CN105098113B - 用于保持牵引电池的电池单元的装置和方法 - Google Patents
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Abstract
本发明公开了一种用于保持牵引电池的电池单元的装置和方法。车辆牵引电池单元保持件包括:侧壁,限定多个窗口,每个窗口由从窗口延伸的窗口凸缘环绕;上通道,从侧壁延伸并终止于上凸缘;下通道,从保持件侧壁延伸并终止于下凸缘,限定多个空气旁通窗口,上凸缘和下凸缘布置为与相邻的车辆牵引电池保持件互锁。车辆牵引电池组件包括:相邻的第一电池单元阵列和第二电池单元阵列,每个电池单元阵列具有关联的第一保持件和第二保持件,第一保持件和第二保持件具有限定气流窗口的侧壁以及由具有互锁凸缘的以一体化结构的形式形成的上通道和下通道,互锁凸缘使第一电池单元阵列与第二电池单元阵列结合。
Description
技术领域
本公开涉及用于保持电池单元(例如,混合动力车辆或电动车辆的牵引电池中的电池单元)的装置和方法。
背景技术
牵引电池(诸如混合动力车辆或电动车辆中的那些牵引电池)由互相连接的电池单元组成。低电压的电池单元通常连接为形成高电压阵列。该阵列的电池单元可通过上轨道和下轨道连接到一起,上轨道和下轨道通过紧固件、箍筋(column tie)、板和/或壳体连接。箍筋可能需要大量的装配时间和高昂的费用。它们可能不适宜承受重大的负载并且超过一定时间会变形。期望具有需要较少的装配时间、能承受重大的负载或冲击并能防止弯曲或变形的用于保持阵列的电池单元的装置和方法。还期望具有能满足特定电池需求的用于保持阵列的电池单元的装置和方法。
通过如下面所概括的本公开解决上述问题和其它问题。
发明内容
在一个实施例中,一种车辆牵引电池单元保持件包括:侧壁,限定多个窗口,每个窗口由从窗口延伸的窗口凸缘环绕;上通道,从侧壁延伸并终止于上凸缘;下通道,从保持件侧壁延伸并终止于下凸缘,限定多个空气旁通窗口,上凸缘和下凸缘布置为与相邻的车辆牵引电池保持件互锁。保持件可包括位于侧壁与上凸缘之间的第一波状部以及位于侧壁与下凸缘之间的第二波状部。第一波状部和第二波状部可适于与多个车辆牵引电池单元的边缘配合。例如,侧壁、上通道和下通道可以以一体化结构的形式由单一材料形成,例如,通过冲压形成。多个窗口可包括呈交替的形状和/或尺寸的窗口。
在各个实施例中,保持件可包括具有至少一个凸块的凸缘,所述至少一个凸块适于与相邻的保持件的凸缘互锁。保持件还可包括多个一体的加强肋,所述加强肋形成在上通道与上凸缘之间。
车辆牵引电池组件的一个实施例包括:相邻的第一电池单元阵列和第二电池单元阵列,每个电池单元阵列具有关联的第一保持件和第二保持件,第一保持件和第二保持件具有限定气流窗口的侧壁以及由具有互锁凸缘的以一体化结构的形式形成的上通道和下通道,互锁凸缘使第一电池单元阵列与第二电池单元阵列结合。
在各个实施例中,提供了一种车辆牵引电池组件,车辆牵引电池组件包括:第一电池单元阵列,具有第一保持件和第二保持件;第二电池单元阵列,设置为邻近第一电池单元阵列并具有第三保持件和第四保持件,其中,第一保持件、第二保持件、第三保持件和第四保持件中的每个包括限定气流窗口的侧壁,并具有由带有互锁凸缘的以一体化结构的形式形成的一体的上通道和下通道,所述互锁凸缘用于使第一电池单元阵列与第二电池单元阵列结合。
在各个实施例中,每个气流窗口由从侧壁突出的凸缘环绕。
在各个实施例中,保持件的下通道包括至少一个空气旁通窗口。
在各个实施例中,保持件通过冲压形成。
在各个实施例中,所述车辆牵引电池组件还包括多个一体的加强肋,所述加强肋在互锁凸缘与各自的侧壁之间延伸。
在各个实施例中,每个保持件包括位于侧壁与上通道之间的第一波状部以及位于侧壁与下通道之间的第二波状部,第一波状部和第二波状部与各个电池单元配合。
在一个实施例中,提供了一种装配车辆牵引电池的方法,所述方法包括:连接多个电池单元以形成第一阵列;将第一保持件附着到第一阵列,第一保持件包括:保持件壁,限定模压窗口;第一凸缘,从保持件壁的第一端延伸;通道凸缘,从与第一端相对的一端延伸,通道凸缘限定空气旁通窗口。
在各个实施例中,第一阵列包括第一侧和与第一侧相对的第二侧,所述方法包括将第一保持件附着到第一侧并将第二保持件附着到第二侧,第二保持件与第一保持件相同。
在各个实施例中,所述方法还包括将角撑板焊接至第一保持件。
在各个实施例中,所述方法还包括:连接多个电池单元以形成第二阵列,第二阵列具有第一侧和第二侧;将第三保持件附着到第二阵列的第一侧;将第四保持件附着到第二阵列的第二侧,第三保持件和第四保持件与第一保持件相同;连接第一阵列和第二阵列。
根据本公开的实施例可提供多个优点。例如,在装配车辆牵引电池的过程中,使用单片保持件相对于采用使用箍筋或多片紧固件的在先策略降低制造装配时间和成本。根据各个实施例的保持件的下通道内的空气旁通窗口减小特定的阵列中的电池单元之间以及相邻的阵列的电池单元之间的温度变化。
附图说明
图1描绘了代表性混合动力电动车辆(HEV)(诸如插电式混合动力电动车辆(PHEV)或全混合动力电动车辆(FHEV)),该HEV的车辆牵引电池具有根据本公开的实施例的保持件;
图2是根据本公开的一个实施例的具有保持件的车辆牵引电池组件的透视图;
图3是如图2所示的保持构件的透视图;
图4是图2的车辆牵引电池组件的另一透视图,示出保持构件的互锁凸缘。
具体实施方式
根据需要,在此描述了本公开的详细的实施例;然而,应理解的是,公开的实施例仅为示例性的并且可以以多种和替代的形式实施。附图不一定按比例绘制;可夸大或最小化一些特征以示出特定部件的细节。因此,在此所公开的具体结构和功能细节不应被解释为限制,而仅作为用于教导本领域技术人员以多种形式使用实施例的代表性基础。
例如,图1描绘了典型的混合动力电动车辆(HEV),诸如PHEV。混合动力电动车辆12可包括机械地连接至传动装置16的一个或更多个电机14。电机14能够作为马达或发电机运转。此外,混合动力传动装置16机械地连接至发动机18。混合动力传动装置16还机械地连接至驱动轴20,驱动轴20机械地连接至车轮22。当发动机18开启或关闭时,电机14能够提供推进和减速能力。电机14还用作发电机,并且能够通过回收在摩擦制动系统中通常将作为热损失掉的能量而提供燃料经济效益。在一定条件下,电机14还可通过允许发动机18在更有效的转速下运转并允许混合动力电动车辆12按照电动模式(发动机18停止)运转而减少车辆排放。
车辆牵引电池或电池包24储存可以被电机14使用的能量。车辆电池包24通常提供高电压直流DC输出。车辆牵引电池24电连接至一个或更多个电力电子模块。一个或更多个接触器(未示出)可在断开时使车辆牵引电池24与其它组件隔离,并在闭合时将车辆牵引电池24连接至其它组件。电力电子模块26还电连接到电机14,并且在车辆牵引电池24和电机14之间提供双向传输能量的能力。例如,典型的车辆牵引电池24可以提供DC电压,而电机14可能需要三相AC电流来运转。电力电子模块26可以将DC电压转换为电机14所需要的三相AC电流。在再生模式下,电力电子模块26可以将来自用作发电机的电机14的三相AC电流转换为车辆牵引电池24所需要的DC电压。在此的描述同样适用于纯电动车辆。对于纯电动车辆,混合动力传动装置16可以是连接至电机14的齿轮箱并且可以没有发动机18。
车辆牵引电池24除了提供用于推进的能量之外,还可以提供用于车辆其它电气系统的能量。典型的系统可包括将车辆牵引电池24的高电压DC输出转换为与车辆其它负载兼容的低电压DC供应的DC/DC转换器模块28。其它高电压负载(例如,压缩机和电加热器)可直接连接至高电压而不使用DC/DC转换器模块28。低电压系统可电连接至辅助电池30(例如,12V电池)。
车辆12可以是具有电气化的动力传动系的任何的车辆,例如,FHEV。车辆12还可以是包括由多个棱柱形的电池单元构成的电池组件的任何车辆。车辆12还可以是电动车辆、PHEV或类似的车辆,在这些类型的车辆中,车辆牵引电池24可通过外部电源36进行再充电。外部电源36可以连接至电插座。外部电源36可电连接至电动车辆充电设备(electricvehicle supply equipment(EVSE))38。EVSE 38可提供电路和控制以调节并管理电源36与车辆12之间的能量的传输。外部电源36可向EVSE 38提供DC电力或AC电力。EVSE 38可具有用于插入到车辆12的充电端口34中的充电连接器40。充电端口34可以是被构造为将电力从EVSE 38传输到车辆12的任何类型的端口。充电端口34可电连接至充电器或车载电力转换模块32。电力转换模块32可以调节从EVSE 38供应的电力,以向车辆牵引电池24提供合适的电压水平和电流水平。电力转换模块32可与EVSE 38交互,以协调向车辆12的电力传递。EVSE连接器40可具有与充电端口34的对应的凹入匹配的接口类型(pin)。可选择地,描述为电连接的各个部件可使用无线感应耦合传输电力。
所讨论的各种组件可具有控制并监视组件的运转的一个或更多个相关联的控制器。控制器可经由串行总线(例如,控制器局域网(CAN))或经由分立的导体进行通信。
图2和图4描绘了诸如车辆牵引电池24(图1)的车辆牵引电池,该车辆牵引电池24具有布置在一起的多个电池单元42以形成被进一步并排布置的阵列44a和44b。特定的阵列44a或44b中的电池单元42的数量和布置方式以及阵列44a和44b的数量和布置方式可依赖于特定的应用和实施方式而变化。间隔件46设置在相邻的电池单元42之间以允许空气在电池单元42之间流动。间隔件46还用作绝缘件,该绝缘件辅助使电池单元42之间的不被期望的电流传输最小化。每个阵列包括设置电池端子的顶表面43、与顶表面43相对的底表面45、相对的端部48和50以及相对的侧部52和54。相对的端部48和50被端板55a和55b(如图4所示)以及端部50上的对应的端板(未示出)覆盖。每个阵列44a和44b的相对的侧部52和54大体上被相对应的保持构件56覆盖。这样,图2中示出的组件包括总共四(4)个保持构件56。
例如,每个保持构件56与阵列44a或44b的电池单元42的关联的顶表面43和底表面45配合。角撑板(gusset)58(诸如通过焊接)紧固到每个保持构件56的每个角,从而每个保持构件56包括四个(4个)角撑板58。紧固件60可插入每个角撑板58中,以接合关联端板55的对应的螺纹孔,以将保持构件56固定到端板,从而固定阵列内的多个电池单元42。多个焊接螺母61可与上凸缘82(如图4中最佳示出的)和下凸缘76的相对应的孔对齐,随后针对阵列的保持和功能,用于将相邻的阵列44a和44b固定到一起或用于将阵列44a和44b固定成牵引电池包结构。为每个阵列44a和44b的每侧提供保持构件56,并且保持构件56附着到每个阵列44a和44b的每侧,从而在说明的代表性实施例中使用四个保持构件56。
保持构件56包括限定一系列的气流窗口62a-62i(如图3中最佳示出的)的保持壁或侧壁59。所述一系列的气流窗口62a-62i可包括以任意顺序布置的不同尺寸和/或形状的窗口,以为关联的电池单元42提供期望的冷却气流。在说明的代表性实施例中,椭圆形的窗口62a、62c、62e、62g、62i与大致呈矩形的窗口62b、62d、62f和62h以交替的方式布置。下通道70由一体化结构一体地形成,从保持壁59延伸并限定多个空气旁通窗口72。空气旁通窗口72与附着到阵列44a和44b的每侧的保持构件56的气流窗口62a-62i配合,以为多个电池单元42提供冷却,从而降低电池单元之间的温度变化。例如,根据电池包流动路径需求或用于液体冷却或制冷剂冷却的牵引电池包,气流窗口62a-62i可被重新构造或完全去除。
图3提供了根据一个实施例的代表性保持构件56的近视图。例如,保持构件56可包括以一体化结构的方式由实质上单一的材料(例如,金属板)一体地形成的多个特征或部分。在图3中示出的实施例中,保持构件包括限定一系列的气流窗口62a-62i的保持壁59,每个气流窗口由关联的凸缘64环绕。所述一系列的气流窗口可具有设计图案,例如,长椭圆形的窗口62a随后为矩形的窗口62b的以此类推下去的重复序列,如之前所描述的。窗口的形状、定向和定位可以根据应用而变化,以对阵列内的电池单元提供期望的被动和/或强制空气冷却。窗口62a-62i可以由冲压、打孔(die cut)或其他方式形成在保持壁59中,或者可以通过对保持壁59冲压、打孔或其他方式而形成。窗口62a-62i可具有环绕其的刚性凸缘64。刚性凸缘64从保持壁59突出并环绕窗口62a-62i的开口。诸如环绕矩形的窗口的那些凸缘的刚性凸缘64可包括相对于其它部分具有不同高度或深度的部分,这可依赖于关联的电池单元42的特定的形状和布置方式或者各种应用的具体封装考虑因素。刚性凸缘64向保持构件56提供额外的结构支撑,以允许其在电池运转、运输和操纵期间保持电池单元的同时承受负载或冲击并防止保持构件56弯曲或变形。
保持构件56具有从保持壁59的顶部延伸的第一波状部66以及从保持壁59的底部延伸的第二波状部68。第一波状部66和第二波状部68与电池单元和间隔件的边缘配合,以允许保持构件56与阵列结合到一起并固定电池单元。在某些实施例中,第一波状部66和第二波状部68可允许保持构件56扣合安装到阵列中。
第二波状部68延伸到与波状部68和保持壁59以一体化结构的形式一体地形成的下通道70。下通道70包括U形或C形截面,具有连接凸缘76的大致竖直部74。大致竖直部74限定多个空气旁通窗口72,所述多个空气旁通窗口72与多个气流窗口62a-62i配合以为阵列内的电池单元42提供冷却。在一个实施例中,空气旁通窗口的高度大约为5mm。下凸缘76可包括一个或更多个升高部或降低部,所述一个或更多个升高部或降低部可包含安装孔78。降低部可用作车辆牵引电池的支脚(foot)、底板或安装表面。安装孔78允许车辆牵引电池安装至诸如牵引电池包内的支撑结构或车辆的底部面板的表面。
再如图2和图3所示,第一波状部66延伸至上侧壁80,然后延伸至上凸缘82。多个V形的加强肋84与呈一体化结构的上侧壁80和上凸缘82一体地形成以支撑上凸缘82。上凸缘82包括多个延伸部或凸块86,一些延伸部或凸块86可包括如之前所描述的孔以及关联的焊接螺母。延伸部或凸块86被定位或布置为与由相邻的保持构件的上凸缘形成的互补的凸块或延伸部配合,从而它们将互锁并形成大致平坦且连续的表面。延伸部或凸块86向具有多个相邻的阵列的子组件提供额外的结构支撑。在某些实施例中,延伸部或凸块86可以不与相邻的保持构件的上凸缘互锁。它们可彼此嵌套以牢固的封装。
参照图4,相邻的保持构件56的互锁的上凸缘82形成大致平坦且连续的表面88。车辆牵引电池组件90包括保持构件56,保持构件56附着到每个阵列的侧部52、54、92和94。在一个实施例中,每个保持构件56由具有被设计为承受负载或冲击并防止弯曲或变形的冲压或打孔的窗口的一体化结构的单片冲压材料形成。在装配车辆牵引电池的过程中,使用单片保持构件56降低与使用箍筋或多片紧固件关联的制造装配时间和成本。
执行的热分析表明,相比利用现有的车辆牵引电池,利用本公开的车辆牵引电池对电池单元的冷却更均匀以及使车辆牵引电池组件更加热平衡。本公开提供了需要较少的装配时间、能承受重大的负载和冲击并能防止弯曲和变形的保持阵列的电池单元的装置和方法。本公开还提供能满足某些电池运输标准(例如,联合国试验和标准手册中的第38.3条(也被称作UN38.3))的保持阵列的电池单元的装置和方法。
虽然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本发明的所有可能的形式。更确切地,在说明书中使用的词语是描述性的词语而非限制性的词语,并且应该理解的是,在不脱离本发明的精神和范围的情况下,可以进行各种改变。此外,各个实施的实施例的特征可组合以形成本发明的进一步的实施例。
Claims (7)
1.一种车辆牵引电池单元保持件,包括:
侧壁,限定多个窗口,每个窗口由从窗口延伸的窗口凸缘环绕;
上通道,从侧壁延伸并终止于上凸缘;
下通道,从侧壁延伸并终止于下凸缘,限定多个空气旁通窗口,上凸缘和下凸缘布置为与相邻的车辆牵引电池保持件互锁。
2.根据权利要求1所述的车辆牵引电池单元保持件,还包括位于侧壁与上凸缘之间的第一波状部以及位于侧壁与下凸缘之间的第二波状部,第一波状部和第二波状部适于与多个车辆牵引电池单元的边缘配合。
3.根据权利要求1所述的车辆牵引电池单元保持件,其中,侧壁、上通道和下通道以一体化结构的方式由单一材料形成。
4.根据权利要求1所述的车辆牵引电池单元保持件,其中,所述多个窗口包括呈交替的形状的窗口。
5.根据权利要求1所述的车辆牵引电池单元保持件,其中,上凸缘包括至少一个凸块,所述至少一个凸块适于与相邻的车辆牵引电池保持件的凸缘互锁。
6.根据权利要求1所述的车辆牵引电池单元保持件,还包括形成在上通道与上凸缘之间的多个一体的加强肋。
7.根据权利要求1所述的车辆牵引电池单元保持件,其中,侧壁、上通道和下通道由单片的冲压金属板形成。
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