Battery cooling element, battery module unit, and method for manufacturing battery cooling element

Abstract

To ensure sufficient heat transfer between a battery module and / or a battery cell on the one hand and a battery cooling element on the other hand in a battery module unit.SOLUTION: There are provided a battery cooling element, a battery module unit, and a method of manufacturing the battery cooling element according to the present invention. The battery cooling element proposed herein has a flexible upper side in the form of a flexible multilayer composite foil. In order to cool the battery cell and / or the battery module, the heat transfer from the battery cell and / or the battery module to the cooling medium is carried out exclusively by relatively inexpensive and lightweight multilayer composite foil, and the multilayer composite foil can further have a high heat transfer coefficient.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] This patent application claims priority from German patent application no. 102020102523.8, the disclosure content of which is expressly incorporated herein by reference.

[0002] The present invention relates to a battery cooling element, a battery module unit, and a method for manufacturing a battery cooling element.

[0003] In particular, the present invention relates to a battery cooling element having a body and a deep drawn multi-layer composite foil, the multi-layer composite foil having a metallic material on at least a portion of the surface facing the interior chamber. [Background technology]

[0004] A battery module unit, in particular a battery module unit designed for use in a motor vehicle, usually has a casing in which one or more battery modules or two or more battery cells that can be grouped together in a battery module are arranged. Since the battery modules give off heat during charging and / or discharging, one or more battery cooling elements are usually also arranged in the casing, which are designed to absorb the heat of the battery modules and transfer it away from the casing. Battery cooling elements, in particular in the form of heat exchangers, are known, which are designed to be circulated by a cooling medium.

[0005] Battery cooling elements are also known in the prior art that are constructed with a high rigidity compared to the composite of battery modules and / or battery cells, and in particular can be arranged on the underside of the casing of the battery module unit.

[0006] As part of the functional integration, the battery cooling element can therefore take over both the heat transfer function and the function of a stiffening element for the battery module unit, which allows a weight reduction for the battery module unit.

[0007] During operation of the battery module unit, different deformation behaviors may occur, in particular when comparing the battery cooling element and the battery module and / or the battery cell complex on the one hand and the battery cooling element on the other hand.

[0008] In order to ensure sufficient heat transfer between the battery modules and / or battery cells on the one hand and the battery cooling element on the other hand, heat transfer elements, in particular in the form of heat transfer pastes and / or heat transfer foils, between the battery cooling element on the one hand and the battery modules and / or battery cells on the other hand are known in the prior art. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] DE 102011075820 [Patent Document 2] JP 2017-062985 A Summary of the Invention [Problem to be solved by the invention]

[0010] The present invention aims to provide an improvement or alternative to the prior art. [Means for solving the problem]

[0011] According to a first aspect of the invention, this problem is solved by a battery cooling element, in particular a battery cooling element for a traction battery, having a body and a multilayer composite foil, which body and the multilayer composite foil at least area-wise surround an interior chamber of the battery cooling element for receiving a cooling medium, the interior chamber being connected with a cooling medium inlet and a cooling medium outlet, and the multilayer composite foil being three-dimensionally shaped.

[0012] In this regard, the following terms are explained.

[0013] First, it is expressly stated that within the framework of this patent application, indefinite articles and numerical descriptions such as "1", "2", etc. should generally be understood as descriptions of "at least", and therefore can mean "at least one", "at least two", etc., unless expressly stated from the respective context or "exactly one" or "exactly two" is obvious or technically necessary for a person skilled in the art.

[0014] Within the context of this patent application, the expression "in particular" should always be understood as meaning that optional preferred features are introduced by this expression. This expression should not be interpreted as "i.e." or "that is to say."

[0015] By "battery cooling element" is understood a device designed to cool battery cells and / or battery modules. Preferably, the heat generated by the battery cells and / or battery modules is dissipated from the battery cooling element by a cooling medium.

[0016] Preferably, the battery cooling element has an outer surface for at least area-wise abutting a battery cell or a battery module of a battery cell module unit having at least two battery cells, an inner chamber for accommodating a cooling medium surrounded at least area-wise by the outer surface, a cooling medium inlet connected to the inner chamber, and a cooling medium outlet connected to the inner chamber, wherein the outer surface is at least area-wise constructed from a thermally conductive and flexibly constructed multilayer composite foil.

[0017] By "traction battery" is understood an energy store, in particular an energy store for electric current. The traction battery is preferably suitable for integration into an electric vehicle and for driving the electric vehicle.

[0018] By "main body" is understood a component of the battery cooling element that is structurally configured as a load-bearing component at least in relation to the battery cooling element, and thus the main body is designed in any case in such a way that it is able to dissipate the mechanical loads occurring in the battery cooling element to the surrounding components.

[0019] By "foil" is understood a thin metal or plastic sheet.

[0020] By "multilayer composite foil" is understood a foil which comprises several layers.

[0021] Preferably in a multi-layer composite foil, different materials can be combined with each other.

[0022] It is preferably proposed here that the multi-layer composite foil comprises a plastic material and a metal material, each configured in the form of a foil layer. If the multi-layer composite foil preferably comprises a metal material, this can advantageously improve the electromagnetic compatibility (EMV; Electromagnetic Vertraeglichkeit) of the multi-layer composite foil. Electromagnetic compatibility refers to the ability of an element not to disturb other elements or not to be disturbed by other elements with undesired electrical or electromagnetic effects.

[0023] Among the multilayer composite foils, those consisting of at least two material layers are considered to be preferred. Among the multilayer composite foils, those with two at least partially planar material layers are considered to be particularly preferred. Thus, in particular, multilayer composite foils with a completely planar first layer and a second material layer at least on a portion of the surface are considered, in particular with a plastic material as the first material layer and a metal material as the second material layer.

[0024] The multi-layer composite foils can in particular be produced by calendering.

[0025] Preferably the material layers of the multi-layer composite foil comprise a metal material.Preferably the material layers of the multi-layer composite foil comprise a plastic material.

[0026] Multilayer composite foils with an outwardly facing plastic layer are preferably conceivable, which can be advantageously designed to protect a second material layer, in particular a metal layer, which is covered by the plastic layer, from external influences.

[0027] Preferably, the multilayer composite foil has a thickness of between 60 μm and 150 μm. Particularly preferably, the multilayer composite foil has a thickness of between 80 μm and 125 μm.

[0028] It is expressly stated that the above values ​​for the thickness of the multi-layer composite foil should not be understood as strict limits, but rather may be exceeded or exceeded on an engineering scale without departing from the above-mentioned aspects of the invention, and simply, the values ​​provide a guide to the thickness magnitudes proposed herein for the multi-layer composite foil.

[0029] In the case of multi-layer composite foils, foils with different metal materials are also conceivable, especially in different layers of the multi-layer composite foil.

[0030] Furthermore, the multi-layer composite foil may be constructed from several different plastic materials.

[0031] Preferably, the multilayer composite foil is a multilayer composite foil having a first material layer facing the outside, in particular made of a plastic material, a second material layer covered by the first material layer, in particular made of a metal material, and at least one third material layer facing the interior space, in particular made of a plastic material, the second material layer and the third material layer also being able to be configured as part of the surface.

[0032] Multilayer composite foils are preferably considered which have a first material layer facing outwards and over the entire surface and a second material layer, in particular made of a plastic material, which is clearly distinguished over at least part of its surface, whereby the second material layer is designed to be connected to the body, in particular to be connected in a material-locking or form-locking manner, in particular to be welded.

[0033] By "internal chamber" is understood the area of ​​the battery cooling element substantially surrounded by the body and the material layers of the multilayer composite foil, the internal chamber being further defined by a cooling medium inlet and a cooling medium outlet.

[0034] By "cooling medium" is understood in particular a gaseous and / or liquid substance or a gaseous and / or liquid substance mixture which can be used to carry away heat.

[0035] By "cooling medium inlet" is understood an opening in the interior chamber configured to supply such cooling medium to the battery cooling element.

[0036] By "cooling medium outlet" it is understood an opening in the interior chamber configured to discharge such cooling medium from the battery cooling element.

[0037] By "three-dimensionally shaped" foils or multi-layer composite foils is understood foils or multi-layer composite foils which, after the initial shaping of the foils or multi-layer composite foils, are no longer shaped purely flat, but rather shaped in such a way that they extend in all three dimensions, in particular so that they extend in all three dimensions without the action of external forces, in particular so that they extend in all three dimensions without any stress being applied to them.

[0038] In other words, a three-dimensionally formed foil or multi-layer composite foil means a three-dimensionally formed foil or multi-layer composite foil which, after the initial forming, has been three-dimensionally formed by a forming method into a flat foil or multi-layer composite foil, in particular without wrinkles, so that the already formed foil or multi-layer composite foil is no longer flat. If the formed foil or multi-layer composite foil is placed on a flat surface under the action of gravity, it will have bumps and / or wrinkles compared to the initially formed flat foil or multi-layer composite foil.

[0039] Preferably, the three-dimensionally shaped foil or the three-dimensionally shaped multilayer composite foil has at least one flat shaped central region and an edge region, respectively, and the at least one flat shaped central region and the at least one edge region are preferably arranged in different parallel planes, and the at least one flat shaped central region and the at least one flat shaped edge region are connected by a connection region, which connects the different planes of the at least one central region and the at least one edge region to each other, preferably without wrinkles.

[0040] Preferably, the shaping of the foil or the multi-layer composite foil is carried out before the connection of the battery cooling element with the body.

[0041] Preferably, the shaping of the foil or the multi-layer composite foil is carried out after the connection of the battery cooling element with the body.

[0042] Preferably, the three-dimensionally formed foil or the three-dimensionally formed multi-layer composite foil is wrinkle-free, at least as long as no external forces are applied to the formed foil or formed multi-layer composite foil.

[0043] Preferably, the three-dimensionally formed foil or formed multi-layer composite foil is three-dimensionally formed by tension compression molding, deep drawing, pressing, internal high pressure molding, hydroforming or other forming methods.

[0044] A "deep-drawn" multi-layer composite foil is understood to be a multi-layer composite foil which has been formed by a deep-drawing process.

[0045] In the battery cooling element proposed here, foils or multilayer composite foils are preferably used which have, in their specified application shape and / or in their three-dimensionally shaped shape and / or in the mounted state of the battery cooling element, a first plane designed for a connection, in particular a material-locking or form-locking connection, with the body and at least one second plane designed for contact over as large an area as possible with at least one battery cell.

[0046] Preferably, the second plane designed for contact with the at least one battery cell is raised from the first plane designed for connection with the body, in particular for a material-locking or form-locking connection, in its designated abutment area with the at least one battery cell.

[0047] It is known from the prior art to cool battery cells and / or battery modules, in particular for use in traction batteries, by means of a cooling body, which is configured as a metal plate.

[0048] Such cooling bodies have a disadvantage of being relatively heavy and require heat transfer materials, in particular heat transfer pastes and / or heat transfer foils, etc., to improve the heat transfer between the battery cells and / or battery modules on the one hand and the cooling body on the other hand and / or between the cooling body on the one hand and the casing from which the heat is to be dissipated on the other hand. In this case, at least a relatively flexible heat transfer material is attached between the two metal surfaces, in such a way that the tolerances between the metal surfaces can also be compensated. However, the heat transfer material is expensive, laborious to apply and has a thermal resistance of its own, which, although it does lead to an improvement in the overall heat transfer, is still not an optimal solution for efficient heat transfer.

[0049] As an alternative to this, a different battery cooling element is proposed here, which comprises a body and a foil or a multilayer composite foil. Furthermore, the battery cooling element proposed here has an internal chamber through which a cooling medium can be circulated as specified.

[0050] According to the envisaged use of the battery cooling element proposed here, heat generated in the battery cells and / or battery modules can be transferred to the cooling medium by indirect contact between the battery cells and / or battery modules on the one hand and the cooling medium on the other hand. The heat transferred to the cooling medium can be discharged by a specified cooling medium circuit and can be discharged to the surroundings by a particularly specified further heat exchanger.

[0051] Here, the foil or multilayer composite foil is designed to be connected to a battery cell and / or a battery module.

[0052] The outer surface of the battery cooling element proposed here is therefore configured to be relatively flexibly in comparison with the solutions known in the prior art and has a plasticity associated with it, which makes it possible to compensate for tolerances between the battery cooling element and the battery cells and / or battery modules, thereby advantageously making it possible to omit heat transfer materials which take on this task in the prior art.

[0053] It is specifically conceivable here that the foil or multilayer composite foil proposed here can be pressed against the battery cell and / or battery module at least in a specified area by the pressure acting on the cooling medium, preferably in the elastic areas of the multilayer composite foil, so that any geometrical tolerances that arise between the battery cooling element and the battery cell and / or battery module can be compensated in a particularly simple manner and in a particularly simple manner, in particular without relying on the heat transfer material.

[0054] In this context, at least regional abutment means that the flexibly configured outer surface of the battery-cooling element made of a foil or multilayer composite foil does not have to extend over the entire circumference of the battery-cooling element, but this specially configured outer surface may form only a partial region of the outer circumference of the battery-cooling element. In this case, the foil or multilayer composite foil also preferably extends only over a partial region of the outer circumference of the battery-cooling element. However, it is also possible for the outer surface, and thus the foil forming the outer surface, to extend over the entire outer circumference of the battery-cooling element.

[0055] Preferably, this results in an outer surface of the battery cooling element in the form of a foil or a multilayer composite foil abutting against the battery cell to be cooled in a specified manner and / or against the battery module to be cooled in a specified manner, thus resulting in a flat contact via which heat transfer can take place.

[0056] It is furthermore specifically proposed here that the foil or the multilayer composite foil is formed from a heat-conductive material, so that good heat transfer between the battery cells or battery modules and the battery cooling element can be achieved without the use of heat-conductive materials, in particular heat-conductive pastes.

[0057] It is furthermore specifically proposed here that the foil or multilayer composite foil is characterized by a small wall thickness, which makes it possible to advantageously reduce the thermal resistance between the heat source and the cooling medium even further.

[0058] In addition, a battery cooling element configured in this way advantageously has a significantly reduced weight compared to conventional battery cooling elements, since the outer surface configuration is no longer highly rigid.

[0059] Furthermore, a flat construction of the battery cooling element is possible, which can therefore be advantageously constructed in a particularly space-saving manner.

[0060] The outer surface proposed here comprises a foil or a multilayer composite foil, whereby the material properties of the various materials combined in the multilayer composite foil can be advantageously combined with one another.

[0061] Preferably in this way it can be advantageously achieved that the outer surface of the battery cooling element formed by the multilayer composite foil can have a high elastic modulus and therefore a relatively high stability even with a small material thickness.

[0062] It is further advantageous to achieve that the multilayer composite foil can have increased tensile strength and / or tear strength independent of the combined materials, so that damage in the multilayer composite foil can be avoided even in the case of large loads acting on the multilayer composite foil.

[0063] In particular, and again specifically here, it is proposed that by combining the materials into a multilayer composite foil, the further properties of the multilayer composite foil can also be ideally adapted to the application envisaged here, in particular the weldability of the multilayer composite foil to the body envisaged here, whereby the battery cooling element can be manufactured cheaply and constructed with high rigidity.

[0064] In order to further increase the stability of the battery cooling element, it is proposed to arrange a support element in the inner chamber of the battery cooling element.

[0065] The support elements can form a support structure that can provide mechanical support to the outer surface of the battery cooling element and thus to the multilayer composite foil. The support elements can be used to absorb and even transfer pressure loads.

[0066] The support element is preferably shaped in such a way that it forms one or more flow channels through which a designated cooling medium can flow through in the interior of the battery cooling element. The flow channel or channels can be formed in such a way that the flow path from the cooling medium inlet to the cooling medium outlet is as long as possible, especially due to the serpentine form of the designated flow path. Cooling of the battery cells and / or battery modules can thus be achieved in a particularly efficient manner.

[0067] The support element can be configured, for example, in the form of a frame, to protect the outer surface of the battery cooling element. Preferably, the support element is made of a rigid material, in particular a rigid plastic material. However, the support element can also be made of a metal material.

[0068] Specifically proposed here is, inter alia, a battery cooling element with a three-dimensionally formed foil or a multilayer composite foil, in other words a battery cooling element having a foil or a multilayer composite foil that is three-dimensionally formed by a forming method, in particular by deep drawing or internal high pressure forming.

[0069] Advantageously, by using a three-dimensionally formed foil or a three-dimensionally formed multilayer composite foil, it can be achieved that no curved wrinkles occur due to the use of the desired curved shape as specified of the foil or multilayer composite foil, which may possibly disadvantageously reduce the contact area of ​​the foil or multilayer composite foil with the battery cells and / or battery modules. In other words, by forming the foil or multilayer composite foil, in particular by deep drawing or internal high pressure forming, it can be achieved that the foil or multilayer composite foil can be conditioned in the specified use shape without wrinkles. In this way, the specified achievable shape or position tolerances of the battery cooling elements, in particular in the contact area with the battery cells and / or battery modules, can be advantageously improved, which can also improve the heat transfer.

[0070] Furthermore, by using three-dimensionally shaped, in particular deep-drawn or internally high-pressure formed, foils or multi-layer composite foils, the material selection can advantageously be adapted. By finish-forming the foil or multi-layer composite foil by forming, in particular by deep-drawing or internally high-pressure forming, it can be achieved particularly advantageously that the foil or multi-layer composite foil no longer has to have any adaptability. In other words, the foil or multi-layer composite foil can thereby have a higher elastic modulus and a smaller stretchability, whereby advantageously an even higher resistance of the foil or multi-layer composite foil can be achieved, in particular a higher burst pressure of the foil or multi-layer composite foil can be advantageously achieved.

[0071] Preferably the body has a groove and / or a recess.

[0072] In this regard, the following terms are explained.

[0073] By "groove" is understood a depression whose longitudinal extent is greater than its lateral extent.

[0074] By "recess" is understood a depression in a body whose lateral extent is greater than its longitudinal extent.

[0075] This advantageously makes it possible to achieve that an internal space shaped for a specified cooling medium is not only achieved by deforming the multilayer composite foil, but also at least partially by molding it in the main body, so that deformation of the multilayer composite foil can be advantageously limited and an optional supporting framework for supporting the battery cells and / or battery modules can likewise have a smaller extent.

[0076] In other words, the height of the series of multilayer composite foils can be limited, or even in a particularly advantageous embodiment, limited to the compensation of positional tolerances between the battery cells and / or battery modules on the one hand and the battery cooling elements on the other hand.

[0077] Preferably the multi-layer composite foil has a welded region.

[0078] In this regard, the following terms are explained.

[0079] By "welding area" is understood an area of ​​the multi-layer composite foil that is designed so that it can be welded to a body. Preferably the welding area has a plastic layer on the surface of the multi-layer composite foil, which plastic layer can be welded to the body.

[0080] Therefore, specifically, a battery cooling element is proposed here, in which the body and the multilayer composite foil are welded to one another.

[0081] Preferably, the welding area of ​​the multi-layer composite foil is injected onto the surface of the multi-layer composite foil, particularly preferably only in the area where the multi-layer composite foil is to be welded to the body.

[0082] In particular, a multilayer composite foil is considered here, which has a layer of metal material on its surface facing the interior space, onto which a plastic layer is applied, in particular injected, at the locations relevant for welding, thereby forming the welded area.

[0083] The "surface facing the interior chamber" of the multilayer composite foil is understood to be the side of the multilayer composite foil which corresponds to the interior chamber of the battery cooling element according to the intended arrangement of the multilayer composite foil.

[0084] Preferably, the surface of the multilayer composite foil facing the interior space is welded to the base plate of the battery cooling element, whereby at the points of welding the multilayer composite foil no longer faces the interior space, since it is connected to the body in a material-bonding manner, but this does not change anything about the side of the multilayer composite foil facing the interior space of the battery cooling element.

[0085] More specifically, a multi-layer composite foil is conceivable which has a layer of plastic material on its surface facing the interior space, to which an additional plastic layer is applied, in particular injected, at the points relevant for welding, so that a welded area is formed. Even if the multi-layer composite foil already has a layer of plastic material on its surface facing the interior space, it is still preferably conceivable that this is not weldable to the body and therefore requires an additional welded area made of plastic. The material layer made of plastic material is not weldable to the body, in particular if the layer made of plastic material is too thin for welding or if it has a plastic material that is not weldable to the plastic material of the body, so that a connection with the body cannot be established.

[0086] By means of the welded region it can advantageously be achieved that the multilayer composite foil and the body are connected to one another in a material-bonding manner by welding.

[0087] Preferably, the multi-layer composite foil has a metallic material on the surface facing the interior chamber, at least on a portion of the surface.

[0088] By "part of a surface" it is understood that the surface of one side of the multilayer composite foil can be divided into different regions of surface material, the associated partial surfaces or regions being defined by alternations of the surface materials.

[0089] By "metallic material" is preferably understood a material which consists predominantly, ie at least 70% by weight, of aluminium or copper.

[0090] According to a possible embodiment of the multilayer composite foil, it has a layer of metal material and a layer of plastic material, the metal material being arranged in the direction of the interior chamber and the plastic material being arranged on the side of the multilayer composite foil opposite to the interior chamber.

[0091] Advantageously, with a multilayer composite foil having a layer of metal material facing the interior space and a layer of plastic material on the opposite side to the interior space, it can be achieved that, despite the use of a plastic layer, a relatively good heat transfer coefficient can still be achieved with the multilayer composite foil, in particular the heat transfer coefficient can be improved over at least a further part of its extent, in particular over its entire extent, compared to a multilayer composite foil having a metal material layer as an intermediate layer and a layer of plastic material in the outer layer.

[0092] According to a specific embodiment of the multilayer composite foil proposed here having a layer of metal material facing the interior space and a layer of plastic material on the opposite side to the interior space, it is conceivable for the multilayer composite foil to have layers of both materials respectively over its entire extent.

[0093] In order to achieve weldability of the multilayer composite foil with the body, it is further proposed to apply to the metal material, at least in the area of ​​the specified weld, a further plastic layer which is weldable to the body by means of plastic, in particular in the weld area.

[0094] According to a further specific embodiment of the multilayer composite foil having a layer of metal material facing the interior space and a layer of plastic material facing the interior space on the opposite side, it is conceivable that the multilayer composite foil has an outer plastic layer over its entire extent, whereas the metal layer facing the interior space as specified is interrupted in the areas to be welded to the body as specified. In this way it can be advantageously achieved that no further plastic layers need to be applied to the multilayer composite foil for weldability between the multilayer composite foil and the body.

[0095] Preferably, the area of ​​the multi-layer composite foil facing the interior chamber and having a metal material on a surface thereof is designed to have a higher heat transfer coefficient than an adjacent area of ​​the multi-layer composite foil facing the interior chamber and having a metal material on a surface thereof.

[0096] In this regard, the following terms are explained.

[0097] By "heat transfer coefficient" is understood the proportionality coefficient that determines the intensity of heat transfer through a multilayer composite foil. It is a specific indicator of the composition of the material.

[0098] Here, then, a battery cooling element is proposed having a multilayer composite foil, which, corresponding to its material selection and in accordance with its material arrangement, has a higher heat transfer coefficient in a first region designed for contact with battery cells and / or battery modules than in a second region, in particular than in an adjacent second region designed for connection, in particular for a material-fit or form-fit connection, in particular for a material-fit connection of the multilayer composite foil to the body by welding.

[0099] Preferably, a multilayer composite foil is considered which has a metal layer on the side facing the interior space, and in the second area provided for welding a plastic layer is applied onto the metal layer, which metal layer likewise faces towards the interior space of the battery cooling element.

[0100] This advantageously makes it possible to achieve that the multilayer composite foil has a higher heat transfer coefficient in areas relevant for efficient heat transfer than in adjacent areas, in particular adjacent areas designed for welding to the body and preferably not in direct contact with the battery cells and / or battery modules.

[0101] According to a preferred embodiment, the metallic material has aluminum as an alloy component, preferably the metallic material has an aluminum proportion of more than 85% by weight, particularly preferably the metallic material has an aluminum proportion of more than 95% by weight.

[0102] In this regard, the following terms are explained.

[0103] By "alloying component" is understood a component of a metal within an alloy having multiple metals.

[0104] By "aluminum proportion in weight percent" is understood the proportion of the chemical element aluminum in an alloy having several elements, this proportion being expressed as a percentage based on the total mass of the alloy.

[0105] By using aluminum as the metallic material, advantageously a high thermal conductivity of the metallic layer can be achieved, so that an overall efficient battery cooling element in terms of heat transfer can be achieved.

[0106] Preferably, the metallic material has an aluminum percentage of more than 70% by weight. Preferably, the metallic material has an aluminum percentage of more than 75% by weight. Preferably, the metallic material has an aluminum percentage of more than 80% by weight. Preferably, the metallic material has an aluminum percentage of more than 90% by weight. Preferably, the metallic material has an aluminum percentage of more than 97% by weight. Preferably, the metallic material has an aluminum percentage of more than 98.5% by weight.

[0107] It is expressly stated that the above values ​​for the aluminum percentages should not be understood as strict limits, but rather may be exceeded or exceeded on an engineering scale without departing from the described aspects of the invention, but simply provide a guide to the magnitude of the aluminum percentages proposed herein.

[0108] According to an optional embodiment, the metallic material as an alloy component comprises copper.

[0109] Suitably, the metal material has a copper proportion of more than 70% by weight, preferably more than 75% by weight, preferably more than 80% by weight, preferably more than 85% by weight, preferably more than 90% by weight, preferably more than 95% by weight, preferably more than 98.5% by weight.

[0110] Advantageously, by using copper as an alloy component of the metal layer, a high thermal conductivity and therefore an overall efficient battery cooling element in terms of heat transfer can be achieved.

[0111] Optionally, the area of ​​the multilayer composite foil having a metallic material on a surface facing the interior chamber substantially corresponds to the area of ​​the multilayer composite foil designed to be in contact with the battery cells and / or battery modules.

[0112] In this regard, the following terms are explained.

[0113] By "battery cell" is understood a store of electrical energy on an electrochemical basis.

[0114] A "battery module" is understood to be a part of a battery module unit, and a battery module has a plurality of battery cells.

[0115] Areas of the multilayer composite foil "designed to be in contact with battery cells and / or battery modules" are understood to be areas of the multilayer composite foil that come into contact with the battery cells and / or battery modules as specified.

[0116] It is proposed here that the multilayer composite foil has a metal layer that is substantially at least as large as the area that is to be contacted to the battery cell and / or battery module as specified.

[0117] In this way, advantageously, a battery cooling element with a high heat transfer coefficient can be achieved in the designated contact areas with the battery cells and / or battery modules, so that efficient heat transfer can be achieved, while in adjacent areas the material properties of the multilayer composite foil can be adapted to the local requirements present there, in particular the weldability with the body.

[0118] Substantially is understood to mean an area of ​​at least 80% identity, suitably an area of ​​at least 90% identity, preferably an area of ​​at least 95% identity, preferably an area of ​​at least 98% identity.

[0119] Preferably the multi-layer composite foil has, on its surface facing the interior chamber, a plastic material over at least part of the surface.

[0120] In this regard, the following terms are explained.

[0121] By "plastic material" is understood a material which consists exclusively of polymers.

[0122] Preferably, plastic material is understood to be a thermoplastic elastomer based on polyethylene, in particular tear-resistant modified polyethylene, and / or polyisobutylene and / or polyvinyl butyral and / or ethylene vinyl acetate and / or polyacrylate and / or polymethylene acrylate and / or polyurethane and / or pre-stretched polypropylene and / or polyvinyl acetate 5 and / or ethylene vinyl acetate and / or urethane.

[0123] Advantageously, this allows the plastics material to be adapted on the surface of the multilayer composite foil facing the interior space so that it can be welded to the body.

[0124] According to an optional embodiment, the area facing the interior chamber and having plastic material on its surface of the multilayer composite foil substantially corresponds to the area of ​​the contact surface with the body, the plastic material being weldable to the body.

[0125] In this regard, the following terms are explained.

[0126] By "body contact surface" is understood the surface which contacts the body or is welded to the body as specified.

[0127] By "weldable" is understood here the weldability of the thermoplastic material, i.e. the material-connectable connectability of the thermoplastic material, in particular the permanent material-connectable connectability of the thermoplastic material.

[0128] Substantially is understood to mean an area of ​​at least 80% identity, preferably an area of ​​at least 90% identity, preferably an area of ​​at least 95% identity, preferably an area of ​​at least 98% identity.

[0129] Advantageously, this makes it possible to achieve a multi-layer composite foil with a regionally optimized material configuration.

[0130] According to a preferred variant, the plastic material corresponds to LDPE or PE or PA or PP.

[0131] "LDPE" is understood to be low density polyethylene, ie polyethylene with low density.

[0132] "PE" is understood to be polyethylene.

[0133] "PA" is understood to be polyamide.

[0134] "PP" is understood to be polypropylene.

[0135] Advantageously, this makes it possible to achieve that the plastic material can be welded to a compatible body.

[0136] Preferably the multi-layer composite foil has a plastic material on the surface facing away from the interior chamber, at least over part of the surface.

[0137] In this regard, the following terms are explained.

[0138] By "surface opposite to the interior chamber" is understood the surface of the multilayer composite foil which at least partially forms the outer surface of the battery cooling element.

[0139] Particularly preferably, the multilayer composite foil has plastic material over the entire surface on the surface facing away from the interior chamber.

[0140] It can thus advantageously be achieved that the metal layers of the multilayer composite foil can be ideally protected from external influences.

[0141] According to an expedient embodiment, the plastic material is structurally viscous.

[0142] Particularly preferably, the plastics material is thixotropic.

[0143] In this regard, the following terms are explained.

[0144] A "structurally viscous" plastic material is understood to be a plastic material whose viscosity decreases with increasing shear stress, in other words, the viscosity of a structurally viscous plastic material decreases as the shear load acting on the plastic material increases.

[0145] A "thixotropic" plastic material is understood to be a plastic material whose viscosity decreases over time under constant shear, preferably increasing again as a function of time after the shear load has ended.

[0146] Preferably, the plastic material is structurally viscous, particularly preferably thixotropic, on the outside of the multilayer composite foil, in other words preferably the plastic material designated to face the battery cell is structurally viscous, particularly preferably thixotropic.

[0147] This advantageously makes it possible to achieve that the plastic layer protecting the metal layer has a comparatively low viscosity in the event of high shear loads, thereby advantageously countering damage to the protective plastic layer due to shear loads.

[0148] Optionally, the body is made of LDPE or PE or PA or PP.

[0149] Advantageously, this allows the body to be constructed particularly lightly and to be achieved by welding with a compatible multi-layer composite foil.

[0150] According to a preferred embodiment, the body has fastening elements for fastening the battery cells and / or battery modules.

[0151] In this regard, the following terms are explained.

[0152] By "fixing element" is understood each device designed to fix a body with a battery cell and / or a battery module.

[0153] Expediently, the body is designed to be used as a load-bearing element of a battery module unit, in particular of a battery module unit of a traction battery.

[0154] In this regard, the following terms are explained.

[0155] By "load-bearing element" is understood a component or group which is not only designed to absorb loads occurring within the component or group without destruction, but rather can be designed to pass external loads acting on the component or group through it without destruction.

[0156] By "battery module unit" it is understood that a battery module system having a plurality of battery modules.

[0157] Advantageously, this can achieve that the battery module unit does not require an additional load-bearing casing, thereby saving material and weight.

[0158] Optionally, the body is designed to be used as a constituent part of a casing of a battery module unit, in particular a battery module unit of a traction battery.

[0159] Advantageously, this makes it possible to achieve that a component of the casing of the battery module unit is formed by the body, which advantageously makes it possible to save material and weight for the battery module unit.

[0160] According to a second aspect of the invention, this problem is solved by a battery module unit, in particular a battery module unit of a traction battery, comprising a battery cell and / or a battery module and a battery cooling element according to the first aspect of the invention.

[0161] It will be appreciated that the advantages of the battery cooling element according to the first aspect of the present invention apply directly to a battery module unit comprising battery cells and / or battery modules and a battery cooling element according to the first aspect of the present invention, as previously described.

[0162] It is expressly stated that the subject matter of the second aspect may be advantageously combined with the subject matter of the first aspect of the invention, ie individually and / or cumulatively in any combination.

[0163] According to a third aspect of the invention, this problem is solved by a method for manufacturing a battery cooling element, in particular a battery cooling element for a traction battery, in particular a battery cooling element according to the first aspect of the invention, which battery cooling element has a body and a three-dimensionally shaped multilayer composite foil, which body and the three-dimensionally shaped multilayer composite foil at least regionally surround the battery cooling element for containing a cooling medium, which manufacturing method comprises: Providing a foil or a multi-layer composite foil, in particular a foil or a multi-layer composite foil having a surface made of a metal material or having plastic surfaces on both sides, Finishing the foil or the multi-layer composite foil by a forming process, in particular by a deep drawing process or an internal high pressure forming process, into a three-dimensionally formed foil or a multi-layer composite foil (20); and b. connecting the foil or multi-layer composite foil to the body.

[0164] In this regard, the following terms are explained.

[0165] By "finish shaping" is understood any shaping of an object by means of which it is possible to achieve a three-dimensional shape, in particular a multilayer composite foil that is finish shaped in a free dimension.

[0166] Preferably, finish forming is understood to mean finish forming by a deep drawing process.

[0167] By "deep drawing" is understood a forming method designed to form hollow bodies open on one side from foils by tension-compression forming.

[0168] Preferably, finish moulding is understood to mean finish moulding by an internal high pressure moulding process.

[0169] By "internal high pressure forming" is understood a forming method in which an object, in particular a multilayer composite foil, is formed into a closed forming tool by internal pressure. Preferably, the internal high pressure forming method is understood to be a hydroforming method.

[0170] By "connection" is understood any method designed to connect a foil or a multilayer composite foil to a body, in particular to connect in a material-connecting or form-connecting manner.

[0171] For material-connection connections, preferably welding methods come into consideration.

[0172] For force connections, in particular the flange method and / or the Rendel method come into consideration.

[0173] It is expressly stated that the steps of the present invention can be performed in the order described, but this is not required, and therefore the steps can be performed in another order.

[0174] It is further explicitly stated that these steps can be carried out at one work station or at several work stations, in particular at work stations arranged in a star configuration with respect to one another.

[0175] In particular, according to a first alternative embodiment for producing a battery cooling element, it is proposed here to finish-shape the foil or multilayer composite foil by a forming method, in particular by a deep drawing process or an internal high pressure forming method, so that in the desired curved shape as specified for use of the three-dimensionally formed foil or the three-dimensionally formed multilayer composite foil, no curved wrinkles occur, which would possibly disadvantageously reduce the contact area of ​​the foil or multilayer composite foil with the battery cells and / or battery modules.

[0176] In other words, by shaping the foil or multilayer composite foil, in particular by deep drawing or internal high pressure shaping, it can be achieved that the three-dimensionally shaped foil or the three-dimensionally shaped multilayer composite foil can be conditioned so as to be wrinkle-free in the specified use shape.

[0177] In this way, the shape or position tolerances achievable as specified of the battery cooling elements, particularly in the contact areas with the battery cells and / or battery modules, can be advantageously improved, whereby the heat transfer can also be improved.

[0178] Furthermore, by forming, in particular by deep drawing or internal high pressure forming, the metal selection can advantageously be adapted. By finish forming the foil or multi-layer composite foil by deep drawing, it can be achieved in a particularly advantageous manner that the foil or multi-layer composite foil no longer has to have any adaptability. In other words, the foil or multi-layer composite foil can thereby have a higher elastic modulus and a smaller stretchability, whereby advantageously a higher resistance of the foil or multi-layer composite foil can be achieved, in particular a higher burst pressure of the foil or multi-layer composite foil can be advantageously achieved.

[0179] After the finish forming, it is preferably proposed to connect the three-dimensionally formed foil or the three-dimensionally formed multilayer composite foil with a body, thereby forming a battery cooling element.

[0180] According to a second particularly alternative embodiment, it is conceivable that the provided molded foil or the provided molded multi-layer composite foil is first connected to the body and then finish-formed, so that the previously flat molded foil or the flat molded multi-layer composite foil is only finish-formed after connection to the body.

[0181] This allows for a simplified connection of the provided foils or of the provided multi-layer composite foils.

[0182] Instead of welding the foil or the multilayer composite foil to the body, it is conceivable that in the connection process the three-dimensionally shaped foil or the three-dimensionally shaped multilayer composite foil is connected to the body in a form-fitting manner by gluing and / or flanging and / or the Rendell method.

[0183] According to an expedient embodiment, the connection of the three-dimensionally shaped multilayer composite foil with the body is achieved by: - applying a layer of plastic material at least locally to a foil or a multilayer composite foil, in particular applying a layer of plastic material to a metal material or to a surface made of plastic material, the applied plastic material being weldable to the body; and welding the body and the layer of plastic material to the battery cooling element.

[0184] In this regard, the following terms are explained.

[0185] By "application" is understood any method designed to apply a layer of plastic material onto the foil and / or onto the multi-layer composite foil.

[0186] It is expressly stated that, although the steps of the present invention may be performed in the order described, this is not required, and thus the steps may be performed in another order.

[0187] For the connection, it is proposed here to apply a material layer made of plastic material onto the foil or onto the multilayer composite foil. This can be done on one or both sides.

[0188] Preferably according to a first variant, it is proposed that the layer of plastic material applied after shaping, in particular deep drawing or internal high pressure shaping, is applied only in the region of the contact area with the body, which can be used for welding to the body. After application of the layer of plastic material, it is proposed to weld the body and the three-dimensionally shaped foil or the three-dimensionally shaped multilayer composite foil to one another to a battery cooling element, in particular by welding the body to the layer of plastic material.

[0189] Furthermore, preferably according to a second variant, it is proposed to apply a layer of plastic material onto the provided formed foil or the provided formed multi-layer composite foil, preferably only in the contact area with the body. The applied layer can then be used to weld the still flat foil or the flat multi-layer composite foil to the body. In a subsequent step, the foil or the multi-layer composite foil connected to the body can be shaped, in particular by deep drawing or internal high-pressure forming.

[0190] Preferably, it is proposed to inject a plastic material.

[0191] Preferably, the welding of the foil or the multilayer composite foil to the body is carried out by means of a welding tool, in particular hot stamping and / or ultrasonic welding and / or high frequency welding.

[0192] Preferably, the finish shaping of the foil or multilayer composite foil and the application of the layer of plastics material take place in one working cycle.

[0193] In this regard, the following terms are explained.

[0194] By "work cycle" is understood a periodic phase during the execution of a method which proceeds repeatedly. Preferably, the method steps of a work cycle are carried out in a station of a machine.

[0195] Advantageously, this allows a station for manufacturing the battery cooling element to be utilized for preferably at least two work steps, thereby saving on investment costs for machines for manufacturing the battery cooling element.

[0196] Preferably, after providing the foil or multilayer composite foil, first a layer of plastic material is applied onto the foil or multilayer composite foil, the foil or multilayer composite foil being welded to the body in the area of ​​the applied layer of plastic material and subsequently three-dimensionally finish-molded.

[0197] It is specifically proposed here that the foil or the multilayer composite foil is only finish-formed by a forming method, in particular by internal high-pressure forming, after welding with the body.

[0198] Preferably, the provided foil or the provided multi-layer composite foil is molded flat.

[0199] More preferably, the foil or the multilayer composite foil is three-dimensionally finish-formed against a shaping die, the shaping die being in at least indirect contact with the body during finish-forming.

[0200] It is conceivable here, inter alia, for the shaping die to be at least indirectly pressed against the body by a holding force, whereby the foil or multi-layer composite foil can be finish-formed against the die by an internal high-pressure forming method, the die thus defining the foil or multi-layer composite foil in its finished shaped final shape, for which the holding force corresponds to the pressure of the fluid pressing the foil or multi-layer composite foil against the die, so that the shaping die remains at least indirectly in contact with the body during the entire process of internal high-pressure forming.

[0201] As part of the internal high pressure moulding method it is proposed here to fill the internal space between the foil or the multilayer composite foil and the body with a fluid and print this, whereby pressures of 1.5 bar to 10 bar, preferably 2 bar to 8 bar, preferably 3 bar to 7 bar and even more preferably 4 bar to 6 bar are conceivable.

[0202] In order to ensure that the fluid cannot leak out of the internal chamber during the internal high pressure molding, it is proposed to seal the body in the direction of the cooling medium inlet and / or the cooling medium outlet by a sealing tool, which provides a fluid inlet to the internal chamber, by means of which the fluid can flow into the internal chamber.

[0203] It is preferably proposed that the finish forming of the foil or multi-layer composite foil is carried out in the same work cycle as the welding between the foil or multi-layer composite foil and the body.

[0204] Advantageously, the foils or multi-layer composite foils can be finish-formed at their designated use point, and the at least indirect contact of the shaping die with the body improves possible tolerances between the designated battery module and the foil or multi-layer composite foil. In particular, the manufacturing method tolerances caused during separate finish-forming and welding of the foil and / or multi-layer composite foil are limited by the method proposed here. In particular, the maximum tolerances between the battery module and the foil or multi-layer composite foil connected to the body as specified can be reduced.

[0205] Particularly preferably, the shaping die is at least indirectly connected to the body by means of a connecting element during the finish forming of the foil or the multilayer composite foil, in particular the shaping die is connected to the body before the finish forming by at least one screw, in particular by means of a plurality of screws, which preferably are in operative relationship with a connecting element of the body, in particular a module screw fastening point, which is also used as specified for fastening the battery module.

[0206] Advantageously, this makes it possible to achieve that possible tolerances resulting from deformation of the body through the finish-forming of the foil or multilayer composite foil are compensated for by fixing the relative position between the body and the shaping die, so that the finish-formed foil or the finish-formed multilayer composite foil can ideally interact with the battery module fixed to the body as specified.

[0207] Preferably, the three-dimensionally shaped foil or the three-dimensionally shaped multilayer composite foil and the body are connected to one another in a form-fitting manner.

[0208] Advantageously in that way it can be achieved that the foil or the multilayer composite foil, or the multilayer composite foil comprising a layer made of plastic, does not have to be suitable for welding to the body.

[0209] According to a particularly expedient embodiment, after the connection of the foil or the multilayer composite foil to the body, a pressure difference test is carried out.

[0210] In this regard, the following terms are explained.

[0211] By "pressure difference test" is understood a test of the connection between the body and the foil or multi-layer composite foil and / or said foil or said multi-layer composite foil, the internal space between the foil or multi-layer composite foil and the body being filled with a fluid whose pressure is greater than the ambient pressure. Preferably, the pressure difference with respect to the ambient pressure is 0.2 bar, more preferably 0.4 bar, preferably 0.6 bar, more preferably 0.8 bar, particularly preferably 1.0 bar, more particularly preferably 1.2 bar.

[0212] Preferably, the contact area of ​​the foil or multi-layer composite foil, designed for contact with the battery module, is supported during the pressure differential test by a support tool. This allows the foil or multi-layer composite foil to be supported at the contact area, so that the differential pressure acts substantially on the edge area of ​​the foil or multi-layer composite foil and / or on the connection with the body, so that in particular the connection area, preferably the weld between the body and the foil or multi-layer composite foil, can be tested under the required test pressure without fear of overloading the specified contact area. Furthermore, the support tool allows the simulation of the behavior of the battery cooling element when used in the specified battery module unit.

[0213] It is preferably proposed that the pressure difference test is carried out in the same working cycle as the finish forming of the foil or multi-layer composite foil.

[0214] It is furthermore preferably proposed that the pressure difference test is carried out in the same work cycle as the finish forming of the foil or multi-layer composite foil and the welding of the foil or multi-layer composite foil.

[0215] Advantageously, pressure differential testing allows for quality control.

[0216] It is understood that what is proposed here is a battery cooling element manufactured by the method according to the third aspect of the invention.

[0217] It is expressly stated that the subject matter of the third aspect may be advantageously combined, individually and cumulatively, in any combination, with the subject matter of the preceding aspects of the invention. Further advantages, details and features of the invention will become apparent from the examples described below. [Brief description of the drawings]

[0218] [Figure 1] FIG. 2 is a schematic diagram of a battery cooling element and a battery module. [Diagram 2] 1 is a schematic diagram of an alternative battery cooling element and battery module. [Diagram 3] FIG. 2 is a schematic plan view of a battery cooling element. [Figure 4] 1 is a schematic diagram of a further alternative battery cooling element and battery module. [Diagram 5] FIG. 2 is a schematic diagram of a welding tool for welding a battery cooling element. [Figure 6] FIG. 1 is a schematic diagram of a shaping die and a sealing tool for finish-shaping the foil or the multi-layer composite foil. [Figure 7] FIG. 7 is a schematic diagram of a foil or multi-layer composite foil finish-formed into a battery cooling element by the tool of FIG. 6. [Figure 8] FIG. 13 is a schematic diagram of a foil or multi-layer composite foil finish-formed into a battery cooling element with a supporting tool for differential pressure testing. [Figure 9] FIG. 1 is a schematic diagram of a battery cooling element with a shaping die connected with a body. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0219] In the following description, the same reference numerals represent the same components or features, so that the description of one component given in relation to one drawing also applies to the other drawings to avoid repetitive description. Moreover, individual features described in relation to one embodiment can also be used separately in other embodiments.

[0220] The battery cooling element 10 of FIG. 1 essentially consists of a three-dimensionally shaped multilayer composite foil 20 and a body 30, which are connected, in particular welded, to one another on part of their faces.

[0221] The body 30 and the three-dimensionally formed multi-layer composite foil 20 together form an interior chamber 40 for containing a cooling medium 42, which can flow into the interior chamber 40 through a cooling medium inlet 44 as specified, and can flow out of the interior chamber 40 through a cooling medium outlet 46 as specified.

[0222] When the battery cooling element 10 is in use as specified, the battery cooling element 10, and in particular the three-dimensionally shaped multi-layer composite foil 20 of the battery cooling element 10, contacts a battery module 50 or battery cell (not shown).

[0223] The three-dimensionally shaped multi-layer composite foil 20 preferably has a metal material layer 22 facing the interior chamber 40 and a plastic material layer 24 on the opposite side to the interior chamber, the plastic material layer being in contact with the battery module 50 as specified.

[0224] Furthermore, the three-dimensionally formed multilayer composite foil 20 has a plastic material layer 26 on part of its surface, by means of which the three-dimensionally formed multilayer composite foil 20 is connected, in particular welded, to the main body 30.

[0225] The battery cooling element 10 of FIG. 2 is characterized in that the body 30 has recesses 32, 34 which advantageously allow the three-dimensionally shaped multilayer composite foil 20 to have relatively small deformations (not shown) to form the interior chamber 40.

[0226] The plan view of the battery cooling element 10 in FIG. 3 shows areas 60, 62 where a three-dimensionally shaped multi-layer composite foil (not shown) is connected, in particular welded, to a body (not shown).

[0227] Further, FIG. 3 , a plan view of the battery cooling element 10, shows an area 70 where the battery cooling element 10, in particular the three-dimensionally shaped multi-layer composite foil (not shown), is designed to make designated contact with the battery module.

[0228] In the battery cooling element 10 of FIG. 4, the three-dimensionally shaped multilayer composite foil 20 preferably has a plastic material layer 28 facing the interior chamber 40, preferably a plastic material layer 28 on the entire surface, preferably a plastic material layer 28 that is thinner than the plastic material layer 26, and a plastic material layer 24 on the opposite side to the interior chamber, which plastic material layer 24 is in contact with the battery module 50 as specified.

[0229] The welding tool 80 of Fig. 5 is designed to weld the foil or multilayer composite foil 20 to the body 30 of the battery cooling element 10. For that purpose, at the points of the foil or multilayer composite foil 20 provided for welding, a plastic material layer 26, which is preferably compatible with the material of the body 30, is injected so that the foil or multilayer composite foil 20 can be welded to the body 30.

[0230] The welding tool 80 may be configured as a hot stamp, and / or as an ultrasonic welding tool, and / or as a radio frequency welding tool.

[0231] The shaping die 82 of figures 6 and 7 is designed to finish-shape the foil or multi-layer composite foil 20, in particular by an internal high pressure forming method. Figure 6 shows the foil or multi-layer composite foil 20 in its configuration before finish-shaping and figure 7 shows it after finish-shaping.

[0232] For this purpose, the shaping die 82 is pressed at least indirectly against the base plate 30 by a holding force, whereby the shaping die 82 preferably presses directly against the weld area. The holding force is preferably determined depending on the pressure acting in the inner chamber 40 during the finish forming, so that the shaping die 82 does not lose at least indirect contact with the body 30 and / or direct contact with the weld area.

[0233] Preferably, a sealing tool 86 is provided for sealing the body 30 in the direction of the cooling medium inlet 44 and / or the cooling medium outlet 46 during the finish forming of the foil or multilayer composite foil 20. This particularly preferably has a fluid connection 88, by means of which a fluid can flow into the inner chamber 40 for the finish forming of the foil or multilayer composite foil. Here, preferably, the cooling medium outlet 46 or alternatively (not shown) or the cooling medium inlet 44 is sealed by the sealing tool 86.

[0234] The support tool 84 of Fig. 8 is designed to support the contact area of ​​the foil or multi-layer composite foil 20, preferably during pressure differential testing of the battery cooling element, which contact area of ​​the foil or multi-layer composite foil 20 is itself designed to contact the battery module (not shown) as specified.

[0235] The support tool 84 allows the foil or multilayer composite foil 20 to be supported in the region of the contact area so that a differential pressure acts substantially on the edge region of the foil or multilayer composite foil 20 and / or on the connection with the main body 30, whereby in particular the connection region, preferably the weld between the main body 30 and the foil or multilayer composite foil 20, can be inspected under the required inspection pressure without fear of overloading the contact area as specified.

[0236] The battery cooling element of Fig. 9 comprises a shaping die 82, which is at least indirectly connected to the body 30 by at least one connection means 52, for finish-shaping the foil or multilayer composite foil 20. Thereby it can advantageously be achieved that possible tolerances resulting from deformations of the body 30 through the finish-shaping of the foil or multilayer composite foil 20 are compensated for by fixing the relative position between the body 30 and the shaping die 82, so that the finish-shaped foil or the finish-shaped multilayer composite foil 20 can ideally interact with a battery module (not shown) fixed to the body 30 as specified. [Explanation of symbols]

[0237] 10 Battery Cooling Element 20 Multi-layer composite foil 22 Metal material layer 24 Plastic material layer, outer 26 Plastic material layers / welding areas 28 Plastic material layer, inner 30 Main unit 32 Recess 34 Recess 40 Inner room 42 Cooling medium 44 Coolant inlet 46 Coolant outlet 50 Battery Module 52 Connection means 60 areas 62 areas 70 areas 80 Welding Tools 82 Shape-giving die 84 Support tools 86 Sealing tools 88 Fluid Connection

Claims

1. A battery cooling element (10) having a body (30) and a multilayer composite foil (20), in particular for a traction battery, wherein said body (30) and said multilayer composite foil (20) at least area-wise surround an internal chamber (40) of said battery cooling element (10) for containing a cooling medium (42), said internal chamber (40) being connected with a cooling medium inlet (44) and a cooling medium outlet (46), A battery cooling element (10), characterized in that the multilayer composite foil (20) is three-dimensionally shaped.

2. The battery cooling element (10) according to claim 1, characterized in that the body (30) has grooves and / or recesses (32, 34).

3. 3. The battery cooling element (10) according to claim 1 or 2, characterized in that the multilayer composite foil (20) has a welded area (26).

4. 4. The battery cooling element (10) according to claim 1, characterized in that the multilayer composite foil (20) has a metallic material (22) on at least a part of the surface facing the interior chamber (40).

5. 5. A battery cooling element (10) according to claim 1, characterized in that a region (70) of the multilayer composite foil (20) facing the interior chamber (40) and having the metal material (22) on a surface thereof is designed to have a higher heat transfer coefficient than adjacent regions (60, 62) of the multilayer composite foil (20) facing the interior chamber (40) and having the metal material (22) on a surface thereof.

6. 6. The battery cooling element (10) according to claim 1, wherein the metallic material (22) has aluminum as an alloy component, preferably the metallic material (22) has an aluminum proportion of more than 85% by weight, particularly preferably the metallic material (22) has an aluminum proportion of more than 95% by weight.

7. 7. The battery cooling element (10) according to claim 1, characterized in that the area (70) of the multilayer composite foil (20) having the metallic material (22) on its surface facing the interior chamber (40) substantially corresponds to the area (70) of the multilayer composite foil (20) designed to be in contact with a battery module (50) and / or a battery cell.

8. 8. The battery cooling element (10) according to claim 1, characterized in that the multilayer composite foil (20) has a plastic material (26) on at least a part of its surface facing the interior chamber (40).

9. 9. A battery cooling element (10) according to any one of claims 1 to 8, characterized in that the area (60, 62) facing the interior chamber (40) and having the plastic material (26) on a surface of the multilayer composite foil (20) substantially corresponds to the area of ​​the contact surface with the body (30), the plastic material (26) being weldable to the body (30).

10. 10. Battery cooling element (10) according to any one of the preceding claims, characterized in that said plastic material (26) corresponds to LDPE or PE or PA or PP.

11. 11. The battery cooling element (10) according to claim 1, characterized in that the multilayer composite foil (20) has a plastic material (24) on at least a part of its surface, on its surface facing outwards towards the interior chamber (40).

12. 12. Battery cooling element (10) according to any one of the preceding claims, characterized in that the plastic material (24) is structurally viscous.

13. The battery cooling element (10) according to any one of the preceding claims, characterized in that the body (30) is made of LDPE or PE or PA or PP.

14. 14. The battery cooling element (10) according to any one of the preceding claims, characterized in that the body (30) comprises fastening elements for fastening battery cells and / or battery modules (50).

15. 15. The battery cooling element (10) according to any one of claims 1 to 14, characterized in that the body (30) is designed to be used as a load-bearing element of a battery module unit, in particular a battery module unit of a traction battery.

16. 16. A battery cooling element (10) according to any one of claims 1 to 15, characterized in that the body (30) is designed to be used as a constituent part of a casing of a battery module unit, in particular a battery module unit of a traction battery.

17. A battery module unit, in particular a traction battery, comprising a battery cell and / or a battery module (50) and a battery cooling element (10) according to any one of the preceding claims.

18. A method for manufacturing a battery cooling element (10), in particular a battery cooling element (10) for a traction battery, in particular a battery cooling element (10) according to any one of claims 1 to 16, said battery cooling element (10) having a body (30) and a three-dimensionally shaped multilayer composite foil (20), said body (30) and said three-dimensionally shaped multilayer composite foil (20) at least in area surrounding an internal chamber (40) of said battery cooling element (10) for containing a cooling medium (42), Providing a foil or a multi-layer composite foil (20), in particular a foil or a multi-layer composite foil (20) having a surface made of a metal material (22) or having a plastic surface on both sides, - finish shaping said foil or said multilayer composite foil (20) by a forming method, in particular by a deep drawing method or an internal high pressure forming method, into a three-dimensionally shaped foil or multilayer composite foil (20); connecting the foil or multi-layer composite foil (20) and the body (30).

19. The connection between the multilayer composite foil (20) and the body (30) is - applying a layer (26) of plastic material to said foil or to said multilayer composite foil (20), at least locally, in particular applying a layer (26) of plastic material to said metal material (22) or to said surface made of plastic material, said applied plastic material (26) being weldable to said body (30); and b. welding the body (30) and the layer (26) of plastic material to the battery cooling element (10).

20. 20. A method according to claim 19, characterized in that the finish shaping of the foil or of the multilayer composite foil (20) and the application of the layer of plastic material (26) are carried out in one working cycle.

21. 21. Method according to claim 19 or 20, characterized in that after providing the foil or the multilayer composite foil (20), first a layer (26) of plastic material is applied onto the foil or the multilayer composite foil (20), the foil or the multilayer composite foil (20) being welded to the body (30) in the area of ​​the applied layer (26) of plastic material and subsequently three-dimensionally finish-molded.

22. 22. The method according to any one of claims 19 to 21, characterized in that the foil or the multilayer composite foil (20) is three-dimensionally finish-formed against a shaping die (82), the shaping die (82) being in at least indirect contact with the body (30) during the finish-forming.

23. 23. The method according to claim 22, characterized in that the shaping die (82) is at least indirectly connected to the body (30) by a connecting element during the finish forming of the foil or multilayer composite foil (20).

24. 19. The method according to claim 18, characterized in that the multilayer composite foil (20) and the body (30) are connected in a form-fitting manner.

25. 25. Method according to any one of claims 18 to 24, characterized in that after connection of the foil or multilayer composite foil (20) with the body (30) a pressure differential test is carried out.