cell holding structure 120 facing at least two accumulators 200, and the potting material 152 is applied to a top and a bottom of the at least one spacer 130.

[0054] The at least two accumulators 130 are spaced apart by at least two guide elements 160, wherein at least one upper guide element 160 is arranged in the upper cell holding structure 110 and extends in the direction of the at least one spacer 130, and wherein at least one lower guide element 160 is arranged in the lower cell holding structure 120 and extends in the direction of the at least one spacer 130.

[0055] Fig. Figure 3 shows the hybrid cell holding structure 100 for battery systems in cross-section. Cooling channels 170 run between the lower cell holding structure 110, the upper cell holding structure 120 and the at least one spacer between the at least two accumulators 200, the cooling channels 200 being formed by the position of the at least one spacer 130 as well as by the position of the at least two guide elements 160 as well as the upper cell holding structure 110 and the lower cell holding structure 120.

[0056] The cooling channels 170 can be filled with a cooling fluid.

[0057] The invention is not limited to the described embodiments. Within the scope of the invention, all described and / or drawn features can be combined with one another as desired, unless otherwise stated. Reference sign 100 Hybrid cell support structures for battery systems 110 Upper cell support structure 120 Lower cell support structure 130 spacers 140 Through opening 150 Multi-layered material 151 Thermoplastic 152 Potting compound 160 guide element 170 cooling channels 180 connecting element 200 accumulator 210 First front 211 First contact area 220 Second front 221 Second contact area

Claims

[1] Hybrid cell support structure (100) for a battery system for a motor vehicle, comprising an upper cell retention structure (110), a lower cell retention structure (120) and at least one spacer (130), wherein the upper cell retention structure (110) and the lower cell retention structure (120) are arranged parallel to each other and spaced apart, wherein at least two accumulators (200) are arranged between the upper cell holding structure (110) and the lower cell holding structure (200), wherein The at least two accumulators (200) penetrate the spacer (130), which is arranged between the upper cell holding structure (110) and the lower cell holding structure (120), at an angle, wherein the at least two accumulators (200) each comprise a first end face (210) with a first contact area (211) and a second end face (220) with a second contact area (221), wherein the upper cell holding structure (110) comprises a through-opening (140) for each of the at least two accumulators (200), wherein the through-openings (140) are designed for contacting with a cell contacting system of the first contact area (211) and the second contact area (221) of the at least two accumulators (200). and the lower cell holding structure (120) for the at least two accumulators (200) each comprises a through-opening (140), wherein the through-openings (140) are designed for contacting with a cell contacting system of the first contact area (211) and the second contact area (221) of the at least two accumulators (200), wherein the upper cell retention structure (110), the lower cell retention structure (120) and the at least one spacer (130) are each formed from a multilayer material (150), wherein the multilayer material (150) comprises or consists of a glass fiber reinforced thermoplastic (151). [2] Hybrid cell holding structure (100) for a battery system according to claim 1, characterized by , that the multilayer material (150) comprises a potting material (152). [3] Hybrid cell holding structure (100) for a battery system according to claim 2, characterized by, that the potting material (152) is applied to one of the sides of the upper cell holding structure (110) and the lower cell holding structure (120) facing the at least two accumulators (200) and / or that the potting material (152) is applied to a top and / or a bottom of the at least one spacer (130). [4] Hybrid cell holding structure (100) for a battery system according to at least one of the preceding claims, characterized by , that the at least two accumulators (130) are spaced apart by at least two guide elements (160), wherein at least one upper guide element (160) is arranged in the upper cell holding structure (110) and extends in the direction of the at least one spacer (130) and wherein at least one lower guide element (160) is arranged in the lower cell holding structure (120) and extends in the direction of the at least one spacer (130). [5] Hybrid cell holding structure (100) for a battery system according to at least one of the preceding claims, characterized by , that at least one spacer (130) runs perpendicular to the at least two accumulators (200) and / or that the spacer (130) runs parallel to the upper cell holding structure (110) and / or the lower cell holding structure (120). [6] Hybrid cell holding structure (100) for a battery system according to at least one of the preceding claims, characterized by , that the spacer (130) is plate-shaped and comprises at least two holes, the size of each hole corresponding to the cross-section of the respective accumulator (200) that penetrates the respective hole. [7] Hybrid cell holding structure (100) for a battery system according to at least one of the preceding claims, characterized by, that cooling channels (170) run between the lower cell holding structure (110), the upper cell holding structure (120) and the at least one spacer between the at least two accumulators (200), wherein the cooling channels (200) are formed by the position of the at least one spacer (130) as well as by the position of the at least two guide elements (160) as well as the upper cell holding structure (110) and the lower cell holding structure (120). [8] Hybrid cell holding structure (100) for a battery system according to at least one of the preceding claims, characterized by that at least two accumulators (200) are designed as cylindrical cells and / or prismatic cells. [9] Motor vehicle comprising a hybrid cell holding structure (100) for a battery system, which is designed according to one of the preceding claims.

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