Cooling system for cooling a vehicle-side charging line, vehicle thermal management system, and battery-powered vehicle comprising at least one such cooling system

Abstract

The invention relates to a cooling system (3) for cooling at least one vehicle-side charging line (4) of a battery-powered vehicle (8), said at least one vehicle-side charging line (4) extending between a battery, in particular a traction battery (10) of the vehicle (8), and a vehicle-side charging terminal connector (5) and electrically connecting same together. According to the invention, at least one heat exchanger (30) is provided and is paired or can be paired with the at least one vehicle-side charging line (4), wherein the at least one heat exchanger (30) extends at least partly along the longitudinal extension of the at least one vehicle-side charging line (4).

Description

[0001] Cooling system for cooling a vehicle-side charging line, vehicle thermal management system and battery-electric vehicle with at least one such cooling system

[0002] The invention relates to a cooling system for cooling at least one vehicle-side charging line of a battery-electrically operated vehicle, wherein the at least one vehicle-side charging line extends between a battery, in particular a traction battery, of the vehicle and a vehicle-side charging connection connector and electrically connects them to one another, a vehicle thermal management system, comprising a closed system of a temperature control circuit of a battery-electrically operated vehicle, in which temperature control medium can flow or flows, wherein the temperature control circuit comprises at least one battery temperature control circuit for temperature control of a battery system containing a traction battery, at least one partial circuit for temperature control of at least one electronic component and at least one partial circuit comprising at least one heat exchanger, in particular a front-end heat exchanger,which serves to absorb heat from ambient air and / or release heat to it and to transfer heat into and / or from the tempering medium, wherein the partial circuits each comprise supply and return lines, as well as a battery-electric vehicle, in particular a land vehicle, comprising at least one battery system with at least one traction battery, at least one vehicle thermal management system for tempering vehicle components, at least one vehicle-side charging line and at least one vehicle-side charging connection connector for charging the traction battery, wherein the vehicle-side charging line extends between the traction battery and the vehicle-side charging connection connector.

[0003] Battery-electric vehicles require regular charging of their traction batteries to enable continued travel. Rapid charging of the traction battery is particularly preferred on longer journeys, as otherwise the interruptions or breaks required to charge the vehicle's traction battery, resulting in significant delays upon arrival at the destination, are significant. Therefore, rapid charging systems have been developed that allow the traction battery of a battery-electric vehicle to be charged quickly.

[0004] However, such a rapid charging process poses the problem that the resistance of the charging cable leads to a voltage drop and corresponding power loss during charging. The heat generated must be dissipated for efficient charging, so cooling is required. Further losses are also caused by on-board chargers installed on the vehicle. Such chargers convert the alternating current from a charging station into direct current for the traction battery. A further problem arises due to the contact resistance at the interface between the charging cable and the vehicle. During frequent charging processes, and thus frequent connection and disconnection of the charging cable to and from the vehicle-side charging connector, the closely spaced contact pins on the vehicle's charging connector become loose and move out of their desired position. This creates contact resistance, which leads to a temperature increase.The contact pins of the vehicle-side charging connector typically have a tight gap, so that temperatures of at least significantly above 90°C lead to thermal expansion of the pins and thus to increased contact resistance. Due to the thermal expansion in the area of ​​the charging connector, it is advisable to provide a cooling device to prevent a maximum temperature of 90°C from being exceeded. Alternatively, the charging process would have to be throttled, which would mean that the charging process would take longer. In connection with monitoring the temperature in the area of ​​the vehicle-side charging connector, it is known to provide temperature sensors in, on, or in the area of ​​the vehicle-side charging connector in order to be able to throttle the charging process in good time and prevent damage or excessive stress on the vehicle-side charging connector.

[0005] From DE 10 2011 119 495 B4, a motor vehicle with a charging cable for charging a motor vehicle-side energy storage unit for electrical energy is known, wherein the charging cable has at least one connection element for connecting to a connection of an external energy source or to a motor vehicle-side connection of a motor vehicle-side energy storage unit for electrical energy.An electric heating device for heating the connection element and at least a portion of the charging cable is also provided, wherein the heating device can be controlled by a motor vehicle control unit. The control unit is operatively connected to a motor vehicle control element by means of which the control unit can be activated by the user to control the heating device, and / or the control unit is configured to automatically control the heating device at predeterminable or predetermined times. However, a cooling option is not provided, so the charging current must be limited, which leads to comparatively longer charging times.

[0006] DE 11 2012 003 099 B4 discloses a vehicle charging station comprising a high-performance charging source for rapidly charging an electric battery of an electric vehicle, a coolant source for providing an electrically insulating coolant, and a connector comprising both an electrical supply section for supplying the electrical charge and a coolant supply section for supplying a coolant. The connector for charging the electric battery and for providing the electrically insulating liquid coolant can be connected from the coolant source to a receptacle of the electric vehicle via a coolant line arranged within the electric vehicle for cooling the electric battery during the charging process. Cooling of the battery is thus provided, with an external cooling circuit being connected to the cooling circuit of the vehicle.A disadvantage of this fast-charging system is that a complex separation between the fluid and the electrical connection must be carried out in the area of ​​the vehicle-side charging connector, i.e., the interface between the cable coming from the high-performance charging source and the vehicle-side charging connector. This raises safety concerns with regard to the high-voltage cable, which must be connected from the high-performance charging source to the vehicle-side charging connector, and the coolant lines must be safely separated from the electrical lines. This is both complex and expensive.Regularly opening the otherwise normally closed system of coolant lines within the vehicle creates further problems due to leaks, contamination, and air pockets that occur when connecting and disconnecting the charging cable and the vehicle-side charging connector. This also gives rise to liability issues in the event of damage to the vehicle, as there is no clear separation between the vehicle and the infrastructure of the high-performance charging source; instead, cooling is provided via the charging infrastructure.

[0007] The present invention is therefore based on the objective of providing a cooling system for cooling a vehicle-side charging line of a battery-electric vehicle, a vehicle thermal management system, and a battery-electric vehicle with at least one cooling system, wherein the above-mentioned disadvantages of the prior art solutions no longer occur and yet efficient cooling of the vehicle-side charging line, which extends between the traction battery of the vehicle and a vehicle-side charging connection connector and electrically connects them to one another, is enabled.

[0008] The problem is solved for a cooling system for cooling at least one vehicle-side charging line according to the preamble of claim 1 in that at least one heat exchanger is provided and can be assigned or is assigned to the at least one vehicle-side charging line, wherein the at least one heat exchanger extends at least partially along the longitudinal extent of the at least one vehicle-side charging line. For a vehicle thermal management system according to the preamble of claim 14, the problem is solved in that the vehicle thermal management system comprises at least one such cooling system for cooling at least one vehicle-side charging line. For a battery-electric vehicle according to the preamble of claim 15, the problem is solved in that the vehicle comprises at least one such cooling system for cooling the at least one vehicle-side charging line. Further developments of the invention are defined in the dependent claims.

[0009] This creates a cooling system for cooling at least one vehicle-side charging cable of a battery-electric vehicle, as well as a vehicle thermal management system and battery-electric vehicle equipped with such a system, in which it is possible to enable a strict separation between the electrical coupling of the vehicle-side charging connection connector and a charging cable provided outside the vehicle and leading from an energy source to the vehicle, on the one hand, and the cooling of the vehicle-side charging cable and in particular of its end-side vehicle-side charging connection connector, on the other. The safety, complexity, and cost issues described in DE 11 2012 003 099 B4 therefore no longer arise in the present case. Rather, efficient cooling of the vehicle-side charging cable is enabled via the at least one heat exchanger assigned to the vehicle-side charging cable.The at least one heat exchanger extends at least partially along the longitudinal extent of the at least one vehicle-side charging line and thereby enables its cooling, in particular in the area of ​​the vehicle-side charging connection connector. As a result, the desired maximum temperature in the area of ​​the vehicle-side charging connection connector, in particular a maximum temperature of 90 °C, can be optimally maintained, since the at least one heat exchanger enables cooling of the vehicle-side charging line, particularly in the area of ​​the vehicle-side charging connection connector. This enables efficient rapid charging to be carried out without any problems, while cooling the vehicle-side charging line in the sensitive area of ​​the vehicle-side charging connection connector. The charging line leading to the vehicle outside the vehicle and which can be coupled to the vehicle-side charging connection connector for supplying electrical energy to the vehicle orIts traction battery serves solely to supply electrical energy. The vehicle-side charging line arranged within the vehicle is provided with only the at least one heat exchanger, or the at least one heat exchanger is assigned to it, in order to enable cooling of the vehicle-side charging line, particularly during a charging process. The at least one heat exchanger is connected to a temperature control circuit of the vehicle or its vehicle thermal management system and, in particular, is flowed through by a temperature control medium. However, this medium does not come into contact with the vehicle-side charging line, so that a strict separation is provided between the temperature control medium and the electrical components of the charging line(s) and the at least one vehicle-side charging connector.

[0010] Advantageously, at least one temperature sensor device is provided for determining the temperature in the region of the vehicle-side charging cable. This represents a measured variable according to which control can be carried out or is carried out. Particularly preferably, the at least one temperature sensor device can be arranged in the region of the vehicle-side charging connection connector. By providing at least one such temperature sensor device, it is possible to determine the current actual temperature of the vehicle-side charging cable, in particular in the region of the vehicle-side charging connection connector arranged at the end thereof or connected to it. Accordingly, optimal temperature control for cooling the vehicle-side charging cable, especially in the region of the vehicle-side charging connection connector, can be achieved. Such control orControl of the temperature, in particular the flow temperature of the tempering medium flowing through the at least one heat exchanger, can be carried out by at least one control and / or regulating device.

[0011] At least one vehicle thermal management system can be provided, and the at least one heat exchanger can be connected to the at least one vehicle thermal management system, thermally and / or fluidically connected to it, or integrated into it. The cooling system for cooling the vehicle-side charging line comprises the at least one heat exchanger. The at least one heat exchanger is thus incorporated or integrated into the vehicle thermal management system, so that at least one temperature control medium flowing in at least one temperature control circuit of the thermal management system can flow through the at least one heat transfer medium.

[0012] The at least one vehicle thermal management system can further advantageously comprise at least one temperature control circuit with a first temperature control medium and the at least one control and / or regulating device for controlling and / or regulating the temperature control medium mass flow m and the temperature control medium flow temperature T vof the first temperature control medium flowing into the heat exchanger, wherein the at least one heat exchanger is arranged in a heat exchanger sub-circuit of the at least one temperature control circuit through which the first temperature control medium can flow or through. Water with antifreeze, i.e. water / glycol, can flow as the first temperature control medium within the temperature control circuit and the heat exchanger sub-circuit. The mass flow and the flow temperature of the first temperature control medium, which flows into the at least one heat exchanger in the flow line to the vehicle-side charging line, can thus be specifically controlled for this heat exchanger sub-circuit through which the first temperature control medium can flow or through. The basis for the control orThe actual temperature of the first temperature control medium in the return flow of the heat exchanger, i.e. after flowing through it and absorbing the heat emitted by the vehicle-side charging line, can be used in particular to regulate the mass flow and the flow temperature of the first temperature control medium.

[0013] The at least one heat exchanger can thus be flowed through by the first temperature control medium flowing in the temperature control circuit in order to enable cooling of the vehicle-side charging line, in particular in the area of ​​the vehicle-side charging connection connector. In principle, it is not absolutely necessary to cool the entire vehicle-side charging line; in many cases it is sufficient to arrange the at least one heat exchanger in just a section of the vehicle-side charging line, for example only in the area of ​​the vehicle-side charging connection connector, since it is precisely there that the thermal stress and wear caused by play in the contact pins of the vehicle-side charging connection connector arise due to numerous coupling and decoupling processes for connecting and disconnecting a charging or disconnecting device.The resulting higher contact resistances are highest in the charging cable leading from the power source to the vehicle and from the vehicle-side charging connector. Therefore, cooling proves particularly advantageous in the area of ​​the vehicle-side charging connector connected to the vehicle-side charging cable.By arranging the at least one temperature sensor device for detecting the actual temperature of the temperature control medium flowing through the at least one heat exchanger precisely in the region of the vehicle-side charging connection connector, and optionally also in other regions of the vehicle-side charging line, it is possible to send this actual temperature detected by the at least one temperature sensor device to the at least one control and / or regulating device, which appropriately controls or regulates the temperature control medium mass flow required for cooling the vehicle-side charging line and the temperature control medium flow temperature required for cooling of the temperature control medium flowing into the heat exchanger.

[0014] As an alternative to arranging the at least one heat exchanger in a heat exchanger partial circuit of the at least one temperature control circuit of the vehicle thermal management system through which the first temperature control medium can flow or through which it flows, it is also possible for the vehicle thermal management system or its temperature control circuit to comprise, in addition to the first temperature control medium, a second temperature control medium, such as thermal oil, and the at least one control and / or regulation device, wherein for controlling and / or regulating the temperature control medium mass flow m and the temperature control medium flow temperature T vof the temperature control medium flowing into the heat exchanger, the at least one heat exchanger is arranged in a heat exchanger sub-circuit of the at least one temperature control circuit through which the second temperature control medium flows or flows. This makes it possible to provide a heat exchanger sub-circuit separate from the at least one other sub-circuit of the temperature control circuit of the vehicle thermal management system, through which the second temperature control medium flows and in which the at least one heat exchanger is or is arranged. The control of the mass flow m and the flow temperature T vThe second temperature control medium flowing through the at least one heat exchanger, which is provided for cooling the vehicle-side charging line, thus takes place in a separate heat exchanger sub-circuit or cooling circuit. The at least one temperature control circuit of the at least one vehicle thermal management system can thus comprise two temperature control media that flow in separate sub-circuits, wherein, for example, thermal oil is provided as the second temperature control medium, which flows only in the second sub-circuit, which serves to cool the vehicle-side charging line and in which the at least one heat exchanger is arranged, while the first temperature control medium, such as a water-glycol mixture or water / glycol, flows through the further sub-circuit(s) of the at least one temperature control circuit of the vehicle thermal management system.

[0015] The at least one heat exchanger for cooling the vehicle-side charging line, especially in the area of ​​the vehicle-side charging connector, can thus be connected or integrated to / into the vehicle thermal management system. The at least one heat exchanger of the system for cooling the vehicle-side charging line can be flowed through by the first temperature control medium, such as water / glycol, which also serves to cool or temperature-control numerous vehicle components and accordingly flows through one or more subcircuits of the at least one temperature control circuit of the vehicle thermal management system.Therefore, this embodiment variant is more cost-effective than providing the second temperature control medium for flowing through the at least one heat exchanger of the system for cooling the vehicle-side charging line, since no separate heat exchanger sub-circuit with its own component for conveying the second temperature control medium through the heat exchanger sub-circuit needs to be provided. The at least one vehicle thermal management system can further advantageously comprise at least one thermal management module, wherein the at least one heat exchanger in the heat exchanger sub-circuit is arranged in the direct feed line to the thermal management module. Such a thermal management module is a device in which the following components are bundled or combined in a structural unit.The at least one thermal management module serves to manage mass flows of the temperature control medium flowing through the at least one temperature control circuit of the vehicle thermal management system of the battery-electric vehicle, wherein the at least one thermal management module comprises at least one component for conveying the temperature control medium and at least one component for mass flow control, as well as fluid channels or fluid paths. Subcircuits of the at least one temperature control circuit of the vehicle thermal management system can be connected to the thermal management module or its fluid paths via fluid connection devices arranged on the thermal management module. Within the thermal management module, the respectively desired mass flows of temperature control medium can be controlled and flowed into the subcircuits of the temperature control circuit connected to the thermal management module via the at least one component for mass flow control, such as at least one valve.Accordingly, the respective supply lines and the respective return lines of the sub-circuits of the temperature control circuit are connected to the thermal management module. The heat exchanger sub-circuit, which comprises the at least one heat exchanger for cooling the vehicle-side charging line, is advantageously arranged in the supply line to the thermal management module, or the thermal management module is advantageously arranged in the supply line to the at least one heat exchanger of the heat exchanger sub-circuit. This makes it possible for the heat emitted by the vehicle-side charging line and absorbed by the heat exchanger that cools the charging line to be conveyed to the thermal management module and from this temperature control medium to flow back at a desired lower supply temperature to the at least one heat exchanger that cools the temperature control medium, for cooling the vehicle-side charging line.The temperature control medium is conveyed via the at least one component for conveying the temperature control medium of the thermal management module, such as in particular at least one pumping device.

[0016] Instead of providing a thermal management module, only at least one switching valve can be provided as part of the at least one vehicle thermal management module, wherein the at least one heat exchanger is arranged in a heat exchanger sub-circuit in the direct supply line to the switching valve. The at least one temperature control circuit of the vehicle thermal management module thus comprises the at least one switching valve, via which the heat exchanger sub-circuit can be switched on, as well as disconnected from the temperature control circuit. In contrast to the provision of only in particular a separate switching valve for switching on or off.If the separate heat exchanger sub-circuit in which the at least one heat exchanger for cooling the vehicle-side charging line is arranged is switched off, connecting this heat exchanger sub-circuit to a thermal management module proves to be advantageous, since such a thermal management module enables a simpler and targeted supply of a suitable temperature control medium mass flow to the heat exchanger with a temperature control medium flow temperature suitable for cooling the vehicle-side charging line.

[0017] Connecting the at least one heat exchanger for cooling the vehicle-side charging line in series with other heat exchangers of the at least one temperature control circuit of the vehicle thermal management system proves to be disadvantageous compared to a parallel connection in a separate heat exchanger sub-circuit, since the vehicle-side charging connector, in combination with the vehicle-side charging line, reacts more sensitively to temperature fluctuations during a rapid charging process than the other vehicle components. Furthermore, compared to the other vehicle components, a different setting is usually required when controlling or regulating the corresponding flow temperature of the temperature control medium flowing through the at least one heat exchanger for cooling the vehicle-side charging line.This is particularly evident from the fact that the temperature in the area of ​​the vehicle-side charging port connector should not exceed 90°C, so that a parallel connection of the heat exchanger sub-circuit, which comprises at least one heat exchanger for cooling the vehicle-side charging line and the vehicle-side charging port connector, proves to be more advantageous. Furthermore, charging of the vehicle battery or traction battery of the vehicle using an external charging or energy source usually takes place when the vehicle is stationary, during which time the other vehicle components, with the exception of the traction battery and the vehicle-side charging line and the vehicle-side charging port connector, usually do not need to be cooled. During the charging process when the vehicle is stationary, it is therefore usually not necessary to operate other sub-circuits of the thermal management system, since these do not need to be temperature-controlled during the charging process.Cooling can be carried out in particular by providing a chiller, i.e. a refrigerant evaporator, which is used here to cool the temperature control medium, as a component of the vehicle thermal management system.

[0018] Further advantageously, the at least one heat exchanger in a heat exchanger sub-circuit of the at least one temperature control circuit of the vehicle thermal management system and a battery temperature control circuit of the vehicle thermal management system for controlling the temperature of a battery system comprising the at least one battery are connected in parallel. The at least one heat exchanger in the heat exchanger sub-circuit of the at least one temperature control circuit of the vehicle thermal management system and the traction battery or the battery system comprising it in a battery temperature control circuit of the vehicle thermal management system, which is provided for controlling the temperature of the at least one traction battery, can thus be or become connected in parallel to one another, i.e. the heat exchanger sub-circuit comprising the at least one heat exchanger and the battery temperature control circuit comprising the battery system.The at least one chiller allows the supply of cooled temperature control medium for cooling both the vehicle-side charging cable or the vehicle-side charging connector and the vehicle's battery system or traction battery via these two parallel-connected subcircuits of the vehicle's temperature control circuit. By providing a thermal management module of the vehicle's thermal management system, direct and selective control of the individual subcircuits is optimally possible.

[0019] The heat exchanger subcircuit of the at least one temperature control circuit of the vehicle thermal management system, which subcircuit comprises the at least one heat exchanger, can advantageously be operated directly and independently of the at least one further subcircuit of the at least one temperature control circuit of the vehicle thermal management system. Furthermore, it is possible for the heat exchanger subcircuit of the at least one temperature control circuit of the vehicle thermal management system, which subcircuit comprises the at least one heat exchanger, to be operated directly and independently of other temperature control components of the vehicle thermal management system.By arranging the at least one heat exchanger in the separate heat exchanger sub-circuit of the at least one temperature control circuit of the vehicle thermal management system, it is thus possible to operate it completely independently of other temperature control components and sub-circuits of the at least one temperature control circuit of the vehicle thermal management system and to use it to specifically and directly cool the vehicle-side charging line or the vehicle-side charging connection connector. The at least one heat exchanger sub-circuit can thus be operated independently of other sub-circuits of the at least one temperature control circuit of the vehicle thermal management system that also perform temperature control tasks, and also independently of other temperature control components that perform temperature control tasks with respect to vehicle components.

[0020] The vehicle thermal management system further advantageously comprises at least one chiller and / or at least one front-end heat exchanger. When the vehicle is stationary and / or when at least one further subcircuit of the at least one temperature control circuit of the vehicle thermal management system is inactive, the at least one chiller and / or the at least one front-end heat exchanger serves to cool the temperature control medium flowing through the heat exchanger subcircuit. The temperature control medium flowing through the at least one heat exchanger in the heat exchanger subcircuit of the temperature control circuit of the vehicle thermal management system can thus be cooled by the at least one chiller and the at least one front-end heat exchanger, especially when the vehicle is stationary or when the further subcircuits of the temperature control circuit of the vehicle thermal management system are inactive.The vehicle's front-end heat exchanger enables heat exchange with the vehicle's ambient air, while the at least one chiller enables heat exchange with a refrigerant flowing in a refrigerant circuit of the vehicle or the vehicle's thermal management system. For example, it is possible to first perform heat exchange in the area of ​​the front-end heat exchanger and then in the area of ​​or in the at least one chiller(s) in order to enable optimal cooling of the temperature control medium for flowing into the heat exchanger sub-circuit for cooling the vehicle-side charging line and the vehicle-side charging connection connector. In the area of ​​the front-end heat exchanger, for example, the temperature of the temperature control medium flowing there can be reduced from 60 °C to 40 °C by allowing ambient air to flow through the front-end heat exchanger, thus correspondingly exchanging heat with the air.By appropriate valve position or adjustment of the at least one component for mass flow control, in particular of the at least one thermal management module, of the vehicle thermal management system, a selective and targeted flow through the at least one front-end heat exchanger and / or the at least one chiller with temperature control medium is possible, which can then flow into the heat exchanger sub-circuit in an appropriately cooled state.

[0021] The at least one heat exchanger can, for example, be or become arranged on one side of the vehicle-side charging line. Furthermore, it is possible to surround the vehicle-side charging line with the at least one heat exchanger. This can, in particular, concentrically enclose the vehicle-side charging line. The at least one heat exchanger can thus be provided in the manner of a casing for the vehicle-side charging line. Furthermore, the heat exchanger can be or become arranged within the vehicle-side charging line. The heat exchanger, which extends completely enclosing or only partially around the circumference of the vehicle-side charging line or within the vehicle-side charging line, can extend over the entire length of the vehicle-side charging line. However, it can also be sufficient if it extends only over a partial section of the length of the vehicle-side charging line.

[0022] To further explain the invention, exemplary embodiments are described in more detail below with reference to the drawings. These show:

[0023] Figure 1 is a schematic diagram of a state-of-the-art vehicle thermal management system,

[0024] Figure 2 shows a first embodiment of a cooling system according to the invention for cooling a vehicle-side charging line as part of a vehicle thermal management system of a battery-electric vehicle,

[0025] Figure 2a shows a detailed view of the vehicle thermal management system according to Figure 2 in the area of ​​a thermal management module thereof,

[0026] Figure 3 is a schematic diagram of a thermal management module for use in a vehicle thermal management system according to the invention, comprising a cooling system according to the invention for cooling a vehicle-side charging line,

[0027] Figure 4 is a schematic diagram of a second embodiment of a cooling system according to the invention for cooling a vehicle-side charging line, wherein the cooling system is part of a vehicle thermal management system,

[0028] Figure 5 is a schematic diagram of a third embodiment of a cooling system according to the invention for cooling a vehicle-side charging line, wherein the cooling system is part of a vehicle thermal management system,

[0029] Figure 6 is a schematic diagram of a control and / or regulating device for controlling and regulating mass flows and flow temperature of a temperature control medium for cooling a vehicle-side charging line with a cooling system according to the invention, and Figure 7 is a schematic diagram of a battery-electric vehicle according to the invention with a cooling system according to the invention for cooling its vehicle-side charging line.

[0030] Figure 1 shows a schematic diagram of a known vehicle thermal management system 1, which comprises a traction battery 10 as part of a battery system 11, a chiller 12, a PTC auxiliary heater 13, an inverter 14, a charger 15, power electronics 16, an electric motor 17, and a front-end heat exchanger 18 as a cooler for heat exchange with the ambient air. Furthermore, the vehicle thermal management system 1 comprises three valves 19, 20, 21 as components for mass flow control for regulating the mass flows of temperature control medium for temperature control of the vehicle components, which are arranged in the partial circuits of the temperature control circuit 100, as well as two pump devices 22, 23 as components for conveying the temperature control medium within the individual media lines of the vehicle thermal management system 1 or its temperature control circuits. As indicated in Figure 1, the battery system 11 or its traction battery 10 are arranged in a battery temperature control circuit 24.

[0031] Temperature control of the battery system 11 or its traction battery 10 is possible via both the chiller 12 and the PTC auxiliary heater 13. Temperature control of the charger 15, the power electronics 16, and the electric motor 17 is possible via another sub-circuit 25 of the temperature control circuit 100. The temperature control medium, which is usually cooled by ambient air via the front-end heat exchanger 18, flows in this area in a separate sub-circuit 26, which is assigned to the front-end heat exchanger 18. The sub-circuits 24, 25, 26 are each supplied with corresponding mass flows of temperature control medium via the valves 19, 20, 21, whereby the flow of the temperature control medium is enabled by the two pumping devices 22, 23 in the sub-circuits 24, 25.

[0032] Figure 2 shows a partial section of the vehicle thermal management system 1 of a battery-electric vehicle 8 (see Figure 7), which according to the invention comprises a cooling system 3 for cooling a vehicle-side charging line 4. The vehicle-side charging line 4 is arranged within the vehicle 8 and is connected at one end to a vehicle-side charging connection connector 5, and at the other end to the traction battery 10 or the battery system 11, as also indicated in Figure 2 and can also be seen in Figure 7. Via the vehicle-side charging connection connector 5, a connection can be made to a charging line located outside the battery-electric vehicle 8, which is intended to conduct electrical energy from a charging or energy source towards the traction battery 10 of the vehicle for charging the traction battery 10 of the vehicle 8.To prevent excessive heat buildup at the vehicle-side charging connector 5, the vehicle-side charging line 4 is cooled by the cooling system 3 during rapid charging of the traction battery 10. In the embodiment shown in Figure 2, this comprises a heat exchanger 30 extending along the vehicle-side charging line 4 (see also Figure 7). The heat exchanger 30 can, as indicated in Figure 2, extend over substantially the entire length of the vehicle-side charging line 4. It is also possible to arrange it only over a partial section of the length of the vehicle-side charging line 4. In this case, an arrangement in the area of ​​the vehicle-side charging connector 5 is particularly suitable in order to be able to cool precisely this area. For this purpose, a temperature control medium flows through the heat exchanger 30.For this purpose, it is arranged in a heat exchanger sub-circuit 31, wherein the heat exchanger sub-circuit 31 is a sub-circuit of the temperature control circuit 100 of the vehicle thermal management system 1. Temperature control medium T flows in the sub-circuits of the temperature control circuit 100 and the heat exchanger sub-circuit 31.

[0033] The temperature control medium T flowing in the heat exchanger sub-circuit 31 can be cooled either by the chiller 12 or by the front-end heat exchanger 18 of the vehicle thermal management system 1. The latter comprises a thermal management module 110. The chiller 12 is integrated into a chiller sub-circuit 125 and a refrigerant circuit 27, through which refrigerant KM flows. The refrigerant circuit 27 is only partially shown in Figures 2 and 2a, namely in the area of ​​the chiller 12. Other components of the refrigerant circuit 27 have been omitted for clarity. The front-end heat exchanger 18 is arranged in its sub-circuit 26. Both sub-circuits 26 and 125, through which the temperature control medium T flows, are coupled to the thermal management module 110. This can be seen in particular from the detailed view in Figure 2a, in which the thermal management module 110 is shown enlarged.

[0034] The heat exchanger 30 in its heat exchanger sub-circuit 31 is arranged in the flow of the thermal management module 110, so that the heat absorbed in the temperature control medium from the vehicle-side charging line 4 via the heat exchanger 30 flows into the thermal management module 110 via a media line 32 of the heat exchanger sub-circuit 31. With respect to the heat exchanger 30 and the vehicle-side charging line 4, the thermal management module 110 is arranged in their return lines. Via a media line 33 of the heat exchanger sub-circuit 31, the temperature control medium, which is provided with a desired flow temperature within the thermal management module 110, flows back out of the thermal management module 110 towards the heat exchanger 30 at a corresponding mass flow rate. With respect to the heat exchanger 30, the thermal management module 110 is thus arranged in the flow of the latter.

[0035] As can be seen in particular from Figure 2a, the heat exchanger sub-circuit 31 and the battery temperature control circuit 24 are preferably connected in parallel to one another, so that temperature control medium cooled by the chiller 12 can flow both into the heat exchanger sub-circuit 31 and, in parallel thereto, into the battery temperature control circuit 24. Therefore, particularly when a battery-electric vehicle is stationary, cooling of both the traction battery 10 and the vehicle-side charging line 4, and accordingly also of the vehicle-side charging connection connector 5, is possible during a rapid charging process of the traction battery 10. The switching position of valves 111, 112, 113 and pump devices 114, 115 within the thermal management module 110 shown in Figure 2a, shows the switching position for cooling both the traction battery 10 and the vehicle-side charging line 4.The temperature control medium cooled by the chiller 12 thus flows into the supply line of the battery temperature control circuit 24, and the temperature control medium heated therein after flowing through the lines of the battery system 11 (shown in dashed lines in Figure 2) thus flows back from the battery temperature control circuit 24 in the return line from the latter into the thermal management module 110, conveyed by the pump device 115. Depending on the valve position of the valve 112, it can flow from there into the supply line of the sub-circuit 26, which includes the front-end heat exchanger 18, in order to carry out a heat exchange with the ambient air of the vehicle, and / or flow via the valve 113 into the chiller sub-circuit 125 in order to carry out a heat exchange there or to be cooled.From the front-end heat exchanger 18, the cooled temperature control medium flows back into the thermal management module 110 in the return line and, after passing through the valve 113, can flow into the chiller 12 together with the heated temperature control medium arriving from the heat exchanger sub-circuit 31 or without it, in order to be cooled therein in heat exchange with the refrigerant circuit 27, which also flows through the chiller 12. The cooled temperature control medium can then flow back into the thermal management module 110 and from there, driven by the pump device 114 and controlled by the valve 111, flow back into one of the two or both sub-circuits 24, 31 of the temperature control circuit 100.

[0036] Figure 3 shows an alternative embodiment of the thermal management module 110 with the two pumping devices 114, 115 contained therein and the three valves 111, 112, 113. Unlike in Figure 2a, these are integrated into the fluid paths within the thermal management module 110. In the embodiment of the thermal management module 110 according to Figure 3, a temperature sensor device 6 is provided in order to be able to detect the temperature of the temperature control medium that can flow into the heat exchanger sub-circuit 31. This can be used to monitor the flow temperature of the temperature control medium flowing into the heat exchanger sub-circuit 31 accordingly in order to be able to provide a suitable temperature control for cooling the vehicle-side charging line 4. The valves 111, 112, 113 can be standard valves, in particular 4 / 2-way valves, 4 / 3-way valves or 3 / 2-way valves.Furthermore, it is possible to conduct the temperature control medium through the thermal management module 110 even without querying the temperature sensor device 6, for example when no charging process of the traction battery 10 is taking place, thus the heat exchanger 30 is not to be flowed through with appropriately tempered temperature control medium suitable for cooling the vehicle-side charging line 4 and the vehicle-side charging connection connector 5.

[0037] Figure 4 shows a cooling system 3 for cooling the vehicle-side charging line 4, modified compared to the embodiment according to Figures 2 and 2a. Two different temperature control media flow within the temperature control circuit 100, for example, water and / or a mixture of water / glycol as a first temperature control medium T1 and thermal oil as a second temperature control medium T2. These two temperature control media flow in different subcircuits, with the second temperature control medium T2, in particular thermal oil, flowing within the heat exchanger subcircuit 31 and the first temperature control medium T1 flowing in all other subcircuits of the temperature control circuit 100, such as in particular the battery temperature control circuit 24. The heat exchanger subcircuit 31 is not integrated into the thermal management module 110, but rather is formed separately therefrom.To still enable cooling of this second temperature control medium T2 within the heat exchanger sub-circuit 31, two chillers 28, 29 are provided, with a first chiller 28 serving to cool the second temperature control medium T2 flowing within the heat exchanger sub-circuit 31, and a second chiller 29 serving to cool the first temperature control medium T1 flowing within the other sub-circuits, in particular the battery temperature control circuit 24. Refrigerant KM of the refrigerant circuit 27 flows through both the first chiller 28 and the second chiller 29. The refrigerant KM can first flow through the first chiller 28, then the second chiller 29, and after flowing through the second chiller 29, an expansion device or a compressor, and subsequently back through the first chiller 28.Instead of the flow direction of the refrigerant KM within the refrigerant circuit 27 shown in Figure 4, a reverse flow direction is also possible, in which the flow first passes through the second chiller 29 and then through the first chiller 28.

[0038] While the first chiller 28 serves to cool the second temperature control medium T2, which also flows through it to cool the heat exchanger 30, the second chiller 29 serves to cool the first temperature control medium T1, which flows, among other things, through the battery temperature control circuit 24. This is also particularly clearly shown in Figure 4. Furthermore, Figure 4 shows that additional sub-circuits can be connected to the thermal management module 110, which serve to control the temperature of additional vehicle components.

[0039] To convey the first temperature control medium T1, the thermal management module 110 can in turn comprise at least one pumping device, as well as a number of valves, in order to allow the desired mass flows of first temperature control medium to flow into the respective sub-circuits, such as in particular the battery temperature control circuit 24. Since the heat exchanger sub-circuit 31 is provided completely separate from the thermal management module 110 as a separate closed system in which the second temperature control medium T2, such as thermal oil, flows, the heat exchanger sub-circuit 31 comprises its own pumping device 34. As can be further seen from Figure 4, the second temperature control medium T2 flows within the heat exchanger sub-circuit 31 from the first chiller 28 toward the heat exchanger 30 and from there back via the pumping device 34 toward the first chiller 28.As an alternative to providing the two chillers 28, 29, a heat exchanger or chiller suitable for passing through three media can also be provided, i.e. for passing through both the first and the second temperature control medium and the refrigerant KM from the refrigerant circuit 27.

[0040] Figure 5 shows a further alternative embodiment of the vehicle thermal management system 1 with the cooling system 3 for cooling the vehicle-side charging line 4. By way of example, in this embodiment, the heat exchanger 30 is not only arranged on the outside of the vehicle-side charging line 4, partially extending over the circumference of the latter, as indicated in Figures 2 and 4, but also encloses it over a partial section of its longitudinal extent. This is merely intended to clarify that the heat exchanger 30 can surround or enclose the vehicle-side charging line 4 like a sleeve, or can be provided simply along the outside of the latter, extending over a partial section of the circumference of the vehicle-side charging line 4. It is also possible for the heat exchanger 30 to be or is arranged within the vehicle-side charging line 4.

[0041] The embodiment of the vehicle thermal management system 1 shown in Figure 5 is a variant without a thermal management module 110, in which individual valves 119, 120, 122, 124 and pump devices 121, 123 of the vehicle thermal management system 1 are each arranged separately at different locations in the vehicle. In this embodiment of the vehicle thermal management system 1, the temperature control circuit 100 also comprises several sub-circuits, including the battery temperature control circuit 24, in which the temperature control medium can flow through the chiller 12 for cooling. For heating, flow through the PTC auxiliary heater 13 is possible, whereby the temperature control medium can be directed via the valve 119 to the chiller 12 or to the PTC auxiliary heater 13, respectively. The temperature control medium flows into the valve 119 after flowing through the battery system 11. In the battery temperature control circuit 24, the

[0042] Tempering medium in the flow direction behind the chiller 12, controlled by a valve 120, flows either in the direction of a pump device 121 for conveying the tempering medium in the direction of the battery system 11 and / or in the direction of the heat exchanger 30 and thus into the heat exchanger sub-circuit 31. The valve 120 makes it possible to divide the mass flow of tempering medium cooled by the chiller 12, on the one hand, between the battery tempering circuit 24 with the battery system 11, and on the other hand, between the heat exchanger sub-circuit 31 with the heat exchanger 30. From the heat exchanger 30, the temperature control medium flows back towards the valve 119. The battery temperature control circuit 24 and the heat exchanger sub-circuit 31 are thus connected in parallel to one another in the embodiment variant of the cooling system 3 for cooling the vehicle-side charging line 4 via the heat exchanger 30.

[0043] The temperature control medium heated in the battery system 11 on the one hand and by the heat exchanger 30 on the other hand can also be directed to the valve 122 via the valve 119. From there, it can flow, conveyed or driven via the pump device 123, towards the vehicle components of the charger 15, the power electronics 16, and the electric motor 17 connected in series. After flowing through the latter, the correspondingly heated temperature control medium can flow to the further valve 124 and from there, either through the partial circuit 26 with the front-end heat exchanger 18 back to the valve 124 or directly towards the inverter 14 and, after passing through the latter, back to the valve 120. The valve 120 can, for example, be a 2 / 3-way valve.

[0044] It can thus be seen from the embodiment variant according to Figure 5 that, even without providing the thermal management module 110, the cooling system 3 for cooling the vehicle-side charging line 4 can be integrated into the temperature control circuit 100 of the vehicle thermal management system 1 via corresponding valves and corresponding valve circuits, in particular by connecting the heat exchanger sub-circuit 31 and the battery temperature control circuit 24 in parallel.

[0045] Figure 6 shows a further embodiment of the cooling system 3 for cooling the vehicle-side charging line 4, including temperature monitoring. The arrangement comprises a control and / or regulating device 7 for controlling and / or regulating both the mass flows m and the flow temperature T vof the temperature control medium for controlling the temperature of the vehicle-side charging line 4 via the heat exchanger 30. To detect the actual temperature of the temperature control medium in the return line of the heat exchanger sub-circuit 31, a temperature sensor device 60 is arranged downstream of the heat exchanger 30 in the direction of flow. Another temperature sensor device 61 is provided in the area of ​​the battery system 11 in order to be able to determine its return temperature. In the arrangement shown in Figure 6, the control and / or regulating device 7 receives the temperature data from the two temperature sensor devices 60, 61 from the respective return lines of the heat exchanger sub-circuit 31 and the battery temperature control circuit 24 and sends corresponding signals to the thermal management module 110 to control the valves and pump devices on the thermal management module 110 for regulating the mass flow and flow temperature of the heat exchanger 30.The actual temperatures of the traction battery 10 or of the battery system 11 are sent to the control and / or regulating device 7 via a signal line 70, the actual temperatures in the area of ​​the vehicle-side charging connection connector 5 are sent via a signal line 72, and control signals from the control and / or regulating device 7 to the thermal management module 110 are sent via a signal line 71.

[0046] The control and / or regulating device 7 serves to control the valves and pump devices of the thermal management module 110 accordingly in order to be able to allow the respectively desired mass flows of temperature control medium with the respectively desired flow temperature to flow in, in particular in the direction of the heat exchanger 30 in the heat exchanger sub-circuit 31 for cooling the vehicle-side charging line 4 and thus also the vehicle-side charging connection connector 5 and also in the direction of the battery temperature control circuit 24 for the corresponding temperature control of the traction battery 10 of the battery system 11.

[0047] Figure 7 shows a schematic diagram of a battery-electric vehicle 8. This comprises the vehicle thermal management system 1 for controlling the temperature of the traction battery 10 and the vehicle-side charging line 4, as well as the electric motor 17, the power electronics 16, and the charger 15. Four wheels 80, 81, 82, 83 of the vehicle, as well as its front 84 and rear 85, are indicated. Furthermore, an arrow P1 indicates the direction of travel in front of the front 84 of the vehicle. The front-end heat exchanger 18 is arranged in the area of ​​the front 84 of the battery-electric vehicle 8. The battery-electric vehicle 8 can, on the one hand, be a vehicle powered exclusively by the battery-powered electric motor 17, or, on the other hand, a hybrid vehicle that is electrically powered at least temporarily. The battery system 11 or the traction battery 10 is provided to supply power to the electric motor 17.The vehicle thermal management system 1 serves to maintain the battery system 11 and the vehicle-side charging line 4, as well as optionally other vehicle components, such as the electric motor 17 and the power electronics 16, at a desired temperature level, and to air-condition or temperature-regulate a vehicle interior 86, in which people sit as the passenger compartment. The refrigerant circuit 27 and the front-end heat exchanger 18 serve this purpose.

[0048] In addition to the embodiments of the system for cooling at least one vehicle-side charging line of a battery-electric vehicle and of such a correspondingly equipped battery-electric vehicle described above and shown in the figures, numerous further embodiments can be provided, in particular any desired combinations of the features mentioned above, wherein in each case at least one heat exchanger is provided which is assigned to the at least one vehicle-side charging line and extends at least partially along it for cooling it and is arranged in a heat exchanger partial circuit through which temperature control medium flows in order to be able to supply the heat exchanger with a sufficient quantity of cooled temperature control medium.

[0049] List of reference symbols

[0050] I Vehicle thermal management system

[0051] 3 Cooling system for cooling

[0052] 4 vehicle-side charging cable

[0053] 5 vehicle-side charging connector

[0054] 6 Temperature sensor device

[0055] 7 Control and / or regulating device

[0056] 8 battery-electric vehicle

[0057] 10 Traction battery

[0058] II Battery system

[0059] 12 chillers

[0060] 13 PTC auxiliary heaters

[0061] 14 inverters

[0062] 15 Charger

[0063] 16 Power electronics

[0064] 17 Electric motor

[0065] 18 front-end heat exchangers / coolers

[0066] 19 Valve

[0067] 20 valve

[0068] 21 Valve

[0069] 22 Pumping device

[0070] 23 Pumping device

[0071] 24 Battery temperature control circuit

[0072] 25 partial circuit

[0073] 26 partial circuit

[0074] 27 Refrigerant circuit

[0075] 28 first chiller

[0076] 29 second chiller

[0077] 30 heat exchangers

[0078] 31 Heat exchanger sub-circuit

[0079] 32 Media Management

[0080] 33 Media Management

[0081] 34 Pump device 0 Temperature sensor device 1 Temperature sensor device 0 Signal line 1 Signal line 2 Signal line 0 Wheel 1 Wheel 2 Wheel 3 Wheel 4 Front 5 Rear 6 Vehicle interior 00 Temperature control circuit 110 Thermal management module 11 1 Valve

[0082] 112 Valve 113 Valve 114 Pumping device 115 Pumping device 119 Valve

[0083] 120 Valve 121 Pumping device 122 Valve 123 Pumping device 124 Valve

[0084] 125 Chiller sub-circuit T Tempering medium T1 First tempering medium T2 Second tempering medium KM Refrigerant

[0085] P1 Arrow / Direction of travel

Claims

Claims 1. Cooling system (3) for cooling at least one vehicle-side charging line (4) of a battery-electric vehicle (8), wherein the at least one vehicle-side charging line (4) extends between a battery, in particular a traction battery (10), of the vehicle (8) and a vehicle-side charging connection connector (5) and electrically connects them to one another, characterized in that at least one heat exchanger (30) is provided and can be assigned or is assigned to the at least one vehicle-side charging line (4), wherein the at least one heat exchanger (30) extends at least partially along the longitudinal extent of the at least one vehicle-side charging line (4).

2. Cooling system (3) according to claim 1, characterized in that at least one temperature sensor device (6, 60) is provided for determining the temperature in the region of the vehicle-side charging line (4).

3. Cooling system (3) according to claim 2, characterized in that the at least one temperature sensor device (6, 60) is arranged in the region of the vehicle-side charging connection connector (5).

4. Cooling system (3) according to one of the preceding claims, characterized in that at least one vehicle thermal management system (1) is provided and the at least one heat exchanger (30) is connected to the at least one vehicle thermal management system (1), is thermally and / or fluidically connected thereto or is integrated into it.

5. Cooling system (3) according to one of the preceding claims, characterized in that the at least one vehicle thermal management system (1) has at least one temperature control circuit (100) with a first temperature control medium, in particular water / glycol, and at least one control and / or regulating device (7) for controlling and / or regulating the temperature control medium mass flow (rh) and the temperature control medium flow temperature (T v) of the first tempering medium flowing into the heat exchanger (30), wherein the at least one heat exchanger (30) is arranged in a heat exchanger sub-circuit (31) of the at least one tempering circuit (100) through which the first tempering medium can flow or through which it flows.

6. Cooling system (3) according to one of claims 1 to 4, characterized in that the at least one vehicle thermal management system (1) comprises at least one temperature control circuit (100) with a first temperature control medium, in particular water / glycol, and with a second temperature control medium, in particular thermal oil, and at least one control and / or regulating device (7), wherein for controlling and / or regulating the temperature control medium mass flow (rh) and the temperature control medium flow temperature (T v) of the tempering medium flowing into the heat exchanger (30), the at least one heat exchanger (30) is arranged in a heat exchanger sub-circuit (31) of the at least one tempering circuit (100) through which the second tempering medium can flow or through which it flows.

7. Cooling system (3) according to one of the preceding claims, characterized in that the at least one vehicle thermal management system (1) comprises at least one thermal management module (110), wherein the at least one heat exchanger (30) is arranged in a heat exchanger sub-circuit (31) in the direct feed line to the thermal management module (110).

8. Cooling system (3) according to one of claims 1 to 6, characterized in that the at least one vehicle thermal management system (1) comprises at least one switching valve (119), wherein the at least one heat exchanger (30) is arranged in a heat exchanger sub-circuit (31) in the direct feed line to the switching valve (119).

9. Cooling system (3) according to one of the preceding claims, characterized in that the at least one heat exchanger (30) in a heat exchanger sub-circuit (31) of the at least one temperature control circuit (100) of the vehicle thermal management system (1) and a battery temperature control circuit (24) of the vehicle thermal management system (1) for temperature control of a battery system (11) comprising the at least one traction battery (10) are connected in parallel to one another.

10. Cooling system (3) according to one of the preceding claims, characterized in that the heat exchanger sub-circuit (31) of the at least one temperature control circuit (100) of the vehicle thermal management system (1) comprising the at least one heat exchanger (30) can be operated directly and independently of the at least one further sub-circuit of the at least one temperature control circuit (100) of the vehicle thermal management system (1).

11. Cooling system (3) according to one of the preceding claims, characterized in that the heat exchanger sub-circuit (31) of the at least one temperature control circuit (100) of the vehicle thermal management system (1) comprising the at least one heat exchanger (30) can be operated directly and independently of further temperature control components of the vehicle thermal management system (1).

12. Cooling system (3) according to one of the preceding claims, characterized in that the vehicle thermal management system (1) comprises at least one chiller (12) and / or at least one front-end heat exchanger (18), wherein when the vehicle (8) is stationary and / or when at least one further sub-circuit of the at least one temperature control circuit (100) of the vehicle thermal management system (1) is inactive, the at least one chiller (12) and / or the at least one front-end heat exchanger (18) serves / serves to cool the temperature control medium flowing through the heat exchanger sub-circuit (31).

13. Cooling system (3) according to one of the preceding claims, characterized in that the at least one heat exchanger (30) is arranged on one side of the vehicle-side charging line (4) or surrounds the vehicle-side charging line (4), in particular concentrically encloses it, or is arranged within the vehicle-side charging line (4).

14. Vehicle thermal management system (1), comprising a closed system of a temperature control circuit (100) of a battery-electrically operated vehicle (8), in which temperature control medium can flow or flows, wherein the temperature control circuit (100) comprises at least one battery temperature control circuit (24) for temperature control of a battery system (11) containing a traction battery (10), at least one partial circuit (25) for temperature control of at least one electronic component (15, 16, 17) and at least one partial circuit (26) comprising at least one heat exchanger, in particular a front-end heat exchanger (18), which serves to absorb heat from ambient air and / or release heat to it and to transfer heat into the temperature control medium and / or from it, wherein the partial circuits (24, 25, 26) each comprise supply and return lines, characterized in that the vehicle thermal management system (1) comprises at least one cooling system (3) according to one of the preceding claims for cooling at least one vehicle-side charging line (4).

15. Battery-electrically operated vehicle (8), in particular a land vehicle, comprising at least one battery system (11) with at least one traction battery (10), at least one vehicle thermal management system (1) for controlling the temperature of vehicle components, at least one vehicle-side charging line (4) and at least one vehicle-side charging connection connector (5) for charging the traction battery (10), wherein the vehicle-side charging line (4) extends between the traction battery (10) and the vehicle-side charging connection connector (5), characterized in that at least one cooling system (3) according to one of the preceding claims is provided for cooling the at least one vehicle-side charging line (4).

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