Cooling circuit distribution system for a battery electric vehicle and battery electric vehicle

Abstract

Cooling circuit distribution system for a battery-electric vehicle (1), comprising: a distribution plate (16) with a plurality of fluid channels (18) which serve for the fluidic connection of different components of a cooling circuit of the vehicle (1), wherein the fluid channels (18) exit from the distribution plate (16) at an edge (20) with a connection piece (22) each, and an interface block (30) to which a number of fluid lines (42) are connected, which transition into counterparts (32) for the connection pieces (22) of the distribution plate (16), wherein the interface block (30) is reversibly attached to the distribution plate (16) by means of at least two clamping fasteners (40) such that each connection piece (22) is fluidly guided and sealed to the correspondingly assigned counterpart piece (32).

Description

The invention relates to a cooling circuit distribution system for a battery-electric vehicle. Furthermore, the invention relates to such a battery-electric vehicle. Battery-electric vehicles, like those powered by internal combustion engines, require cooling. This cooling applies not only to the actual drive motor but also to the (traction) battery. The battery must not exceed a predetermined temperature, otherwise its performance will decrease or it risks thermal damage, which in the worst case can lead to an explosive combustion of the battery cells through a thermal chain reaction involving strong exothermic reactions. During normal driving, however, the cooling system aims to maintain the battery temperature within a specified range to preserve performance and lifespan as much as possible. Besides driving, battery cells also heat up during charging. This heating should be prevented or at least kept within a reasonable range to avoid negatively impacting charging performance and battery lifespan. In a combustion engine vehicle, cooling of vehicle components, particularly the combustion engine, transmission, or similar components, is not necessary, except for air conditioning. Cooling systems based on refrigerants and cooling fluids are used, particularly in high-performance batteries or battery-electric vehicles. These systems have a refrigerant circuit that cools the battery to approximately 15 to 30 degrees Celsius and a separate cooling circuit that regulates the temperature or cools the electric drive motor and power electronics to below 60 degrees Celsius. A chiller—a heat exchanger for comparatively low temperatures that is effective for both the refrigerant and the coolant, or can be effective for both with appropriate valve configuration—is frequently used. The refrigerants used are media that exist in different states of matter (usually gaseous and liquid) for heat transfer. A water-based mixture is typically used as the coolant. Supplying the individual components with coolant or refrigerant requires a comparatively large amount of piping. Traditionally, this was achieved using dedicated pipes or hoses. To reduce installation effort, plate-like distribution structures, usually injection-molded components, have been introduced, which at least partially reduce the installation effort required for individual hose lines. The invention is based on the objective of enabling the least possible assembly effort. This problem is solved according to the invention by a cooling circuit distribution system with the features of claim 1 and a battery-electric motor vehicle with the features of claim 10. Further advantageous and partly inventive embodiments and developments of the invention are set out in the dependent claims and the following description. The cooling circuit distribution system according to the invention is designed and intended for use in or with a battery-electric vehicle. The cooling circuit distribution system comprises a distribution plate with a plurality of fluid channels, each serving to guide a coolant or refrigerant, wherein the fluid channels serve for the fluidic connection of different components of a cooling and / or refrigeration circuit system of the vehicle. The fluid channels exit the distribution plate at an edge (in particular a front edge) with a connecting piece. The cooling circuit distribution system also comprises an interface block to which a number of fluid lines are connected, which transition into counterparts for the connecting pieces of the distribution plate. In particular, the interface block has a number of counterparts corresponding to the connecting pieces.The fluid lines, like the coolant channels, serve primarily to guide the cooling or refrigerant. The interface block is reversibly attached to the distributor plate – at least in its intended operating state – by means of at least two clamping fasteners, such that each connection piece is fluidly guided and sealed to its corresponding counterpart. Components of the cooling and / or refrigeration circuit system (also referred to simply as the cooling circuit, regardless of the fluid used - refrigerant or coolant -) include, for example, a condenser, a compressor, heat exchangers (e.g. a cooling plate for a traction battery of a motor vehicle), a "chiller" or the like. The use of the interface block significantly reduces assembly effort when using the distribution plate. Individual cables no longer need to be connected to the fittings and secured and sealed, for example, with hose clamps. Instead, the interface block can be connected to the distribution plate as a single unit, particularly using the clamping fasteners. This saves considerable time and effort during maintenance. Preferably, only one supply line for the refrigerant and one supply line for the coolant, along with their respective outlets (i.e., specifically only the respective flow and return lines), connect to the interface block. Instead of having to close a separate plug connection for each fitting during installation (e.g., approximately eight to fourteen fittings), only four pipe or hose connections (supply and return lines, one each for refrigerant and coolant) at the interface block and the connection between the interface block and the manifold block need to be closed. This allows the interface block to be easily detached from the manifold plate for maintenance purposes. The clamping fasteners are preferably designed to exert a tensile force in the connection direction between the distributor plate and the interface block. This simplifies the sealing effect between the distributor plate and the interface block. According to a particularly advantageous embodiment, the respective clamping closure is formed by a toggle clamping lever arranged on the interface block or the distributor plate and a clamping hook arranged on the distributor plate or the interface block (and in particular, rigidly designed). When the toggle clamping lever is closed, this embodiment generates a tensile force in the closing direction between the distributor plate and the interface block. This reinforces the sealing effect between these two. According to a preferred embodiment, the toggle clamping lever has a toggle lever pivotally attached to the interface block or the distributor plate at a pivot point. Furthermore, the toggle clamping lever has a pull hook that is offset (in particular at a pivot point) from the pivot point on the toggle lever, and in particular, is movably attached to this pivot point. In the intended clamping state, this pull hook is engaged with the clamping hook. Due to this arrangement of the pull hook, it (or at least its pivot point) moves in a circular path around the pivot point when the toggle lever is pivoted. This exerts a tensile force on the clamping hook when the toggle lever is closed as intended, thus pulling the distributor plate and the interface block together. This principle is comparable, for example, to the buckles of a ski boot. According to an alternative embodiment, the respective clamping device (particularly as an alternative to the toggle clamping lever described above) features a straight-pull toggle clamp arranged on the interface block or the distributor plate. A clamping hook is arranged on the distributor plate or interface block, as described above. Thus, the only difference between this embodiment and the previously described embodiment is the kinematics (here, a toggle kinematics). This allows for the simple application of high (tensile) forces. According to a practical alternative embodiment, the respective clamping mechanism is formed by a pivot hook and a retaining pin, both located on the interface block or distributor plate. In the intended clamping state, the pivot hook engages behind the retaining pin, particularly in a claw-like manner. Specifically, the pivot hook has a claw- or U-shaped extension that engages behind the retaining pin during assembly and, as the pivot hook is further rotated, slides off the retaining pin, thereby drawing it towards the distributor plate or interface block. This fastening concept is known from connectors sold under the "Harting" brand. According to a suitable embodiment, the interface block and / or the distributor plate has a sealing arrangement. In a properly connected state, this sealing arrangement provides an individual seal between each connector and its corresponding counterpart. Specifically, the sealing arrangement is formed by several sealing rings (either individually or as a single, continuous component) surrounding the respective connector and / or counterpart. Thus, an individual seal is advantageously provided for each channel formed by the respective fluid channel and the associated fluid line. For example, a butt joint can be formed between the respective connector and the corresponding counterpart, with the aforementioned sealing arrangement, in particular the respective sealing ring, being inserted between the connector and the counterpart. According to an alternative, practical design, the respective connecting piece is designed as a socket or pipe section for insertion into the socket, and the counterpart is designed as a pipe section or socket for receiving the pipe section. This design has the advantage of comparatively simple sealing and / or simple assembly, since sockets and pipe sections have a centering effect. In the event that coolant (e.g., water) and refrigerant (e.g., carbon dioxide) are carried in corresponding fluid channels and fluid lines in the distributor plate and the interface block, the sealing arrangement has, in addition to the above-described individual sealing means (e.g., sealing rings), additional sealing means, e.g., also sealing rings or sealing beads, which preferably surround fluid channels or fluid lines arranged in groups with respect to the respective medium (coolant or refrigerant) and thus form a second sealing level for increased safety with regard to a mixing of the two media. According to another alternative, but equally practical embodiment, each connector and its corresponding counterpart each have a hydraulic quick-release coupling element at their end for a fluid-tight connection between the respective fluid channel and the corresponding fluid line. During assembly of the interface block, an automatic and, in particular, fluid-tight coupling is preferably achieved by means of the respective hydraulic quick-release couplings. According to an advantageous embodiment, the connecting pieces in the manifold plate and the mating pieces in the interface block are arranged such that a clear alignment of the manifold plate to the interface block is enforced during assembly. In particular, the connecting pieces and the corresponding mating pieces are arranged asymmetrically, e.g., in groups of optionally varying numbers. Due to the centering effect of the sockets and pipe sections mentioned above, a poka-yoke effect can be achieved. The distributor plate described above, in conjunction with the interface block, also allows for the simple division of a hose- or pipe-shaped fluid line, which, for example, forms a supply or return line for the coolant or refrigerant, into several sub-lines (especially within the interface block), which are then connected to the fluid channels of the distributor plate. Division into multiple returns within the interface block or the merging of multiple supply lines within the interface block is also possible. The battery-electric vehicle according to the invention is equipped with a cooling circuit distribution system of the type described above, and thus has such a system. Therefore, the vehicle also has all the features described here and below in the context of optional embodiments in the corresponding optional embodiments. The conjunction “and / or” is to be understood here and in the following in particular as meaning that the features linked by means of this conjunction can be formed both jointly and as alternatives to each other. Exemplary embodiments of the invention are explained in more detail below with reference to a drawing. In this drawing, schematic and exemplary representations are shown: Fig. 1 in a side view of a motor vehicle, Fig. 2 in a top view of a cooling circuit distribution system of the motor vehicle, and Fig. 3 in a view according to Fig. 2 an alternative embodiment of the cooling circuit distribution system. Corresponding parts in all figures are always marked with the same reference symbols. Figure 1 schematically depicts a battery-electric vehicle 1. This vehicle has an electric motor (not shown) as its drive motor, which draws its operating energy from a traction battery 2. For temperature control—i.e., for heating or cooling the traction battery 2 as needed, as well as other components of the vehicle 1 (e.g., the drive motor's power electronics)—the vehicle 1 has a cooling system 4. This system comprises a radiator 6 (including a radiator fan, not shown in detail), a compressor 8, a heat exchanger designated as a "chiller 10," and a cooling plate 12 for the traction battery 2. An electric heater is not shown in detail. These components are interconnected and / or at least connected to the radiator 6 and the compressor 8 via fluid lines. To reduce the effort required for pipe installation, part of the pipe routing is carried out using a distribution plate 16. This is shown in more detail in Fig. 2 and has a multitude of different (fluid) channels 18 for a coolant or refrigerant. The cooling system 4 is designed as a cooling system carrying both coolant and refrigerant. The cooling system 4 therefore has two cooling circuits (not shown in detail), one of which contains a coolant, e.g., a water mixture, and the other a refrigerant. The refrigerant is characterized by the fact that it changes between the gaseous and liquid phases when passing through the associated cooling circuit (for example, it is carbon dioxide). The distribution plate 16 is part of a cooling circuit distribution system. Each of the channels 18 terminates at an edge 20 of the distribution plate 16 in a connecting piece 22 extending beyond the edge 20. To enable simple and time-saving connection with the corresponding lines for coolant or refrigerant, the cooling circuit distribution system features an interface block 30. This interface block 30 incorporates corresponding counterparts 32 for the connection pieces 22. By mounting the interface block 30 onto the distribution plate 16, particularly by pushing it into position, all connection pieces 22 and counterparts 32 are coupled together and, in particular, sealed against fluid flow. Clamping fasteners 40 are provided to hold the interface block 30 against the distribution plate 16 and to exert a sealing force between the two. Optionally, the counterparts 32 are designed as lines, e.g., hose or pipe sections (see Fig. 2), which are individually embedded in a housing body of the interface block 30 by injection molding, each assigned to a connection piece 22. This means that the lines only need to be connected to the corresponding components; the coupling to the distributor plate 16 is advantageously achieved in one step via the connection of the interface block 30. To achieve a particularly efficient distribution, especially with regard to assembly effort through the interface block 30, the counterparts 32 are, in a practical embodiment (see Fig. 3), routed to various manifolds 42 (fluid lines), each forming a supply and a return line for the refrigerant and the coolant. Therefore, in the present embodiment, four manifolds 42 (two supply lines and two return lines) are shown by way of example. In the present embodiment, the connecting pieces 22 are designed in the form of pipe sections that project from the edge 20 of the distributor plate 16. The counterparts 32 of the interface block 30 are designed as sockets that receive the connecting pieces 22, specifically, during assembly, they are slid over the connecting pieces 22. The sockets therefore have a larger diameter than the pipe sections. For sealing between the connecting pieces 22 and the counterparts 32, the interface block 30 has a sealing arrangement. This in turn is formed by individual ring seals 44, which are located in the respective socket and seal the received pipe section on the outside in a ring-shaped closed manner. Optionally, the sealing arrangement can also include several additional sealing frames, which are positioned at the end face between the interface block 30 and the edge 20 of the distributor plate 16 and are clamped between them in the intended assembly state (see Fig. 2). These sealing frames are arranged circumferentially around the groups of supply and return lines assigned to a refrigerant circuit (e.g., on the left side in Fig. 2), as well as around the groups of supply and return lines assigned to a coolant circuit (e.g., on the right side in Fig. 2). This creates a second sealing level, which helps to prevent the mixing of refrigerant and coolant in the event of leaking ring seals 44. The clamping fasteners 40 serve to detachably connect the distributor plate 16 and the interface block 30, and to create a clamping effect (i.e., apply a tensile force) between these two. Each clamping fastener 40 has a toggle lever 50, which in turn has a toggle lever 52. In the present embodiment, the toggle lever 52 is pivotally connected to the interface block 30 at a pivot point 54, and a pull hook 56 is pivotally connected to the toggle lever 52 at a further pivot point 58. The clamping fasteners 40 also have a tension hook 60, which is arranged on the distributor plate 16. For locking, the pull hook 56 – with the rocker arm 52 pivoted approximately 90 degrees relative to Fig. 2 – is hooked into the clamping hook 60, and then the rocker arm 52 is pivoted towards the closed position shown in Fig. 2. Due to the offset pivot points 52 and 58, the pull hook 56 exerts a tensile force on the clamping hook 60, thus pulling the distributor plate 16 and the interface block 30 together. As shown in Fig. 2, the connecting pieces 22 and the mating pieces 32 are arranged in "groups" of varying numbers (independent of their assignment to the refrigeration or coolant circuit), with the groups being spaced apart from each other. The arrangement of the groups is therefore asymmetrical. The mounting of the interface block 30 on the distribution plate 16 is therefore only possible in one orientation relative to each other (Poka Yoke concept). The subject matter of the invention is not limited to the embodiment described above. Rather, further embodiments of the invention can be derived by a person skilled in the art from the above description. Reference symbol list 1 Motor vehicle 2 Traction battery 4 Cooling system 6 Radiator 8 Compressor 10 Chiller 12 Cooling plate 16 Distributor plate 18 Channel 20 Edge 22 Connector 30 Interface block 32 Counterpart 40 Tension lock 42 Manifold 44 Ring seal 50 Toggle clamp 52 Toggle lever 54 Pivot point 56 Pull hook 58 Pivot point 60 Tension hook

Claims

Cooling circuit distribution system for a battery-electric vehicle (1), comprising: a distribution plate (16) with a plurality of fluid channels (18) which serve for the fluidic connection of different components of a cooling circuit of the vehicle (1), wherein the fluid channels (18) exit from the distribution plate (16) at an edge (20) with a connection piece (22) each, and an interface block (30) to which a number of fluid lines (42) are connected, which transition into counterparts (32) for the connection pieces (22) of the distribution plate (16), wherein the interface block (30) is reversibly attached to the distribution plate (16) by means of at least two clamping fasteners (40) such that each connection piece (22) is fluidly guided and sealed to the correspondingly assigned counterpart piece (32). Cooling circuit distribution system according to claim 1, wherein the respective clamping closure (40) is formed by a tilting clamping lever (50) arranged on the interface block (30) or the distributor plate (16) and a clamping hook (60) arranged on the distributor plate (16) or the interface block (30). Cooling circuit distribution system according to claim 2, wherein the tilting clamping lever (50) has a tilting lever (54) pivotally mounted on the interface block (30) or the distributor plate (16) at a pivot point (54) and a draw hook (56) pivotally mounted on the tilting lever (54) offset from the pivot point (54), which is hooked onto the clamping hook (60) in the intended clamping state. Cooling circuit distribution system according to claim 1, wherein the respective clamping closure (40) is formed by a straight-pull toggle clamp arranged on the interface block (30) or the distributor plate (16) and a clamping hook arranged on the distributor plate (16) or the interface block (30). Cooling circuit distribution system according to claim 1, wherein the respective clamping closure (40) is formed by a pivot hook arranged on the interface block (30) or the distributor plate (16) and a retaining pin arranged on the distributor plate (16) or the interface block (30), wherein the retaining pin engages behind the retaining pin in the intended clamping state. Cooling circuit distribution system according to one of claims 1 to 5, wherein the interface block (30) and / or the distributor plate (16) has a sealing arrangement which, in an intended connection state of the interface block (30) with the distributor plate (16), provides an individual seal of a connection between each connecting piece (22) and the associated counterpart (32). Cooling circuit distribution system according to one of claims 1 to 6, wherein the respective connecting piece (22) is designed as a socket or pipe section for insertion into the socket and the counterpart (32) is designed as a pipe section or as a socket for receiving the pipe section. Cooling circuit distribution system according to one of claims 1 to 7, wherein the respective connecting piece (22) and the corresponding counterpart (32) each have at their ends an element of a hydraulic quick-release fastener for a fluid-tight connection of the respective fluid channel (18) with the corresponding fluid line (42). Cooling circuit distribution system according to one of claims 1 to 8, wherein the connecting pieces (20) in the distributor plate (16) and the counterparts (32) in the interface block (30) are arranged such that a unique alignment of the distributor plate (16) to the interface block (30) is enforced during assembly. Battery electric motor vehicle (1) with a cooling circuit distribution system according to one of claims 1 to 9.

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