DE102016216050B4 - Battery assembly and vehicle with such a battery assembly - Google Patents

Abstract

What is proposed is, among other things, a battery assembly (3) with a battery housing (4) in which at least one battery module (5) is held. The battery housing (4) has a frame-shaped support structure (7) which at least partially encloses the at least one battery module (5) laterally, a first, dimensionally stable lower shell (8) which is fastened or can be fastened to the support structure (7), and also a first, dimensionally stable lower shell (8) which is also fastened to the support structure (7 ) attached or attachable cover element (9). A second, flexible and/or supple lower shell (17) is arranged between the support structure (7) including the battery module (5) and the first, dimensionally stable lower shell (8), which separates an upper volume (18) of the battery housing (4) from a lower one The volume (19) of the same is hermetically sealed. The at least one battery module (5) is arranged in the upper volume (18) and a cooling device (20) of the battery assembly (3) is arranged in the lower volume (19). The second, flexible and/or supple lower shell (17) is part of said cooling device (20) and is in thermal contact with the module housing (6) of the at least one battery module (5).

Description

The invention relates to a battery assembly according to the combination of features of patent claim 1 of the invention. According to claim 8 of the invention, the same further relates to a vehicle, in particular a hybrid or electric vehicle, with such a battery assembly.

The DE 10 2009 058 809 A1 describes a so-called vehicle drive battery assembly with a two-part battery housing (upper and lower part), a battery cell group and a cooling device. A housing of the battery cell group has a fastening flange to which, on the one hand, a contact plate of the cooling device is attached via a screw connection and, on the other hand, the two parts of the battery housing are attached. Coolant lines of the cooling device are assigned to the contact plate. The contact plate is screwed to the said fastening flange via an edge profile of the same. A thermal insulation component is arranged between the contact plate and the lower part of the two-part battery housing. Furthermore, a spring element can be provided, which presses the contact plate against the battery cell group by means of a fastening rail to compensate for tolerances. In general, such battery assemblies have a hermetically sealed battery housing, which protects the battery components from dirt and moisture. The lower part of the battery housing, also referred to as the lower shell, is designed as a load-bearing component. Ie, the battery assembly is supported in/on the vehicle via said lower part. However, if there is a leak in the cooling system, it cannot be ruled out that leaking coolant will cause electrical errors or even damage electrical battery components.

From the DE 10 2011 107 607 A1 a vehicle battery with a cooling device is known, which, forming a coolant line, is formed by a first, flat metal sheet and a second, formed metal sheet, which are joined together. In addition, a deformable, heat-conducting, electrically insulating layer, in particular a soft silicone mat with ceramic additives, is provided, which mat is arranged between the flat surface of the first metal sheet and a surface of the vehicle battery to be cooled.

From the DE 10 2015 101 096 A1 a battery assembly with a battery housing is known, in which at least one battery module with at least one battery cell arranged in a module housing thereof is held, the battery housing having a frame-shaped support structure which laterally surrounds the at least one battery module, a base which forms the battery housing and is fastened to the support structure or attachable first, dimensionally stable lower shell and a cover element which is also attached or attachable to the support structure, a second lower shell in the form of a temperature control plate being arranged between the support structure including the battery module and the first, dimensionally stable lower shell, which separates an upper volume of the battery housing from a lower volume the same, wherein the at least one battery module is arranged in the upper volume and a cooling device of the battery assembly is arranged in the lower volume, and the second lower shell is part of said cooling device and is in thermal contact with the module housing of the at least one battery module.

From the DE 10 2010 038 600 A1 A battery assembly similar to that described above is known.

The object of the invention is to create an alternative battery assembly with regard to the prior art, which enables both simple and cost-effective assembly and disassembly of the same while ensuring a high level of crash and functional safety. A further object of the invention is to provide a vehicle, in particular a hybrid or electric vehicle, with a battery assembly of the type described above.

• - wobei das Batteriegehäuse eine das wenigstens eine Batteriemodul zumindest teilweise seitlich einfassende, rahmenförmige Tragstruktur, eine einen Boden des Batteriegehäuses ausbildende und an der Tragstruktur befestigte oder befestigbare erste, formstabile Unterschale sowie ein ebenfalls an der Tragstruktur befestigtes oder befestigbares Deckelelement aufweist,
• - wobei zwischen der Tragstruktur samt Batteriemodul und der ersten, formstabilen Unterschale eine zweite, flexible und/oder schmiegsame Unterschale angeordnet ist, die ein oberes Raumvolumen des Batteriegehäuses von einem unteren Raumvolumen desselben hermetisch dicht separiert, wobei
• - im oberen Raumvolumen das wenigstens eine Batteriemodul und im unteren Raumvolumen eine Kühlvorrichtung der Batteriebaugruppe angeordnet sind,
• - wobei die zweite, flexible und/oder schmiegsame Unterschale Bestandteil der besagten Kühlvorrichtung ist und in einem thermischen Kontakt mit dem Modulgehäuse des wenigstens einen Batteriemoduls steht, und
• - wobei die Tragstruktur ein fest mit derselben verbundenes Stützelement zur vertikalen Abstützung und Halterung des wenigstens einen Batteriemoduls an der Tragstruktur aufweist.

The task is solved by a battery assembly with a battery housing in which at least one battery module with at least one battery cell arranged in a module housing of the same is held,

• - wherein the battery housing has a frame-shaped support structure which at least partially encloses the at least one battery module laterally, a first, dimensionally stable lower shell which forms a bottom of the battery housing and is fastened or can be fastened to the support structure, and a cover element which is also fastened or can be fastened to the support structure,
• - wherein a second, flexible and/or supple lower shell is arranged between the support structure including the battery module and the first, dimensionally stable lower shell, which hermetically separates an upper volume of the battery housing from a lower volume of the same, whereby
• - the at least one battery module is arranged in the upper volume and a cooling device of the battery assembly is arranged in the lower volume,
• - wherein the second, flexible and/or supple lower shell is part of said cooling device and is in thermal contact with the module housing of the at least one battery module, and
• - wherein the support structure has a support element firmly connected thereto for vertically supporting and holding the at least one battery module on the support structure.

A battery assembly is created which reliably protects the electrical components of the battery module from any leakage of the cooling device. The stability of the battery assembly is preferably determined by the said support structure, so that the lower shell no longer necessarily has to be designed to be load-bearing. The essential components of the battery assembly are supported on the support structure. The storage of the battery assembly, for example in a vehicle, can therefore preferably take place via said support structure. Because the support structure has a support element that is firmly connected to it for vertical support and holding of the at least one battery module on the support structure, the battery module is advantageously fixed both in the vertical downward direction and in the horizontal direction and is therefore supported exclusively on said support structure .

The subclaims describe preferred developments or refinements of the invention.

The battery module is then preferably supported or can be supported on the support element by means of at least one module housing shoulder of the module housing arranged at a distance from a module housing base. By choosing the spacing of the module housing shoulder from the module housing base, the at least one battery module is supported or can be supported on the support element in such a way that the battery module partially extends through the support structure including the support element towards the first, dimensionally stable lower shell. This facilitates the thermal contacting of the second, flexible and/or pliable lower shell with the module housing.

As the invention also provides, a cooling plate of the cooling device is arranged between the first, dimensionally stable lower shell and the second, flexible and / or pliable lower shell, which cooling plate is preferably supported directly by means of at least one spring element on the first, dimensionally stable lower shell, which acts as an abutment or indirectly thermally contacts the second, flexible and/or supple lower shell via a heat-conducting foil under pretension. This measure ensures a functionally reliable thermal contact of the cooling plate on the module housing when any dimensional tolerances are compensated for.

It is preferably provided that a heat-conducting foil is also assigned to the module housing in the contact area with the second, flexible and/or pliable lower shell, which improves the desired heat exchange from the module housing to the cooling plate of the cooling device.

More preferably, the second, flexible and/or supple lower shell is formed by a thin-walled metal part or a metal foil. Metal is known to be a good conductor of heat. For example, the thin-walled metal part or the metal foil can be made of aluminum or an aluminum alloy or a stainless steel. Alternatively, the second lower shell can also be formed by a heat-conducting plastic part or a plastic film. For example, said plastic part or plastic film can consist of a silicone, which preferably contains inclusions and / or particles made of a heat-conducting material, e.g. B: metal particles and/or ceramic particles. Such a second lower shell advantageously fulfills both the task of a heat-conducting foil and a sealing function for hermetically sealing the upper volume from the lower volume of the battery housing. This measure makes an additional heat-conducting foil unnecessary.

As far as the at least one spring element is concerned, according to a simple and cost-effective embodiment, this can be formed by a resilient foam part, which preferably consists of a plastic foam.

The invention also relates to a vehicle, in particular a hybrid or electric vehicle, with a battery assembly of the type described above. As already indicated above, the battery assembly is preferably mounted in or on the vehicle via the support structure of the battery housing. For this purpose, the support structure can be assigned at least holding devices or can have at least one holding device.

• 1 äußerst schematisch ein mit einer erfindungsgemäß ausgebildeten Batteriebaugruppe ausgestattetes Kraftfahrzeug,
• 2 eine perspektivische Teilansicht der besagten Batteriebaugruppe (teilweise geschnitten),
• 3 die Einzelheit „Z“ nach 2, und
• 4 eine perspektivische Explosionsdarstellung der erfindungsgemäßen Batteriebaugruppe (teilweise geschnitten).

The invention is explained in more detail below using an exemplary embodiment shown schematically in the drawings. However, it is not limited to this, but covers all configurations defined by the patent claims. Show it:

• 1 extremely schematically a motor vehicle equipped with a battery assembly designed according to the invention,
• 2 a partial perspective view of said battery assembly (partially cut),
• 3 the detail “Z”. 2 , and
• 4 a perspective exploded view of the battery assembly according to the invention (partially cut).

1 first shows a vehicle 1, in this case a motor vehicle, with an electric motor 2 as a drive motor and a battery assembly 3 forming a traction battery. According to this exemplary embodiment, it is therefore a purely electrically operated vehicle 1. The invention of course also includes a so-called hybrid vehicle, which in addition to one or more electric motors 2 also has an internal combustion engine, or any other vehicle 1 which has or can have a battery assembly 2 of the type described below (not shown in the drawing).

According to the 2 until 4 the battery assembly 3 has a battery housing 4, in which at least one battery module 5, here only one battery module 5 shown, is held with at least one battery cell, not shown in the drawing, and arranged in a module housing 6 of the battery module 5.

The battery housing 4 has a frame-shaped support structure 7 that at least partially surrounds the said battery module 5 on the side. According to this exemplary embodiment, said support structure 7 consists of box and flat profiles, which are firmly connected to one another, in particular welded, and essentially follow the lateral contour of the battery module 5 based on the cuboid design of the battery module 5 selected according to this exemplary embodiment. A first, dimensionally stable lower shell 8, which forms a bottom of the battery housing 4, is attached to the support structure 7. Fastening is preferably carried out using fastening screws not shown in the drawing. The first lower shell 8 can be made of metal or plastic. In addition, the battery housing 4 has a cover element 9 (cf. 4 ), which according to this exemplary embodiment is also designed in the shape of a shell and can preferably be fastened to the support structure 7 by means of fastening screws (not shown in the drawing).

At least the cover element 9, but preferably both the cover element 9 and the first lower shell 8, are attached to the support structure 7 in such a way that an interior volume of the battery housing 4 is hermetically sealed from the outside world. In view of this, the cover element 9 and the first lower shell 8 are preferably fastened with the aid of sealing elements not shown in the drawing, for example ring seals, which are/are arranged in the area of the respective contact surfaces of the cover element 9 and the first lower shell 8 with the support structure 7.

Like that 2-4 As can be further seen, the support structure 7 has a support element 10 that is firmly connected to it, preferably welded, for vertically supporting and holding the battery module 5 inserted into the support structure 7. The support element 10 extends along the underside of the support structure 7 and protrudes into the free space enclosed by the support structure 7 by means of extensions 11 only in the area of the corners thereof. Corresponding to said extensions 11, the module housing 6 of the battery module 5 each has a module housing shoulder 12 arranged at a distance from the module housing base 12. By means of said module housing shoulders 12, the battery module 5 or its module housing 6 is supported vertically on the support element 10 of the support structure 7 in such a way that the battery module 5 faces the first, dimensionally stable lower shell 8, ie downwards, partially through the support structure 7 together with the support element 10 is enough (see esp. 2 and 3 ). According to this exemplary embodiment, the battery module 5 is fastened to the support structure 8 by means of fastening screws 14a, 14b, which in turn pass through through holes 15, 16, the latter preferably threaded holes, in the module housing 6 and in the support element 10.

Like that 2-4 can still be seen, a second, now flexible and / or supple lower shell 17 is arranged between the support structure 7 including the battery module 5 and the first, dimensionally stable lower shell 8. According to this exemplary embodiment, the second lower shell 17 is circumferentially clamped between the support structure 7 and the first dimensionally stable lower shell 8, whereby an annular seal is formed, so to speak. Through this measure, an upper volume 18 of the total interior volume of the battery housing 4 is hermetically separated from a lower volume 19 of the same. Depending on the choice of material for said second lower shell 17, the above-mentioned ring seal between the support structure 7 and the first lower shell 8 may be unnecessary, but this will be discussed in more detail below.

The battery module 5 is arranged in the upper volume 18. A cooling device 20 is arranged in the lower volume 19. The second, flexible and/or supple lower shell 17 is part of said cooling device 20 and is in thermal contact with the module housing 6, in particular its module housing base 12.

In addition, a known cooling plate 21 of the cooling device 20 is arranged between the first, dimensionally stable lower shell 8 and the second, flexible and / or pliable lower shell 17. The cooling plate forms at least one media line 22, which in 4 is indicated by dashed lines. According to this exemplary embodiment, the at least one media line 22 is integrated into a cooling circuit of the vehicle 1, which is not shown in the drawing.

With the help of a spring element 23, the cooling plate 21 is supported on the first, dimensionally stable lower shell 8 and indirectly contacts the second, flexible and/or pliable lower shell 17 via a heat-conducting foil 24 made of a thermally conductive material, for example made of a metal such as aluminum. With the help of the spring element 23, the thermal contacting takes place under prestress. As a result of the second lower shell 17 being designed to be flexible and/or supple, it is advantageously pressed with a large surface area against the contour of the module housing 6, in particular the module housing base 12, whereby an effective heat exchange is/is ensured. In this context, according to this exemplary embodiment, such a heat-conducting film 25 is also provided in the contact area between the module housing 6 and the second lower shell 17.

As far as the second, flexible and/or supple lower shell 17 is concerned, according to a first preferred embodiment variant of the invention, this can be formed by a thin-walled metal part or a metal foil. Metal is known to be a good conductor of heat. For example, the thin-walled metal part or the metal foil can be made of aluminum or an aluminum alloy or a stainless steel.

According to a second preferred embodiment variant of the invention, the second lower shell 17 can also be formed by a heat-conducting plastic part or a plastic film. For example, said plastic part or plastic film can consist of a silicone, which preferably contains inclusions and / or particles made of a heat-conducting material, e.g. B: metal particles and/or ceramic particles (not shown in the drawing). Such a second lower shell 17 advantageously fulfills both heat-conducting and sealing functions for hermetically sealing the upper volume 18 from the lower volume 19 of the battery housing 4. An additional heat-conducting film 25 can be dispensed with due to this measure.

As far as the spring element 23 is concerned, this is merely an example of a spring-elastic mat element, for example a spring-elastic foam part that can be produced easily and cost-effectively and is preferably made of a plastic foam, which in the assembly assembly applies prestress to the cooling plate 21 against the module housing 6. The invention is therefore not limited to this specific embodiment of the spring element 23, but also covers any other, suitable spring element 23 or a plurality of such spring elements 23, which in their entirety provide the cooling plate 21 with large-area contact against the second lower shell 17 and further against that Press module housing 6. For example, the desired contact pressure can also be achieved by a plurality of individual spring elements in the form of leaf or coil springs made of metal or plastic, which are evenly distributed over the cooling plate surface, or by a plate element made of metal or plastic with a plurality of molded-on or molded-on, resilient support webs (not shown in the drawing shown).

As already indicated above, the battery assembly 3 is preferably mounted in or on the vehicle 1 via the support structure 7 of the battery housing 4. For this purpose, the support structure 7 can be assigned at least one holding device or can have at least one holding device. Here, for example, a rigid connection or a resilient connection using elastomer bearings can be provided with the vehicle body (not shown in the drawing).

Like that 2 and 4 As can be seen, the support element 10 also forms outward-facing extensions 26. At least one of the extensions 26 corresponds to a disc-shaped fastening means 27 arranged above it. Said disc-shaped fastening means 27 is held and fixed in position by means of the fastening screw 14b. Both this extension 26 and the corresponding fastening means 27 have positive locking means 28 in the form of centering bolts and in the present case serve to fix the battery module 5 to the support structure 7 in the transverse direction and upwards.

Reference symbol list

1

vehicle

2

Electric motor

3

Battery assembly

4

Battery case

5

Battery module

6

Module housing

7

Support structure

8th

first subshell

9

Lid element

10

Support element

11

Extensions (support element 10)

12

Module housing base

13

Module housing paragraph

14a

Fastening screw

14b

Fastening screw

15

Through hole (module housing 6)

16

Through hole (support element 10)

17

second subshell

18

upper room volume

19

lower volume of space

20

Cooling device

21

cooling plate

22

Media management

23

Spring element

24

Thermal conductive foil

25

Thermal conductive foil

26

Extensions (support element 10)

27

Fasteners

28

Positive locking means

Claims (9)

Battery assembly (3) with a battery housing (4), in which at least one battery module (5) with at least one battery cell arranged in a module housing (6) of the same is held, - wherein the battery housing (4) has a frame-shaped support structure (7) which at least partially encloses the at least one battery module (5) laterally, a first, dimensionally stable lower shell (7) which forms a bottom of the battery housing (4) and is fastened or can be fastened to the support structure (7). 8) and a cover element (9) which is also attached or can be attached to the support structure (7), - A second, flexible and/or supple lower shell (17) is arranged between the support structure (7) including the battery module (5) and the first, dimensionally stable lower shell (8), which has an upper volume (18) of the battery housing (4). a lower volume (19) of the same hermetically sealed, whereby - the at least one battery module (5) is arranged in the upper volume (18) and a cooling device (20) of the battery assembly (3) is arranged in the lower volume (19), - wherein the second, flexible and/or supple lower shell (17) is part of said cooling device (20) and is in thermal contact with the module housing (6) of the at least one battery module (5), and - wherein the support structure (7) has a support element (10) firmly connected thereto for vertically supporting and holding the at least one battery module (5) on the support structure (7). battery assembly (3). Claim 1 , characterized in that the battery module (5) is supported or can be supported on the support element (10) by means of at least one module housing shoulder (13) of the module housing (6) arranged at a distance from a module housing base (12). battery assembly (3). Claim 2 , characterized in that by choosing the spacing of the module housing shoulder (13) from the module housing base (12), the at least one battery module (5) is supported or can be supported on the support element (10) in such a way that the battery module (5) is first , dimensionally stable lower shell (8) partially extends through the support structure (7) including the support element (10). Battery assembly (3) according to one of the Claims 1 until 3 , characterized in that a cooling plate (21) of the cooling device (20) is arranged between the first, dimensionally stable lower shell (8) and the second, flexible and / or pliable lower shell (17), which cooling plate (21) is arranged through at least one Spring element (23) is supported on the first, dimensionally stable lower shell (8) and thermally contacts the second, flexible and / or supple lower shell (17) directly or indirectly via a heat-conducting film (24) under pretension. Battery assembly (3) according to one of the Claims 1 until 4 , characterized in that a heat-conducting film (25) is assigned to the module housing (6) in the contact area with the second, flexible and / or pliable lower shell (17). Battery assembly (3) according to one of the Claims 1 until 5 , characterized in that the second, flexible and/or supple lower shell (17) is formed by a thin-walled metal part or a metal foil or by a plastic part or a plastic foil. battery assembly (3). Claim 6 , characterized in that said Plastic part or said plastic film has inclusions and / or particles made of a heat-conducting material. Vehicle (1) with a battery assembly (3) according to one of the Claims 1 until 7 . Vehicle (1) after Claim 8 , characterized in that the battery assembly (3) is mounted in or on the vehicle (1) via the support structure (7) of the battery housing (4).

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