Method for assembling a battery cooling device

Abstract

To provide an assembly method of a battery cooling device, the method not requiring a fixture for fixing at a fixing position, a plate metal member forming an air flow channel toward a battery stack housed in a housing, and furthermore the method enabling the plate metal member to be fixed to the housing.SOLUTION: An assembly method of a battery cooling device is adopted to a battery pack having a battery stack housed in a housing. The battery cooling device comprises: a plate metal member forming an air flow channel toward the battery stack; and a duct having a sponge member at a fitting portion where the duct is fitted with the plate metal member. The assembly method comprises: an assembling step; and a fixing step. The assembling step is a step of assembling the duct to the housing. The fixing step is a step of fixing the plate metal member to the housing via a fixing tool in a state where the plate metal member is held at the fixing position by overlapping the plate metal member with the duct assembled to the housing via a sponge member.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present disclosure relates to a method for assembling a battery cooling device applied to a battery pack. [Background technology]

[0002] Patent Document 1 discloses a battery pack structure. This battery pack structure includes a chamber inside a pack case that serves as an air flow path to a battery module, a cooling duct disposed outside the pack case, and a connector that connects the chamber and the cooling duct. The connector is connected to each of the chamber and the cooling duct via a seal member. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2017-228495 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the battery pack structure described in Patent Document 1, when the chamber is fixed to the case of the battery module using a fastener, a jig is required to hold the chamber in a fixed position.

[0005] The present disclosure has been made in consideration of the above-mentioned problems, and aims to provide a method for assembling a battery cooling device that enables sheet metal members that form an air flow path to a battery stack contained within a housing to be fixed to the housing while eliminating the need for a jig for holding the sheet metal members in a fixed position. [Means for solving the problem]

[0006] A method for assembling a battery cooling device according to the present disclosure is applied to a battery pack having a battery stack housed in a housing. The battery cooling device includes a sheet metal member forming an air flow path to the battery stack, and a duct having a sponge member at a fitting portion with the sheet metal member. The assembly method includes an assembly step and a fixing step. The assembly step is a step of assembling the duct to the housing. The fixing step is a step of fixing the sheet metal member to the housing via a fixing device in a state in which the sheet metal member is held in a fixed position by overlapping the sheet metal member with the sponge member interposed on the duct assembled to the housing.

[0007] The duct may be divided into a first downstream duct having an inlet connected to the outlet of the blower, and a second downstream duct having a fitting portion that connects between the outlet of the first downstream duct and the inlet of the sheet metal member and is provided with a sponge member. The assembling step may be a step of assembling the second downstream duct to the housing. Effect of the Invention

[0008] According to the assembly method of the battery cooling device 10 of the present disclosure, by assembling the duct to the housing before the sheet metal member, it is possible to hold (temporarily hold) the sheet metal member in a fixed position by utilizing the frictional force due to the reaction force of the sponge member provided at the fitting portion of the duct. Then, with the sheet metal member held in this state, the sheet metal member is fixed to the housing via a fixing device. This makes it possible to fix the sheet metal member to the housing without the need for a jig for holding the sheet metal member in a fixed position. [Brief description of the drawings]

[0009] [Figure 1] 1 is a diagram illustrating an example of the configuration of a battery cooling device assembled by an assembly method according to an embodiment. [Diagram 2] FIG. 2 is a diagram showing a schematic cross section taken along the line AA in FIG. [Diagram 3] 11A to 11C are diagrams for explaining a method of assembling a battery cooling device according to an embodiment. [Figure 4]11A to 11C are diagrams for explaining a method of assembling a battery cooling device according to a comparative example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. In addition, elements common to the various drawings will be denoted by the same reference numerals, and duplicated descriptions will be omitted or simplified.

[0011] 1. Battery Cooling Device Configuration Fig. 1 is a diagram that shows a schematic example of the configuration of a battery cooling device 10 assembled by an assembly method according to an embodiment. Fig. 2 is a diagram that shows a schematic cross section taken along line AA in Fig. 1 (a cross section at the position of a fitting portion 28a described below). More specifically, Fig. 1 is a diagram that shows a battery pack 1 as viewed from above the vehicle.

[0012] The battery pack 1 is mounted on an electric vehicle such as a hybrid electric vehicle (HEV) or a battery electric vehicle (BEV). The battery pack 1 includes a battery stack 3 housed in a housing 2. The housing 2 has, for example, a substantially rectangular parallelepiped shape.

[0013] The battery cooling device 10 is applied to the above-mentioned battery pack 1. The battery cooling device 10 is a device for cooling the battery stack 3, and is mounted, for example, on the floor of a vehicle together with the battery pack 1. FIG. 1 shows the battery cooling device 10 attached to the battery pack 1. The battery cooling device 10 includes a sheet metal member 12 and a blower device 14.

[0014] The sheet metal member 12 is a member for forming an air flow path 4 to the battery stack 3. More specifically, the air flow path 4 corresponds to an inlet flow path of the air flow paths formed in the battery pack 1 for cooling the battery stack 3. The sheet metal member 12 is fixed to the housing 2 via fasteners (e.g., bolts) 16.

[0015] More specifically, the sheet metal member (chamber cover) 12 forms an air flow path 4 between itself and a side surface 2a of the housing 2, for example. The side surface 2a faces, for example, toward the front of the vehicle. As an example, the sheet metal member 12 entirely covers the side surface 2a, and the ends of the sheet metal member 12 in the left and right direction of the vehicle are opened as inlets 12a and 12b, respectively. As another example, the sheet metal member 12 has a substantially U-shaped cross section as shown in FIG. 2. Note that an air flow path is formed inside the battery pack 1 to circulate the air (cooling air) introduced from the air flow path 4 to each part of the battery stack 3.

[0016] The blower device 14 is a device for taking in air and sending the taken-in air into the battery pack 1 through the sheet metal member 12. As an example, the blower device 14 is configured as a pair of blower devices 20 and 30 arranged on the vehicle front side and at the left-right ends of the battery pack 1, respectively.

[0017] One blower device 20 includes a blower 22, an upstream duct 24, and a first downstream duct 26 and a second downstream duct 28 formed by dividing the blower 22. The upstream duct 24 is connected to the inlet of the blower 22. The outlet of the blower 22 is connected to the inlet of the first downstream duct 26 located on the upstream side of the two downstream ducts 26 and 28. The second downstream duct 28 is formed to connect between the outlet of the first downstream duct 26 and the inlet 12a of the sheet metal member 12. According to the blower device 20 configured in this manner, the air taken in from the upstream duct 24 by the blower 22 can be introduced into the air flow path 4 inside the sheet metal member 12 via the first and second downstream ducts 26 and 28. The upstream duct 24, the first downstream duct 26, and the second downstream duct 28 are made of, for example, resin.

[0018] The other blower device 30 includes a blower 32, an upstream duct 34, and a first downstream duct 36 and a second downstream duct 38 divided into two. The configuration of the blower device 30 is similar to that of the blower device 20 described above, and therefore a detailed description thereof will be omitted.

[0019] 1, the second downstream duct 28 has, on its outlet side, a fitting portion 28a for fitting with the sheet metal member 12. And, as shown in Figs. 1 and 2, the second downstream duct 28 has a sponge member (seal sponge) 40 at the fitting portion 28a.

[0020] More specifically, the fitting portion 28a and the sheet metal member 12 are overlapped such that the sheet metal member 12 covers the second downstream duct 28 from the outside of the battery pack 1. The fitting portion 28a includes a hanging portion 28a1 for hanging the sheet metal member 12. As shown in FIG. 2, the sponge member 40 is adhered to the fitting portion 28a so as to cover the entire periphery of the fitting portion 28a. The fitting portion 28a is in close contact with the inlet portion of the sheet metal member 12 via the sponge member 40 (axial seal structure). Note that, at a portion of the fitting portion 28a on the side facing the housing 2 (the right side in FIG. 2), the fitting portion 28a is in close contact with the side surface 2a of the housing 2 via the sponge member 40.

[0021] The other, second downstream duct 38, has a sponge member 40 at a fitting portion 38a with the sheet metal member 12. The configuration of the fitting portion 38a is similar to that of the above-mentioned fitting portion 28a. Note that a seal member 42 similar to the sponge member 40 is provided at each of the connection portion between the first downstream duct 26 and the second downstream duct 28 and the connection portion between the first downstream duct 36 and the second downstream duct 38.

[0022] 2. Battery Cooling Device Assembly Method 3 is a diagram for explaining a method for assembling the battery cooling device 10 according to the embodiment. This assembly method includes the following "assembly process" and "fixing process." Note that the assembly process is performed, for example, on a production line for the battery pack 1.

[0023] 3(A), the "assembly process" is a process of assembling each of the second downstream ducts 28 and 38 to the side surface 2a of the housing 2. More specifically, in a process prior to the assembling process, the sponge member 40 is attached by adhesion to the fitting portions 28a and 38a of the second downstream ducts 28 and 38. Then, in the assembling process, the second downstream ducts 28 and 38 to which the sponge member 40 is attached are assembled (fixed) to the side surface 2a of the housing 2 using, for example, fasteners such as bolts (not shown).

[0024] 3(B) to 3(D) correspond to a "fixing step." The fixing step is a step of fixing the sheet metal member 12 to the housing 2 via fasteners 16 such as bolts in a state in which the sheet metal member 12 is held in a fixed position by overlapping the sheet metal member 12 with the second downstream ducts 28 and 38 already assembled to the housing 2 via sponge members 40.

[0025] More specifically, first, as shown in FIG. 3(B), the sheet metal member 12 is overlapped via the sponge member 40 so as to cover respectively the mating portions 28a and 38a of the second downstream ducts 28 and 38 which are assembled to the housing 2 prior to the sheet metal member 12.

[0026] As shown in FIG. 2, the sheet metal member 12 has a shape that fits along each of the second downstream ducts 28 (and 38). By overlapping the sheet metal member 12 and each of the second downstream ducts 28 and 38 in such a relationship via the sponge member 40, the sheet metal member 12 can be fitted into (in other words, hooked onto) each of the second downstream ducts 28 and 38 by utilizing the frictional force due to the reaction force of the sponge member 40. As a result, as shown in FIG. 3(C), the sheet metal member 12 can be temporarily held at a fixed position by each of the previously assembled second downstream ducts 28 and 38. In addition, since the second downstream ducts 28 and 38 are made of resin, they can be easily formed into a shape that easily generates a reaction force for temporary holding.

[0027] Then, in the fixing step, as shown in FIG. 3(D), in the above-mentioned temporarily held state, the sheet metal member 12 is fixed to the side surface 2a of the housing 2 via fasteners 16 such as bolts.

[0028] In addition, in a process subsequent to the above-mentioned fixing process (more specifically, a process after the battery pack 1 is mounted on the vehicle in a vehicle factory), the blower 22, the upstream duct 24, and the first downstream duct 26, which are components of the blower device 20 excluding the second downstream duct 28, are assembled. In addition, the blower 22, the upstream duct 24, and the first downstream duct 26 may be integrally assembled in advance as a blower assembly, or may be assembled in order in this process. The above also applies to the blower device 30.

[0029] 3.Effects 4 is a diagram for explaining a method of assembling the battery cooling device 100 according to the comparative example. The effects of the method of assembling the battery cooling device 10 according to the embodiment will be explained in comparison with the method of assembling the battery cooling device 100 according to the comparative example.

[0030] The battery cooling device 100 according to the comparative example differs from the battery cooling device 10 according to the embodiment in the configuration of the downstream duct. Specifically, the downstream duct according to the comparative example (for convenience, referred to as "downstream duct A") is not divided into two, but connects between the outlet of the blower 22 and the inlet 12a (or 12b) of the sheet metal member 12. According to the assembly method according to the comparative example, the sheet metal member 12 is fixed to the housing 2 as shown in FIG. 4 in a state in which the downstream duct A is not assembled to the housing 2. That is, in order to prepare a portion for inserting the downstream duct A on the battery pack 1 side, the sheet metal member 12 on the battery pack 1 side is assembled to the housing 2 in advance. Then, the downstream duct A is inserted into the inlet 12a (or 12b) of the sheet metal member 12 in a state in which the sheet metal member 12 is fixed to the housing 2, and then assembled to the housing 2.

[0031] In the above-mentioned comparative example, since the sheet metal member 12 is assembled to the housing 2 before the downstream duct A, a jig is required to hold the sheet metal member 12 at a fixed position (see FIG. 4). More specifically, in order to fix the sheet metal member 12 to the housing 2 with a fastener 16 such as a bolt, the worker needs to hold a tool in one hand and the fastener 16 in the other hand, and therefore needs to remove both hands from the sheet metal member 12. For this reason, a jig is required to prevent the sheet metal member 12 from falling. This leads to an increase in cost due to the occurrence of capital investment such as setting the jig, and an increase in tact time due to the setting of the jig when assembling the sheet metal member 12. In addition, as a measure other than setting the jig to prevent the sheet metal member 12 from falling during assembly, for example, the addition of a stud bolt or a pin with threads on both sides can be considered. However, such a measure has a large trade-off, such as an increase in parts cost and a need for a dedicated tool for assembly.

[0032] In contrast, the assembly method of the battery cooling device 10 according to this embodiment includes the above-mentioned "assembly process" and "fixing process". As a result, by assembling the second downstream ducts 28 and 38 to the housing 2 before the sheet metal member 12, it is possible to temporarily hold the sheet metal member 12 at a fixed position by utilizing the frictional force due to the reaction force of the sponge members 40 provided at the fitting portions 28a and 38a. Then, in a state in which the sheet metal member 12 is temporarily held in this manner, the sheet metal member 12 is fixed to the housing 2 via the fixing device 16. This makes it possible to fix the sheet metal member 12 to the housing 2 while eliminating the need for a jig for holding the sheet metal member 12 at a fixed position.

[0033] Therefore, according to this embodiment, unlike the comparative example, it is possible to avoid an increase in costs due to capital investment such as for setting up jigs. More specifically, by eliminating the need for jigs for assembling the sheet metal members 12, the following effects can be obtained. That is, the development and manufacturing costs of jigs are unnecessary. The maintenance costs of jigs are unnecessary. There is no need to secure a space for jigs within the process. Furthermore, according to this embodiment, since it is unnecessary to set up jigs when assembling the sheet metal members 12, the takt time can be shortened compared to the comparative example.

[0034] In addition, the duct downstream of the blower 22 used for temporarily holding the sheet metal member 12 (the "duct" according to the present disclosure) does not necessarily have to be divided into two in the form of a first downstream duct connected to the blower 22 (in other words, outside the battery pack 1) and a second downstream duct connected to the sheet metal member 12 (in other words, on the battery pack 1 side). However, by providing the first downstream ducts 26 and 36 and the second downstream ducts 28 and 38 divided into two in the above manner, as in the battery cooling device 10 according to the present embodiment, the following effect can be obtained. That is, it is possible to adopt a structure in which the second downstream ducts 28 and 38 connected to the sheet metal member 12 are first assembled to the housing 2 for temporarily holding the sheet metal member 12, and then in a subsequent process, a blower assembly including the remaining first downstream ducts 26 and 36 (i.e., connected to the blower 22) is assembled to the vehicle.

[0035] In addition, by dividing the duct downstream of the blower 22, it is possible to accommodate different vehicle models by simply changing the shape of the first downstream ducts 26 and 36 upstream of the second downstream ducts 28 and 38, without the need to change the second downstream ducts 28 and 38 for each vehicle model. This makes it possible to standardize the battery pack part number when the battery pack 1 is used between different vehicle models.

[0036] 4. Other examples of battery cooling device configurations The battery cooling device to which the assembly method according to the present embodiment is applied may be configured, for example, as follows, instead of the example of the battery cooling device 10 described above.

[0037] When multiple blower devices are provided, such as a pair of blower devices 20 and 30, the "sheet metal member" that forms an air flow path to the battery stack does not have to be shared by the multiple blower devices, and may be provided individually for each of the multiple blower devices, for example.

[0038] The battery cooling device may include only one blower device. [Explanation of symbols]

[0039] REFERENCE SIGNS LIST 1 battery pack, 2 housing, 3 battery stack, 4 air flow path, 10 battery cooling device, 12 sheet metal member, 14 (20, 30) blower device, 16 fixing device, 22, 32 blower, 24, 34 upstream duct, 26, 36 first downstream duct, 28, 38 second downstream duct, 28a, 38a fitting portion, 40 sponge member, 100 battery cooling device (comparative example)

Claims

1. A method for assembling a battery cooling device applied to a battery pack having a battery stack housed in a housing, comprising the steps of: The battery cooling device includes: a sheet metal member that forms an air flow path to the battery stack; a duct having a sponge member at a fitting portion with the sheet metal member; Equipped with The assembly method includes: an assembly process of assembling the duct to the housing; a fixing step of fixing the sheet metal member to the housing via a fixing tool in a state where the sheet metal member is held in a fixed position by overlapping the sheet metal member with the duct assembled to the housing via the sponge member; Equipped A method for assembling a battery cooling device.

2. A method for assembling the battery cooling device according to claim 1, comprising the steps of: The duct is a first downstream duct having an inlet connected to the outlet of the blower; a second downstream duct that connects between the outlet of the first downstream duct and the inlet of the sheet metal member and has the fitting portion in which the sponge member is provided; It is divided into two parts: The assembling step is a step of assembling the second downstream duct to the housing. A method for assembling a battery cooling device.

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