CN104512216A - 电池冷却设备 - Google Patents

电池冷却设备 Download PDF

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CN104512216A
CN104512216A CN201410515072.XA CN201410515072A CN104512216A CN 104512216 A CN104512216 A CN 104512216A CN 201410515072 A CN201410515072 A CN 201410515072A CN 104512216 A CN104512216 A CN 104512216A
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high voltage
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唐·D·普汉
杰苏斯·卡杜索
贝丝·安·达瑞珀尔
路易斯·罗佩兹
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Ford Global Technologies LLC
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    • B60—VEHICLES IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • H01M10/625—Vehicles
    • H—ELECTRICITY
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    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
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    • H01M10/66—Heat-exchange relationships between the cells and other systems, e.g. central heating systems or fuel cells
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    • B60—VEHICLES IN GENERAL
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    • B60H1/00—Heating, cooling or ventilating [HVAC] devices
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Abstract

一种电池冷却设备，所述电池冷却设备设置在车辆中，所述车辆包括被构造为调节车舱内的温度的气候控制系统。所述车辆还包括：电池室，设置在后备箱内；软装饰组件，至少部分地限定所述车辆的后备箱内的空间。所述车辆还设置有形成在软装饰组件的一部分上并支撑软装饰组件的一部分的刚性的隔热材料件，使得所述隔热材料件和所述一部分限定流体地连接车舱和电池室的管道，以冷却电池室。

Description

电池冷却设备
技术领域
本公开涉及一种电池电动车辆和电池电动车辆中高压电池的冷却。
背景技术
电动车辆和混合动力电动车辆通常具有高压电池，所述高压电池明显大于传统的内燃发动机车辆的电池。内燃发动机车辆的较小的电池通常为12V至14V，以为车辆的发动机的点火系统以及其它低压电附件供电。高压牵引电池在操作(包括充电和放电)期间趋向于更加容易受到温度升高的影响。
在乘用车中，牵引电池通常被封装在车辆的车厢中。普通车厢通常不被包括在车辆内的气候控制的区域中。这样的车厢的温度会通过电池发的热或通过外部环境而升高。因为被引导到电池的气流通常在到达电池之前由于电池被封装在其中的车厢中的热而经历温度升高，所以电池冷却效率会降低。
发明内容
一种车辆包括被构造为调节车舱内的温度。所述车辆还包括：电池室，设置在后备箱内；软装饰组件，至少部分地限定所述车辆的后备箱内的空间。所述车辆还设置有形成在软装饰组件的一部分上并支撑软装饰组件的一部分的刚性的隔热材料件，使得所述隔热材料件和所述一部分限定流体地连接车舱和电池室的管道，以冷却电池室。
所述车辆还可包括：气候控制系统，被构造为调节车舱内的温度；软装饰件，至少部分地限定所述车辆内的后备箱，电池室，设置在后备箱内；刚性的隔热材料件，形成在软装饰件的一部分上并支撑软装饰件的一部分，使得所述隔热材料件和所述一部分限定流体地连接车舱和电池室的管道，以冷却电池室。
所述软装饰件可包括织物。
所述软装饰件可以是地毯。
所述管道的一部分可通过所述软装饰件的一体壁形成。
所述管道可包括气流入口和气流出口，其中，形成隔热材料件的隔热材料具有隔热值，使得当入口气温是25摄氏度时，入口和出口之间的气温的升高不超过5摄氏度。
所述隔热材料可具有至少4K·m2/W的隔热值(R值)。
所述隔热材料可以是具有至少6mm厚度的发泡聚丙烯(EPP)。
所述车辆还可包括将车舱与后备箱在气候上分开的托盘，并且所述托盘限定连接车舱和管道的空气通风口。
一种高压牵引电池冷却设备设置有至少部分地覆盖电池组件的软装饰件。所述高压牵引电池冷却设备还包括隔热材料件，所述隔热材料件与所述软装饰件配合，以限定流体地连接到电池组件并被构造为将空气引导到电池组件的管道。
所述隔热材料件可由隔热值(R值)至少为4K·m2/W的隔热材料形成。
所述软装饰件可包括织物。
所述管道的一部分可通过所述软装饰件的一体壁形成。
所述管道包括气流入口和气流出口，其中，隔热材料可具有隔热值，使得当入口气温是25摄氏度时，入口和出口之间的气温的升高不超过5摄氏度。
所述隔热材料可以是具有至少6mm厚度的发泡聚丙烯(EPP)。
一种车辆设置有客舱和将客舱与后备箱在气候上分开并限定第一空气通风口的结构面板。所述车辆还包括至少部分地限定后备箱内的电池室的装饰组件，所述电池室限定第二空气通风口。隔热材料件一体地形成在所述装饰组件之上，以限定将来自客舱的空气引导到电池室的管道。
一种车辆可包括：客舱；面板，将客舱与后备箱在气候上分开并限定第一空气通风口；装饰组件，至少部分地限定后备箱内的电池室，所述电池室限定第二空气通风口；隔热材料件，一体地形成在所述装饰组件之上，并与所述装饰组件配合，以限定将来自客舱的空气引导到电池室的管道。
所述隔热材料件可由隔热值(R值)至少为4K·m2/W的隔热材料形成。
所述隔热材料件可包胶模制在所述装饰组件之上。
所述装饰组件可包括织物地毯，并且所述隔热材料件被布置为支撑所述地毯。
所述隔热材料可以是具有至少6mm厚度的发泡聚丙烯(EPP)。
在此描述的特定构造中，所述装饰件可以是至少由织物制成的地毯。
附图说明
图1示出了车辆的侧面示意图；
图2示出了车辆的后备箱区域的侧面示意图；
图3是电池组件的正前部透视图；
图4是与图3的电池组件配合的空冷系统的前部透视图；
图5是管道系统安装路径的上部的后部的透视安装视图；
图6是包括冷却系统的软装饰组件安装路径的前部透视图；
图7是软装饰组件安装路径的后部透视图；
图8是侧装饰面板的下侧的后部透视图；
图9是图8的侧装饰面板的截面图。
具体实施方式
参照附图披露了示出的实施例。然而，应该理解的是，所公开的实施例意图仅仅是可以采用各种和可替代的形式实施的示例。不需要按照比例绘制附图，为了显示具体组件的细节，可能会夸大或最小化一些特征。在此公开的具体结构和功能性细节不应当被解释为限制，而仅作为用于教导本领域的技术人员如何实施本公开的构思的代表性基础。
图1示出了车辆50A的示意性侧视图，车辆50A具有与后备箱54的区域分开的客舱52。结构面板、或封装托盘56用作车辆的客舱52和后备箱54之间的环境屏障。虽然封装托盘56不是完整的密封介质，但是其形成了车辆50A的在环境方面不同的两个气候区域。按照这种方法，客舱52可限定与后备箱54在气候上分开的环境。每个区域可具有单独的环境性能，从而每个环境的气候可彼此隔离。
车辆50A还设置有包括暖通空调(HVAC)单元58的气候控制系统。HAVC单元58通过调节循环空气的温度和湿度来控制客舱52的气候，以提高乘客的舒适度。通过车辆50A的前部吸进新鲜空气并通过HVAC单元58的鼓风机60在客舱52内吹送所述空气。可从前部区域沿向后的方向吹送空气，并使其在客舱52内循环。具体地讲，在温暖或潮湿的外部环境中，HVAC单元58的空气调节操作可被激活，以向客舱52吹送冷却的空气。从车辆外部引入新鲜空气可增大客舱52中的气压，这可允许通过至少一个抽气机62从车辆排气。虽然可允许气压从客舱泄到后备箱54，但是由于封装托盘56提供的环境屏障，客舱52内的空气温度通常低于后备箱54内的空气温度。
图2示出了与图1的车辆类似但带有电池冷却系统的车辆50B的后部区域的示意性侧视图。车辆50B设置有设置在后备箱54内的高压牵引电池组件64。示出的车辆50B代表具有燃烧推进动力源和电池推进动力源二者的混合动力电动车辆、具有作为其唯一动力的高压牵引电池组件64的纯电池电动车辆、或具有为车辆50B提供推进力的高压牵引电池组件64的任何车辆。虽然通过示例的方式在此讨论了混合动力电动车辆，但是其他类型的电池电动车辆类似地设置有高压电池，并且可得益于本公开的实施例。术语电池电动车辆通常是指具有高压电池的任何车辆。与高压电池的操作相关，靠近电池的区域的温度会经历通过电池发出的热而导致的温度升高。在至少一个实施例中，高压牵引电池组件64设置在车辆50B的后备箱54内。
参照图3，示出了说明性的高压牵引电池组件64。高压牵引电池组件64可以是包括几个部件(例如，主体电控模块(BECM)、具有内部DC/DC转换器单元的DC/DC转换器模块68)的组件。高压牵引电池组件64还可包括内部单体阵列，以储存和提供用于操作车辆50B的车辆牵引电机和其他系统的能量。电池单体阵列可与BECM、DC/DC转换器单元以及其他车辆部件电连通。BECM可响应于来自各种控制系统的输入信号而产生合适的控制信号。这些控制信号可用于激活和/或禁用各种车辆部件，并从高压牵引电池组件64提取电流。DC/DC转换器模块68可将来自电池单体的高电压转换成低电压以供车辆部件和系统使用。电池单体还可通过连接到外部电源或从车载发电机提供的电而被再充电。上述操作中的每个操作在执行时均会引起高压牵引电池组件64发热。
不同的电池构造也可适用于处理单独的车辆变量，车辆变量包括封装约束和动力需求。高压牵引电池组件64还可通过热管理系统被加热和/或冷却，以辅助保持期望的操作温度范围。热管理系统的一些示例包括空冷系统、液冷系统以及气液组合的系统。在至少一个实施例中，空冷系统设置有一个或更多个被提供动力的鼓风机、风扇和管道的组合。冷却系统使空气分布到高压牵引电池组件64的部件(包括DC/DC转换器模块68和内部电池单体)上，以帮助消散在车辆运行期间产生的热。
仍然参照图3，高压牵引电池组件64包括电池模块盖74，电池模块盖74可至少部分地限定容纳内部电池部件的电池室。电池模块盖74还可限定入口76和入口78。在至少一个实施例中，电池组件的入口76、78被定向为引导气流穿过电池的部件。在一些其他的实施例中，入口76、78可相对于高压牵引电池组件64倾斜地和/或按角度布置，以增强高压牵引电池组件64内的空气循环。此外，可有专用的DC/DC转换器入口80，以允许空气直接到达DC/DC转换器模块68。
图4示出了与图3的电池配合的冷却系统82的实施例，其中，至少一个管道被设置为与高压牵引电池组件64流体连通。第一气流管道84和第二气流管道86两者各自限定气流入口88和气流出口90。第一气流管道84的气流出口90可流体地连接到电池组件的入口76，第二气流管道86的气流出口90可流体地连接到电池组件的入口78。第二气流管道86的气流出口90还可流体地连接到DC/DC转换器入口80。气流管道84、86还可限定管壁92，以容纳并增强通过管道84、86内部的气流。可以预见的是聚丙烯管道可包括具有管状部的封闭部分。此外以及可选地，所述管道可包括通过附近的其它部件填补的局部敞开部分。在另一实施例中，管道的出口可靠近但不连接到电池的结构。
在至少一个实施例中，冷却系统82还设置有鼓风机单元94。鼓风机单元94可包括被提供动力的风扇以及排放口96，以在空气循环通过电池冷却系统82之后引导空气。鼓风机单元94可沿气流的方向相对于内部电池单体和DC/DC转换器模块68设置在下游。按照这种方法，当沿第一气流方向驱动鼓风机单元94时，鼓风机单元94可使气流方向偏移而通过第一气流管道84和第二气流管道86并穿过高压牵引电池组件64以起到冷却作用。鼓风机单元94可设置在电池盖排放口98附近，以抽取气流使其通过高压牵引电池组件64。鼓风机单元94还可被构造为使得排放口96靠近车辆的抽气机62设置，以净化来自车辆50B的空气。可以预见的是鼓风机可布置在气流路径的不同位置处，并依然运转以引导空气穿过电池。
参照图5，冷却系统82还可设置有上管道延伸件100，以与图4中示出的管道配合。上管道延伸件100可被构造为在结构封装托盘56和第一气流管道84的入口88之间以及在结构封装托盘56和第二气流管道86之间提供流体连接。上管道延伸件可具有单个入口102、第一出口104和第二出口106，第一出口104被构造为与第一气流管道84的入口88对应，第二出口106被构造为与第二气流管道86的入口88对应。上管道延伸件100还限定管壁108，以容纳并增强通过上管道延伸件100的内部的气流。
根据公开的实施例的第一气流管道84和第二气流管道86与上管道延伸件100的连接提供双空气路径电池冷却系统。所述两个路径设置在车辆50B在横向上相对的两侧上。按照这种方式，管道的路线可被设置为使得其被成形为与后备箱54的外周一致。这种管道的路线构造有助于优化可用的后备箱储存空间。此外，可提供具有用于使空气进入高压牵引电池组件64的两个分开的入口位置，以用于增强在电池的部件中的冷气流的分布。
空气通风口110设置在封装托盘56上，并且可用作用于使空气从客舱52进入到后备箱54中的流体通道。在至少一个实施例中，空气通风口110横跨车辆50B的横向跨度基本上位于封装托盘56的中部上。空气通风口110的基本上居中的位置可增强对于来自客舱52的循环空气的接收。
如上所述，后备箱54中的空气的温度通常高于客舱52中的空气的温度。期望在空气穿过靠近高压牵引电池组件64的各个管道时气温的任何升高最小化。最小化的气温变化可通过减少对车辆HVAC系统的需求以及对位于电池冷却系统附近的任何鼓风机的需求来提高整个系统的效率。较低速度的鼓风机操作不但减小冷却高压牵引电池组件64所需要吸取的能量，而且还减小与高速操作鼓风机相关的噪音。在至少一个实施例中，当入口气温是25摄氏度时，由管道外部环境温度导致的管道的入口和出口之间的气温的升高不超过5摄氏度。
第一气流管道84和第二气流管道86和/或上管道延伸件100可各自由具有高隔热性能的材料形成。高硬度发泡聚丙烯(EPP)、或乙烯丙烯二烃单体(EPDM)橡胶是合适的隔热材料的示例，通过所述高硬度发泡聚丙烯(EPP)、或乙烯丙烯二烃单体(EPDM)橡胶形成管道中一个或更多个管道的管壁。上述示例性材料中的任何一种可设置有气穴、或是气泡，以在保持隔热性能的同时减轻重量。另外，通过指定各个管道的管壁92、108的具体的壁厚，可进一步增强管道的隔热性能。足够的壁厚进而能够有助于确保电池冷却系统的总体目标效率。例如，管壁由刚性的泡沫状EPP材料形成，可期望具有至少6.35mm的壁厚。类似地，在可选的实施例中，管壁由EPDM材料形成，可期望壁厚大于12mm以实现类似的隔热性能。
可选地，可期望指定管道和/或电池冷却系统的目标隔热R值。使用这种方法，可评估具有可选择的壁厚的管壁的材料的列表，从而达到期望的冷却效率。在至少一个实施例中，管道的管壁具有至少4K·m2/W的隔热R值，以确保理想的系统性能。
可利用高压牵引电池组件64周围区域中的车辆装饰组件进一步辅助管理电池的热状态。参照图6和图7，通过电池保持架结构114和被构造为至少部分地隐藏高压牵引电池组件64的至少一个第一装饰组件118的组合来限定围绕高压牵引电池组件64的电池室112。另外设置第二装饰组件116，以包括隔热管道。第一装饰组件118和第二装饰组件116可以是软装饰组件。所述软装饰组件能够为车辆用户提供优美的界面，并且可包括柔性无支撑部(例如，地毯装饰组件)。在这样的情况下，地毯装饰组件可由织物材料部分地制成。
所述软装饰组件中的至少一个可设置有至少一个刚性的整体管道120。管道120可为一个或更多个软装饰组件的柔性部分提供刚性，从而作为结构支撑构件来操作。软装饰组件配合以遮蔽和容纳高压牵引电池组件64。管道120还可包括一对管道，所述一对管道流体地连接到车辆在横向上相对的两侧上的高压牵引电池组件64。所述一对管道中的每个均限定与客舱流体连接的内部通道，与上述实施例类似，出口将空气引导到高压牵引电池组件64。虽然描述了第一装饰组件118叠置在第二装饰组件116之上，但是可以预计的是可期望可选的叠置构造至少与后备箱54的内部空间的组件和外观相关。
在另一实施例中，第一气流管道和/或第二气流管道可被设置为与侧装饰面板一体的构件。图8和图9示出了这样的隔热管道122与侧装饰面板一体的构造。举例来说，隔热管道122利用刚性的结构泡沫材料包胶模制(over-mold)在地毯装饰件124上，其中，隔热管道122包括敞开的U形截面。所述截面的构造使得地毯装饰件124的一体壁126填补所述截面，以封闭由结构泡沫材料形成的开口部128。地毯装饰件124通常具有柔性部分，因此刚性的隔热管道122的使用增加了地毯装饰件124的刚性，并且隔热管道122可作为结构构件来操作，以提供衬托并支撑地毯装饰件124。这种方法可通过利用地毯装饰件124的下侧的表面来完成管道的管道截面的封闭来节省材料成本和重量。另外，一体的部件可减小组装成本并降低与在振动车辆操作条件下管道接触装饰件的下侧相关的嗡嗡声、吱吱声或咯咯声的风险。
图9示出通过图8的实施例截取的截面图。从截面可以看出，隔热管道122的至少一个侧壁130可与地毯装饰件124的下侧部132共线。这提供用于包胶模制隔热管道122的第一结合区134。还可提供至少一个额外的结合区136，使得隔热管道122牢固地附着到地毯装饰件124的下侧部132。
在此公开的实施例的另一优点在于优化了货物封装空间。在公开的实施例中，所述一对管道跨越到车辆的后备箱的横向相对的两侧，从而与后备箱的外部对应。此外，每个管道再接合在后备箱的上部处，并通过车辆中基本上居中位置处的空气通风口来连接到结构封装托盘。这样的居中位置有利于通过空气通风口接收来自客舱的被循环的经调节的空气。
虽然在上面描述了示例性实施例，但是并不意味着这些实施例描述了由权利要求所包含的所有可能形式。在说明书中使用的词语是描述性词语而非限制性词语，应该理解，在不脱离本公开的精神和范围的情况下能够进行各种改变。如之前描述的，各个实施例的特征可组合，以形成可能未明确描述或示出的本发明的进一步的实施例。虽然各个实施例可能已经被描述为提供优点或者在一个或更多个期望特性方面优于其它实施例或现有技术实施方式，但是本领域的普通技术人员应该认识到，根据具体应用和实施方式，可综合一个或更多个特征或特性，以实现期望的总体系统属性。这些属性可包括但是不限于成本、强度、耐用性、生命周期成本、可销售性、外观、包装、尺寸、可维修性、重量、可制造性、装配容易性等。这样，在一个或多个特性方面被描述为比其它实施例或现有技术实施方式效果稍差的实施例仍在本公开的范围之内，且可期望用于特定应用。

Claims (6)

1.一种高压牵引电池冷却设备，包括：
软装饰件，至少部分地覆盖电池组件；
隔热材料件，与所述软装饰件配合，以限定流体地连接到电池组件并被构造为将空气引导到电池组件的管道。
2.根据权利要求1所述的高压牵引电池冷却设备，其中，所述隔热材料件由隔热值至少为4K·m2/W的材料形成。
3.根据权利要求1所述的高压牵引电池冷却设备，其中，所述软装饰件包括织物。
4.根据权利要求1所述的高压牵引电池冷却设备，其中，所述管道的一部分通过所述软装饰件的一体壁来形成。
5.根据权利要求1所述的高压牵引电池冷却设备，其中，所述管道包括气流入口和气流出口，其中，形成所述隔热材料件的隔热材料具有隔热值，使得当入口气温是25摄氏度时，入口和出口之间的气温的升高不超过5摄氏度。
6.根据权利要求1所述的高压牵引电池冷却设备，其中，所述隔热材料件是具有至少6mm厚度的发泡聚丙烯。
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