An electrical flat cable having at least one cooling channel, an assembly having such a flat cable, and the use of such a flat cable.

Abstract

The present invention provides an electrical flat cable that provides a selectively acting, space- and cost-saving cooling means for electrical applications, and an assembly having the electrical flat cable and a battery having at least one cell. [Solution] The electrical flat cable (1) comprises at least one core (4) having at least one core sheath (6), at least one cooling channel (8) having at least one cooling channel sheath (10), and at least one web (12), wherein the at least one core (4) and the at least one cooling channel (8) extend parallel to each other, and the at least one web (12) extends along the at least one core (4) and the at least one cooling channel (8), and the at least one core sheath (6) and the at least one cooling channel sheath (10) are integrally joined.

Description

Technical Field

[0001] The present invention relates to an electrical flat cable, for example, a flexible flat cable having at least one integral cooling channel. The present invention further relates to an assembly, for example, a battery assembly having such an electrical flat cable, and to the use of such an electrical flat cable for cooling, for example, but not limited to, a battery assembly.

Background Art

[0002] In the field of electromobility, batteries comprising at least one cell, typically several cells, are used. Often, these cells are connected by an electrical flat cable that mostly extends along the upper surface of the cell. However, typically only the lower surface of the cell, which faces away from the flat cable, is cooled. Thus, due to heat dissipation in the electrochemical charge and discharge process in these cells, a significant thermal gradient can occur across the height of the cell.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Thus, the present invention is based on the aim of preventing the generation of high thermal gradients in battery cells and other electrical technology devices, particularly in the field of electromobility, without increasing the required installation space that must comply with strict specifications.

Means for Solving the Problems

[0004] This objective is achieved by an electrical flat cable comprising at least one core having at least one core sheath, at least one cooling channel having at least one cooling channel sheath, and at least one web, wherein the at least one core and the at least one cooling channel extend parallel to each other, and the at least one web extends along the at least one core and the at least one cooling channel, and the at least one core sheath and the at least one cooling channel sheath are integrally joined to each other.

[0005] By integrating at least one cooling channel with the electrical flat cable, available installation space is used efficiently, resulting in a space-saving active cooling solution. The resulting cooling effect not only affects at least one core but also the area surrounding the electrical flat cable, i.e., nearby battery cells. Furthermore, by extending parallel to at least one core, at least one cooling channel can also easily reach locations where electrical waste heat is generated, because such locations often coincide with the locations through which the flat cable is routed. As part of the installation of the flat cable according to the present invention, at least one cooling channel is already integrated into the flat cable and can therefore be installed at the same time as at least one core is placed, thus ultimately saving the additional cost of placing a separate cooling line.

[0006] The present invention can be further improved by the following embodiments, which are advantageous in themselves and can be arbitrarily combined with one another.

[0007] To improve the manageability of the flat cable according to the present invention during installation, the flat cable according to the present invention can be designed to be flexible. At least one core sheath, at least one cooling channel sheath, at least one cooling channel, and at least one web can preferably be formed from a flexible material. Accordingly, at least one core can be formed from a conductive and flexible material.

[0008] According to a further embodiment of the present invention, at least one core sheath and / or at least one cooling channel sheath and / or at least one web are each formed from an electrically insulating material to ensure the electrical safety of the flat cable according to the present invention. In particular, at least one core and at least one cooling channel are separated from each other by at least one core sheath and / or at least one cooling channel sheath and / or at least one web.

[0009] At least one core sheath and / or at least one cooling channel sheath and / or at least one web are preferably formed from polyvinyl chloride (PVC). Even with a small material thickness, this material is characterized by high dielectric strength, i.e., high electrical insulation properties. The small material thickness is particularly advantageous with respect to at least one cooling channel sheath, as it results in lower heat resistance and thus improved cooling performance. Of course, other plastic materials can also be used.

[0010] Depending on the selection of materials for at least one core sheath, at least one cooling channel sheath, and at least one web, the flat cable according to the present invention may be an extruded flat cable or a laminated flat cable.

[0011] At least one core sheath, at least one cooling channel sheath, and at least one web are optionally formed from a single, integrally molded material, i.e., made of the same material as a single workpiece. This optional embodiment is characterized in particular by simplified manufacturability.

[0012] Further simplification of the manufacturability of the flat cable according to the present invention can be achieved if at least one cooling channel is formed by a cavity formed in at least one cooling channel sheath. In this embodiment, for example, a conventional method for manufacturing an electrical flat cable having at least two cores can be used to manufacture the flat cable according to the present invention, and the cavity is created by intentionally omitting at least one core.

[0013] According to an alternative embodiment, the walls of at least one cooling channel, particularly the inner wall, can be formed from a different material than at least one cooling channel sheath. The different material is provided where different chemical and / or physical and / or mechanical properties are present. The inner wall of at least one cooling channel can be formed in particular by a tube embedded in at least one cooling channel sheath. The tube is extruded, for example, simultaneously with at least one cooling channel sheath. The resulting flexibility with respect to the material selection for the tube makes it possible to provide the flat cable according to the present invention with higher compressive strength and / or temperature resistance.

[0014] Improved mechanical stability of an electrical flat cable is achieved when at least one web extends continuously along at least one core and at least one cooling channel. In this case, the at least one web can be a material bridge that continuously connects at least one core sheath and at least one cooling channel sheath to each other along the direction of extension of the electrical flat cable.

[0015] Alternatively, at least one web may have at least one discontinuity to save material cost and / or weight. At least one web configured as a material bridge may intermittently connect at least one core sheath and at least one cooling channel sheath along the direction of extension of the electrical flat cable. In this case, as well as alternatively, at least one web may be formed by spacers extending transversely to the direction of extension of the electrical flat cable, such spacers being arranged at regular or irregular intervals along the direction of extension of the electrical flat cable.

[0016] According to further embodiments, at least one core and / or at least one cooling channel may have a rectangular profile in the cross-section of the electrical flat cable, particularly in the cross-section perpendicular to the direction of extension of the electrical flat cable. Each rectangular profile is preferably oriented flat, and thus the installation height is as low as possible for the flat cable according to the present invention. Installation height refers to the outer dimensions of the electrical flat cable measured perpendicular to the direction of extension of the electrical flat cable and perpendicular to the direction of arrangement of the at least one core and at least one cooling channel. Alternatively, at least one core and / or at least one cooling channel may have a square, circular, or elliptical profile.

[0017] In a further embodiment, at least one web may be part of the cable jacket of an electrical flat cable, and at least one core and / or at least one cooling channel may be embedded in the cable jacket. For example, at least one core may be a copper conductor embedded in the cable jacket. In this specification, the term “embedded” means that at least one core and / or at least one cooling channel is surrounded on all sides by the cable jacket in at least one cross section of the electrical flat cable perpendicular to the direction of extension. The cable jacket may be formed by at least one web and at least one core sheath and / or at least one cooling channel sheath. Accordingly, the cable jacket has an electrical insulating function and protects at least one core and at least one cooling channel from external mechanical, chemical, and / or thermal effects.

[0018] In a further embodiment, the electrical flat cable may further comprise at least one connecting member, preferably for an inlet and / or outlet of a liquid coolant. This makes it possible to connect at least one cooling channel to a coolant source and / or coolant sink for the purpose of cooling by convection heat transfer. For example, a coolant circuit can be connected via at least one connecting member. In particular, coolant can be passed in and out of at least one cooling channel via at least one connecting member.

[0019] At least one connecting member can be positioned at one end of the electrical flat cable. Alternatively, at least one connecting member can also be positioned as a T-shaped member between the two ends of the electrical flat cable.

[0020] Preferably, at least one connecting member ensures separation between at least one core and at least one cooling channel.

[0021] In further possible embodiments, the electrical flat cable may comprise at least two cores and / or at least two cooling channels extending through the electrical flat cable, spaced apart from one another. The at least two cores ensure greater electrical transmission capacity by having a larger cross-sectional area, and the at least two cooling channels increase cooling capacity by having a larger cooling surface area.

[0022] The cores and / or cooling channels preferably extend parallel to each other, with one cooling channel positioned between two adjacent cores and / or one core positioned between two adjacent cooling channels. The cores and cooling channels of the flat cable according to the present invention are positioned adjacent to each other, particularly along a positional direction perpendicular to the extension direction of the flat cable, and do not occupy additional space for installation height. In this specification, space for installation height refers to the installation space occupied by the electrical flat cable due to an already defined installation height.

[0023] The cores and cooling channels can optionally be arranged alternately in the electrical flat cable. This means that the cores and cooling channels are arranged alternately transversely to the direction of extension of the electrical flat cable. For example, the cooling channels extend in place of individual cores in the electrical flat cable. Alternatively, each cooling channel can also extend between adjacent cores. The alternating arrangement results in homogeneously distributed cooling.

[0024] In an electrical flat cable having at least two cooling channels, at least two, and in particular all, cooling channels can be connected to each other at at least one connection point. In this way, the cooling channels can be connected in parallel, and thus the coolant is uniformly distributed across the cooling channels at at least one connection point. The at least one connection point can be located on at least one connecting member of the electrical flat cable.

[0025] An arrangement having an electrical flat cable according to one of the foregoing embodiments and a battery comprising at least one cell likewise achieves the above-described object. At this time, at least one core of the electrical flat cable is in electrical contact with at least one cell of the battery. For example, at least one core is in contact with the high-voltage connection of at least one cell or the sensor of at least one cell for the purpose of reading out a measurement signal. Particularly in the case of a sensor, electrical contact can be established by an insulation displacement terminal that is orthogonal to the extension direction and orthogonal to the arrangement direction.

[0026] According to the advantages of the flat cable according to the invention already described, the space-saving and cost-saving characteristics of the invention also act in the assembly according to the invention. In particular, the installation space already provided for routing the measurement signal line and / or the power supply line can also be effectively used for the cooling purpose of at least one cell. At this time, it is advantageous for the electrical flat cable to achieve the dual functions of cell connection and cooling. This is advantageous, for example, in the use of a battery having an active cell management system.

[0027] According to an optional embodiment, at least one cell of the battery can be a pouch cell. In this embodiment, the typical space-saving and / or weight-saving characteristics of a pouch cell design without a housing can be utilized.

[0028] Alternatively, at least one cell of the battery can be a cylindrical cell, a prismatic cell, or any other type of galvanic cell.

[0029] In a further embodiment, the battery may comprise at least two cells connected to each other by cell connectors, preferably plate-shaped cell connectors, and an electrical flat cable in at least partial contact with the cell connectors. As is common in conventional battery assemblies as initially described above, the cell connectors may be located on the top surfaces of at least two cells. In this case, the cell connectors should be located outside the direct range of action of conventional battery cooling means, such as battery cooling plates, which are typically located below the cells. Thus, this embodiment is advantageous because the contact between the electrical flat cable and the cell connector allows for direct cooling of the cell connectors or the tops of at least two cells, respectively. In this case, the generation of a high thermal gradient across the height of at least two cells can be suppressed.

[0030] Naturally, the assembly according to the present invention can also be cooled by a battery cooling plate.

[0031] The electrical flat cable preferably extends along the entire cell connector, and thus reaches the first and last cells of the battery. In other words, the electrical flat cable reaches the two outermost cells of at least two cell arrays. Therefore, a cooling effect can occur at any connection point, such as a high-voltage connection, and high-voltage connections are typically located at the first and last cells of the battery.

[0032] To prevent the electrical flat cable from unintentionally loosening, in a further embodiment, the electrical flat cable can be adhesively bonded to the cell connector. By adhesively bonding the electrical flat cable, good thermal contact between the electrical flat cable and the cell connector is also ensured. Depending on the choice of adhesive, improved heat transfer between the cell connector and the electrical flat cable can also be achieved.

[0033] Adhesive bonding can be applied over the entire contact length between the electrical flat cable and the cell connector. This completely prevents localized disconnection of the electrical flat cable from the cell connector in the event of vibration or oscillation.

[0034] Alternatively, electrical flat cables and cell connectors can be bonded together using adhesive in individual parts only. In this embodiment, firstly, adhesive can be saved, and secondly, better expansion compensation can be obtained, for example, in the case of thermal stress.

[0035] Instead of adhesive bonding, electrical flat cables can also be attached to cell connectors by screwing, welding, soldering, crimping, or other methods.

[0036] The objective stated above can also be achieved by using an electrical flat cable according to one of the aforementioned embodiments for cooling a battery having at least one cell, wherein a coolant, preferably a liquid coolant, flows through at least one cooling channel of the electrical flat cable. Due to the advantages of the flat cable according to the present invention described above, the use according to the present invention also results in a space-saving and cost-saving cooling means. In addition, cooling by convective heat transfer through at least one cooling channel results in selective effectiveness of the cooling means, for example, preventing a high thermal gradient across the height of at least one cell.

[0037] For example, a water-glycol mixture can be used as a coolant. Alternatively, other technical coolants or mixtures thereof can be used.

[0038] The present invention will be described in more detail below using several embodiments and with reference to the drawings, and the various features of these embodiments can be arbitrarily combined with each other in accordance with the above description. [Brief explanation of the drawing]

[0039] [Figure 1] This is a front view of a schematic cross-sectional view of an electrical flat cable according to a possible embodiment of the present invention. [Figure 2] This is a schematic perspective cross-sectional view of an electrical flat cable according to a further embodiment of the present invention. [Figure 3] This is a schematic perspective view of an assembly of the present invention according to an exemplary embodiment. [Figure 4] This is a schematic diagram of a circuit diagram of an assembly of the present invention according to a further exemplary embodiment. [Modes for carrying out the invention]

[0040] First, the schematic structure of the electrical flat cable 1 according to the present invention will be described with reference to Figures 1 and 2. Next, the schematic structure of the assembly 2 according to the present invention will be described with reference to Figures 3 and 4. Finally, the use of the present invention will be described with reference to Figure 4.

[0041] As shown in Figure 1, the electrical flat cable 1 according to the present invention may comprise at least one core 4 having at least one core sheath 6, at least one cooling channel 8 having at least one cooling channel sheath 10, and at least one web 12. Here, at least one web 12 integrally connects at least one core sheath 6 and at least one cooling channel sheath 10 to each other. Furthermore, at least one core 4 and at least one cooling channel 8 are separated from each other by at least one core sheath 6 and / or at least one cooling channel sheath 10 and / or at least one web 12.

[0042] At least one web 12 can extend along at least one core 4 and at least one cooling channel 8. For example, at least one web 12 can be a material bridge 14 that connects at least one core sheath 6 and at least one cooling channel sheath 10 to each other continuously or intermittently along the extension direction 16 of the electrical flat cable 1. In the case of intermittent connections, the material bridge 14 may include discontinuities (not shown). Alternatively, at least one web 12 can be formed by spacers (not shown) that extend transversely to the extension direction 16 of the electrical flat cable 1. The spacers can be arranged at regular or irregular intervals along the extension direction 16 of the electrical flat cable 1.

[0043] As can also be seen in Figure 1, at least one core sheath 6 and / or at least one cooling channel sheath 10 and / or at least one web 12 can each be formed from different materials, i.e., they can differ in terms of chemical and / or physical and / or mechanical properties. Alternatively, at least one core sheath 6, at least one cooling channel sheath 10, and at least one web 12 can also be formed from the same material. This is shown in Figure 2, where at least one core sheath 6, at least one cooling channel sheath 10, and at least one web 12 together form the cable jacket 18 of the electrical flat cable 1. The cable jacket 18 can preferably be formed from an electrical insulating material such as polyvinyl chloride (PVC).

[0044] The electrical flat cable 1 may comprise at least two cores 4 and / or at least two cooling channels 8 extending through the electrical flat cable 1, spaced apart from each other. In the embodiment shown in Figure 2, an electrical flat cable 1 having three cores 4 and three cooling channels 8 is shown as an example. As can also be seen in Figure 2, the cores 4 and cooling channels 8 extend parallel to each other.

[0045] Each cooling channel 8 can be positioned between two adjacent cores 4a, 4b, and / or each core 4 can be positioned between two adjacent cooling channels 8a, 8b. In other words, the cores 4 and cooling channels 8 in the electrical flat cable 1 are positioned adjacent to each other along the positioning direction 32. The cores 4 and cooling channels 8 can be positioned alternately in the electrical flat cable 1. This means that the cores 4 and cooling channels 8 are positioned alternately transversely with respect to the extension direction 16 of the electrical flat cable 1.

[0046] At least one cooling channel 8 is integrated into the electrical flat cable 1. For example, at least one cooling channel 8 can be formed by a cavity 20 fabricated in at least one cooling channel sheath 10. All of the cooling channels 8 in Figure 2 are formed by cavities 20, each of which is fabricated in a cooling channel sheath 10 that forms part of the cable jacket 18.

[0047] Alternatively, the walls 22 of at least one cooling channel 8, particularly the inner wall 24, can be formed from a different material from at least one cooling channel sheath 10. The inner wall 24 can be formed in particular by a tube 26 embedded in at least one cooling channel sheath 10. In other words, the tube 26 is surrounded on all sides by at least one cooling channel sheath 10 or cable jacket 18 in at least one cross section 28 of the electrical flat cable perpendicular to the extension direction 16. Accordingly, at least one core 4 can be a copper conductor 30 embedded in at least one core sheath 6 or cable jacket 18. This is shown in Figure 1.

[0048] Each of the at least one core 4 and / or at least one cooling channel 8 may have a rectangular profile in the cross-section of the electrical flat cable 1, particularly in the cross-section 28 perpendicular to the extension direction 16 of the electrical flat cable 1. Each rectangular profile is preferably oriented to be flat. This means that the long edge of each rectangular profile is parallel to the arrangement direction 32 of the at least one core 4 and at least one cooling channel 8. Alternatively, each of the at least one core 4 and / or at least one cooling channel 8 may have a square, circular, or elliptical profile.

[0049] Figures 3 and 4 show possible embodiments of assembly 2 according to the present invention. Assembly 2 may comprise an electrical flat cable 1 according to the embodiments described above and a battery 34 having at least one cell 36. In this case, at least one core 4 of the electrical flat cable 1 is in electrical contact with at least one cell 36 of the battery 34. For example, at least one core 4 is in contact with a high-voltage connection (not shown) or a sensor (not shown) of at least one cell 36. In the case of sensor contact, the read sensor measurement data can be transmitted through at least one core 4 to, for example, an active cell management system 54 (see Figure 4).

[0050] At least one cell 36 can be, for example, a pouch cell, a cylindrical cell, a rectangular cell, or any other type of galvanic cell.

[0051] The battery 34 may comprise at least two cells 36 connected to each other by a cell connector 38. Figure 3 shows a battery 34 having five cells 36 as an example. Here, the electrical flat cable 1 is at least partially in contact with the cell connector 38. The electrical flat cable 1 extends particularly along the entire cell connector 38, and thus the electrical flat cable 1 reaches the first cell 36a and the last cell 36b of the battery 34, respectively.

[0052] Figure 3 also shows that the flat cable 1 according to the present invention can be configured to be flexible. The electrical flat cable 1 can conform to the uneven surface structure of the cell connector 38 and conform well to the cell connector 38. The electrical flat cable 1 can be adhesively bonded to the cell connector 38 over the entire contact length between the electrical flat cable 1 and the cell connector 38. Alternatively, the electrical flat cable 1 and the cell connector 38 can be adhesively bonded only in individual parts. Instead of adhesive bonding, the electrical flat cable 1 can also be attached to the cell connector 38 by screwing, welding, soldering, crimping, or other methods.

[0053] The assembly 2 according to the present invention shown in Figures 3 and 4 is also shown to have a battery cooling plate 42. The battery cooling plate 42 may be positioned as part of a coolant circuit 44 that cools the battery 34 below the cell 36. An electrical flat cable 1 according to the present invention can also be used to cool the battery 34. According to this use of the present invention shown in Figure 4, a liquid coolant can exit the coolant circuit 44 and flow through at least one cooling channel 8 of the electrical flat cable 1.

[0054] For this purpose, the electrical flat cable 1 may be provided with at least one connecting member 46 for inlets 48 and / or outlets 50 for the coolant. Figure 4 shows the electrical flat cable 1 having connecting members 46 for the inlets 48 and outlets 50, respectively, through which the coolant can be delivered in or out of the three cooling channels 8 shown. Each connecting member 46 is located at one end 52 of the electrical flat cable 1. Alternatively, at least one connecting member 46 may also be located as a T-shaped member between the two ends 52 of the electrical flat cable 1.

[0055] All of the cooling channels 8 of the connecting member 46 can be connected to each other at the connection point. This means that the coolant of the connecting member 46 for the inlet 48 is uniformly distributed to each cooling channel 8 at each connection point. Similarly, the coolant merges at the connecting member 46 for the outlet 50. [Explanation of symbols]

[0056] 1. Electric flat cable 2 Assembly 4, 4a, 4b cores 6 Core Sheath 8, 8a, 8b Cooling Channels 10 Cooling channel sheath 12 Web 14 Material Bridge 16 Extension direction 18 Cable Jacket 20 cavities 22 Wall 24 Inner wall 26 tubes 28 Cross-section 30 Copper conductors 32 Placement direction 34 batteries Cells 36, 36a, and 36b 38-cell connector 42 Battery cooling plate 44 Coolant Circuit 46 Connecting Member 48 Entrance 50 exit 52 End 54 Cell Management System

Claims

1. An electrical flat cable (1) comprising at least one core (4) having at least one core sheath (6), at least one cooling channel (8) having at least one cooling channel sheath (10), and at least one web (12), wherein the at least one core (4) and the at least one cooling channel (8) extend parallel to each other, the at least one web (12) extends along the at least one core (4) and the at least one cooling channel (8), and the at least one core sheath (6) and the at least one cooling channel sheath (10) are integrally joined to each other.

2. The electrical flat cable (1) according to claim 1, wherein the at least one cooling channel (8) is formed by a cavity (20) formed in the at least one cooling channel sheath (10).

3. The electrical flat cable (1) according to claim 1 or 2, wherein the walls (22, 24) of the at least one cooling channel (8) are formed from a material different from the at least one cooling channel sheath (10).

4. The electrical flat cable (1) according to any one of claims 1 to 3, wherein the at least one core (4) and / or the at least one cooling channel (8) has a rectangular profile in cross-section (28).

5. The electric flat cable (1) according to any one of claims 1 to 4, wherein the at least one web (12) is part of the cable jacket (18) of the electric flat cable (1), and the at least one core (4) and / or the at least one cooling channel (8) are embedded in the cable jacket (18).

6. The electrical flat cable (1) according to any one of claims 1 to 5, comprising at least one connecting member (46) for an inlet (48) and / or outlet (50) for a coolant.

7. The electrical flat cable (1) according to any one of claims 1 to 6, comprising at least two cores (4, 4a, 4b) and / or at least two cooling channels (8, 8a, 8b) extending through the electrical flat cable (1) spaced apart from each other.

8. The electrical flat cable (1) according to claim 7, wherein a cooling channel (8) is located between two adjacent cores (4a, 4b) and / or a core (4) is located between two adjacent cooling channels (8a, 8b).

9. The electrical flat cable (1) according to claim 7 or 8, wherein the cooling channels (8, 8a, 8b) are connected to each other at at least one connection point.

10. The electrical flat cable (1) according to any one of claims 1 to 9, wherein the cores (4, 4a, 4b) and the cooling channels (8, 8a, 8b) are arranged alternately in the electrical flat cable (1).

11. An assembly (2) comprising an electrical flat cable (1) according to any one of claims 1 to 10 and a battery (34) having at least one cell (36), wherein the at least one core (4) of the electrical flat cable (1) is in electrical contact with the at least one cell (36).

12. The assembly (2) according to claim 11, wherein at least one cell (36) is a pouch cell.

13. The assembly (2) according to claim 11 or 12, wherein the battery (34) comprises at least two cells (36, 36a, 36b) connected to each other by a cell connector (38), and the electrical flat cable (1) is at least partially in contact with the cell connector (38).

14. The assembly (2) according to claim 13, wherein the electrical flat cable (1) is adhesively bonded to the cell connector (38).

15. Use of an electrical flat cable (1) according to any one of claims 1 to 10 for cooling a battery (34) having at least one cell (36), wherein a coolant flows through the at least one cooling channel (8) of the electrical flat cable (1).

Images