DE102013113797A1 - Floor element, side part and cooling module and method for producing a cooling module - Google Patents

Abstract

The present invention relates to a floor element for a composite of a plurality of floor elements cooling module, in particular a cooling module of a multi-cell rechargeable battery, such. B is a lithium-ion battery, wherein each floor element consists of a first and a second, each having at least one flow channel having side part and a cooling ducts having connecting means, the cooling channels extending between the flow channels of the side parts. Furthermore, a side part, a cooling module and a method for producing a cooling module is claimed.

Description

The present application relates to a floor element, a side part and a cooling module for a rechargeable battery, and a method for producing a cooling module

In the PCT application of Akasol GmbH with the official publication number WO 2012/028298 describes a cooling module for a multi-cell battery module, in particular with accumulators, in particular lithium-ion cells, which is used to form a traction battery module or a traction battery module for vehicles with an electric drive train. Due to the modular design of a battery module, it can also be used for other purposes, eg. In stationary applications or small traction applications, such as in a wheelchair.

For example, a battery module system composed of a plurality of similar battery modules may be designed to cover a power range with an energy content of between 1 kWh and 400 kWh or more. If, for example, a battery module system is designed for a continuous power of 20 kW, peak power of, for example, 100 kW can nevertheless be demanded from the battery for acceleration purposes at short notice, as a result of which excellent acceleration values can be achieved. In the charging mode, for example, a charging power of 40 kW can be used.

The values given above are purely exemplary, but on the other hand represent values that can be achieved with commercially available lithium-ion batteries.

It is the object of the above-mentioned PCT application to provide a method of manufacturing a modular cooling module or alternative construction of a modular cooling module which also permits excellent heat exchange between the battery cells and the coolant. Furthermore, an extremely efficient production should also be ensured in the design of the Kuhlmoduls, which can be carried out with little cost of materials and low economic costs. The battery module is designed to be compact and thermally optimized, and in particular designed so that the operating temperature of the battery module or the battery module system can be kept within narrow limits in order to local overheating of individual cells, elevated temperatures of one or more cells or operation at avoid low cell temperatures as much as possible.

To achieve this object, in said PCT application, a cooling module is provided for a multi-cell battery module, the cooling module being in the form of a body having an internal space for receiving battery cells, the body being between an inlet area and an outlet area has one or more cooling passages extending parallel to each other and is at least partially formed from one or more lengths of a hollow profile. Heatsinks are used between the lateral hollow profiles of the cooling module to form compartments for receiving the battery cells and to lead heat out of the cells. Instead of cooling plates can also be used with cooling wings, which protrude laterally from the hollow profiles used in the interior of the cooling module and also form compartments for receiving the battery cells.

The operating temperature of the individual battery cells should normally have a working range of z. B. 18 ° C to 25 ° C, otherwise the life of the individual battery cells of a battery module can be drastically reduced in part. The fact that in previous cooling modules, the side panels of the cooling module forming cooling plates are typically provided with cooling circuits to realize the cooling of the battery cells, there may be problems with the cooling, since the dissipation of heat from the interior of the cells to the coolant is not always can be sufficiently ensured.

The object of the present application is to provide an alternative method for producing a modular cooling module or an alternative construction of a modular cooling module, which also allows excellent heat exchange between the battery cells and the coolant, preferably while improving the already existing stability of the cooling module. Furthermore, it should also be ensured in the alternative design an extremely efficient production, which can be carried out with little cost of materials and low economic costs.

To solve this problem, a first floor element is provided according to claim 1, ie a floor element for a composite of several floor elements cooling module, in particular a cooling module of a multi-cell rechargeable battery, such as. B a lithium-ion battery, wherein each floor element of a first and a second, each having at least one flow channel having side part and a cooling channels having connecting means, preferably one Connecting plate, consists, whose cooling channels extend between the flow channels of the side parts.

With such a construction, one deviates from the previous solution, in which simple heat-dissipating cooling plates or cooling vanes extend between cooling plates which extend around three sides of the cooling module and guide cooling liquid around these three sides of the cooling module in a plurality of mutually parallel paths. Instead, according to the invention, use is made of a construction in which connection devices are provided between the side parts which have cooling channels and are actively cooled, these connecting devices simultaneously guiding the cooling fluid from one side part of the floor element to the other, and it is no longer necessary to produce extruded hollow profiles to bend to form cooling plates, which extend around three sides of the cooling module.

Although leaves the known construction according to the WO 2012/028298 However, the additional bending operation is relatively complex and the cooling of the cells by heat removal via the connection means is not as uniform as in the present solution. This lack of uniformity can be a problem when higher thermal requirements are placed on a battery module, since the corresponding measures rather lead to a deterioration of the removal of heat. In the solution according to the invention not only an extremely efficient production is made possible with less material expenditure, but also an excellent heat dissipation and increased stability of the finished cooling module or the finished battery module.

According to a preferred embodiment of the present invention, the connecting device is attached approximately in the middle of each side part. In this way, a free space above and below the connecting device and between the side parts is formed, which is dimensioned so that the respectively used preferably cuboid battery cells, also called flat cells or pouch cells, have space in any free space, d. H. the available space in each free space is at least substantially completely filled by the corresponding flat cell and any other necessary construction elements. The free space that is created between two connecting devices of two adjacent floor elements can also be chosen so that at least one battery cell, preferably two battery cells substantially fill it.

It is also possible for the connection device to be arranged out of the center, provided that the distance between two adjacent connection devices of different floor elements is selected such that at least one battery cell can be arranged in the created free space. In this case, for example, a free space can be created only above or below the connecting device, such floor element then serve usually the upper or lower end of a cooling module.

The floor element is usually square or rectangular in plan view, but this does not limit the concrete shape of the floor element. It is equally possible to think of trapezoidal or polygonal designs or even of circular or elliptical shapes when the two opposite side parts are made curved. Although this is not necessarily considered optimal, but quite possible.

• a) Eine Konstruktion in Kunststoff, wie zum Beispiel aus einem Thermoplast oder Polyamid, mit ersten und zweiten extrudierten oder spritzgegossenen Seitenteilen in der Form von Kunststoffprofilen sowie einer extrudierten oder spritzgegossenen, dünnwandigen Verbindungseinrichtung mit mehreren im Vergleich zum Querschnitt der Strömungskanäle kleinere Querschnitte aufweisenden Kühlkanälen, wobei die Seitenteile und die Verbindungseinrichtung durch z. B. Heißgas- oder Ultraschallschweißen aneinander befestigt werden. Eine solche Konstruktion kann nicht nur sehr kostengünstig realisiert werden, sie ist darüberhinaus relativ leicht an Gewicht.
• b) Ferner kann mann sich einer Strangpresslösung bedienen mit ersten und zweiten als Strangpressprofile ausgebildeten Seitenteilen aus Metall mit einer dünnwandigen, hartgelöteten Verbindungseinrichtung mit mehreren im Vergleich zum Querschnitt der Strömungskanäle kleineren Querschnitten aufweisenden Kühlknälen, wobei die Seitenteile und die Verbindunbgsplatte z. B. durch Löten, Schweißen oder Kleben aneinander befestigt werden. Bisherige Erfahrungen haben gezeigt, dass auch eine solche Konstruktion durchaus strangpresstechnisch zu realisieren ist. Dabei ist es nicht zwangsläufig erforderlich, die Verbindungseinrichtungen auch als Strangpressteile zu realisieren, sie können beispielsweise auch durch eine Blechkonstruktion mit Abstandselementen zwischen einem oberen Deckelblech und einem unteren Bodenblech gebildet werden, um die Kühlkanäle zu realisieren, wobei die Abstandselemente auch durch Blechfaltungen realisierbar sind, die in einem oder in beiden der Blechteile vorgenommen werden können. Auch können die verschiedenen Komponenten mittels eines Tiefziehverfahrens hergestellt werden.
• c) Auch käme eine Druckgussvariante in Frage, bei der die Strömungskanäle der Seitenteile und die Kühlkanäle der Verbindungseinrichtung mittels beweglicher Schieber der Druckgussform relisiert werden können.

There are several possibilities in the production of the floor elements according to the invention, the following constructions are possible:

• a) A construction in plastic, such as a thermoplastic or polyamide, with first and second extruded or injection-molded side parts in the form of plastic profiles and an extruded or injection-molded, thin-walled connection device with a plurality of smaller compared to the cross section of the flow channels cooling cross-sections, wherein the side parts and the connection means by z. B. hot gas or ultrasonic welding are fastened together. Such a construction can not only be realized very cheaply, it is also relatively light in weight.
• b) Furthermore, man can use an extrusion solution with first and second formed as extruded side panels made of metal with a thin-walled, brazed connection device with a plurality of compared to the cross section of the flow channels smaller cross-sections having cooling knobs, wherein the side parts and the Verbindunbgsplatte z. B. by soldering, welding or gluing to each other. Previous experience has shown that even such a construction can be realized in terms of extrusion technology. It is not necessarily necessary to realize the connecting means as extruded parts, they can for example also be formed by a sheet metal construction with spacers between an upper cover plate and a lower floor panel to realize the cooling channels, wherein the spacer elements are also realized by sheet metal folds, which can be made in one or both of the sheet metal parts. Also The various components can be produced by means of a deep-drawing process.
• c) Also, a diecast variant would be in question, in which the flow channels of the side parts and the cooling channels of the connecting device can be relieved by means of movable slide of the die casting mold.

Also, a combination of the various manufacturing methods is conceivable to produce a floor element or a cooling module consisting of at least one floor element.

The floor elements according to the present invention are preferably used in combination with two insulating shells, which are glued to the two sides of the connecting device.

These insulating shells may also be used to seal open cooling channels of the connectors so that these cooling channels may be intentionally made open on one or both sides of the connectors, which may be advantageous in a die cast construction (but not only in such a construction). The bonding of the insulating shells (which consist for example of PET) to the connecting device promotes heat transfer, in particular if a good heat-conducting adhesive is used. The insulating is z. B. realized as a deep-drawn part, as a result, a relatively thin insulating with little material and high uniformity (in thickness) can be produced and a good heat dissipation is ensured.

To electrically isolate the Bateriezellen, they could also be isolated separately before insertion into the respective space of the floor elements elektische, this is z. B. by means of an adhesive tape.

Furthermore, preferably one battery cell is adhered to each plastic shell. This also promotes heat dissipation from the cell into the coolant.

It is particularly advantageous if an insulating plastic shell in the form of a deep-drawn shell for receiving a battery cell with recesses for the cell tabs or cell terminals is used. The insulating shell can also be made so thin that the heat dissipation from the cells into the cooling liquid is hardly disturbed.

The cooling module according to the invention can then be assembled simply by stacking a plurality of inventive and similar floor elements on top of each other.

In this case, an inner space is formed between the adjacent connection means of adjacent floor elements and the spaces are designed to receive battery cells, in particular flat, rectangular or square battery cells. Furthermore, each floor element can preferably be preassembled with two insulating shells and two cells (one each above and below the connection device), which is particularly easy to realize due to the glued construction, since an easily applicable "floor module" is created.

Alternatively, the floor elements can be stacked without preassembled flat cells to a cooling module and two flat cells with the associated insulating subsequently inserted into the corresponding rooms.

It is particularly advantageous if retaining springs are provided which hold the side parts of at least two stacked floor elements together, wherein the retaining springs have hook-shaped ends which engage in form-adapted niches of the side parts of the floor elements. This is a simple, yet safe construction that is also compact and easy to assemble.

The cooling module according to the invention is preferably complemented in such a way that the flow channels of each side part on the input side of the cooling module are in fluid communication with a distributor carrying coolant and the flow channels of each side part on the output side of the cooling module are in fluid communication with a collector carrying coolant.

Furthermore, it may be advantageous according to the invention if each floor element or a cooling module consisting of several floor elements is provided with at least one turbulator in each flow channel on the input side and / or on the output side. Such a solution, not only in the present inventive construction, but also in other constructions, such as in the construction according to the above-mentioned WO 210/2/028298 can be used in the cavities or flow passages described therein, although leads to the need for increased flow capacity for the coolant, but also increases the heat dissipation, which in turn is not only good for the Wehehaushalt, but also makes the cooling more efficient.

In this case, the turbulator can be designed so that there is a constant repetition between reduced and enlarged cross-section.

• a) an einer Längsseite eine U-förmige Nut,
• b) an der anderen Längsseite einen Steg, der in die U-förmige Nut eines benachbarten Seitenteils einpasst,
• c) einen hohlen Bereich, der einen Strömungskanal definiert mit einer seitlichen Öffnung oder mehreren seitlichen Öffnungen, die eine Fluidverbindung zu einem weiteren Fluid führenden Element wie eine Kühlkanäle aufweisende Verbindungseinrichtung ermöglicht bzw. ermöglichen,
• d) eine weitere sich in Längsrichtung des Seitenteils erstreckende Bohrung oder Passage zur Aufnahme eines Befestigungselements wie eine Schraube,
• e) mindestens eine und vorzugsweise zwei seitlich abstehende Nasen auf der der seitlichen Öffnung bzw. den seitlichen Öffnungen entgegengesetzten Seite des Hohlprofils, d. h. auf der äußeren Seite des Seitenteils, wobei die Nase bzw. Nasen Nischen zur Aufnahme der Haken von Halterungsfedern bilden, die benachbarte Seitenteile aneinder halten, beispielsweise derart, dass der Steg des einen Seitenteils in die Nut des oder eines benachbarten Seitenteils hineingedrückt ist.

The present invention also includes a side part for use in a floor element of a cooling module, but in particular not exclusively in a floor element of the type described above, wherein the side part is realized as a hollow profile, which has the following features:

• a) on one longitudinal side a U-shaped groove,
• b) on the other longitudinal side a web, which fits into the U-shaped groove of an adjacent side part,
• c) a hollow region defining a flow channel having a lateral opening or a plurality of lateral openings enabling a fluid connection to a further fluid-carrying element such as a connecting device comprising cooling channels,
• d) a further bore or passage extending in the longitudinal direction of the side part for receiving a fastening element such as a screw,
• e) at least one and preferably two laterally projecting lugs on the lateral opening or the side openings opposite side of the hollow profile, ie on the outer side of the side part, wherein the nose or nests form niches for receiving the hooks of support springs, the adjacent Keep side parts aneinder, for example, such that the web of the one side part is pressed into the groove of or an adjacent side part.

Such a construction can be relatively easily realized as an extruded element and fastened by relatively simple spring clips with lower or upper side parts.

• a) Herstellung mehrerer gleichartiger Etagenelemente, wobei jedes Etagenelement aus einem ersten und einem zweiten, je mindestens einen Strömungskanal aufweisenden Seitenteil sowie aus einer Kühlkanäle aufweisenden Verbindungseinrichtung besteht, deren Kühlkanäle sich zwischen den Strömungskanälen der zwei Seitenteile erstrecken,
• b) Bildung eines Stapels aus den Etagenelementen,
• c) Einführung der Zellen in Räume, die von den Verbindungseinrichtungen definiert sind,
• d) Anbringung eines Strömungsverteilers auf der Eingangsseite des Stapels an den dortigen Seitenteilen und Anbringung eines Sammlers auf der Ausgangsseite des Stapels an den dortigen Seitenteilen,
• e) Verschließen der Strömungskanäle der Seitenteile auf den dem Strömungsverteiler bzw. dem Sammler abgewandten Enden der Strömungskanäle der Seitenteile und
• f) Verbindung der Etagenelemente mittels Anbringung von Halteklammern bzw. Haltefedern und/oder eines Klebstoffs und/oder mittels Schweisen oder Ultraschallschweisens, um die Etagenelemente aneinander zu halten.

Finally, the present invention also includes methods for manufacturing a cooling module of a rechargeable cell battery module. According to a first variant, the method comprises the following steps

• a) producing a plurality of similar floor elements, wherein each floor element consists of a first and a second, each having at least one flow channel side part and a cooling channels having connecting means, the cooling channels extending between the flow channels of the two side parts,
• b) formation of a stack of the floor elements,
• c) introduction of the cells into spaces defined by the connection means,
• d) attaching a flow distributor on the input side of the stack to the local side parts and attaching a collector on the output side of the stack to the local side parts,
• e) closing the flow channels of the side parts on the flow distributor or the collector facing away from the ends of the flow channels of the side parts and
• f) connection of the floor elements by means of attachment of retaining clips and / or retaining springs and / or an adhesive and / or by means of welding or ultrasonic welding in order to hold the floor elements together.

In a second variant of the method according to the invention, in each case one cell is preferably attached to each side of each connecting device, and the tier elements are subsequently assembled into a stack. This second variant of the method according to the invention is particularly easy to handle and, in particular, good to use if the method further Step of attaching insulating shells on the two sides of the connecting means and on the flat sides of the battery cells comprises. In this case, the insulating shells are preferably applied prior to assembling the floor elements in a stack on this and the corresponding battery cells are only then applied to the exposed side of the insulating shells. Alternatively, the insulating shells can each be applied to one side of a cell and then the free side of each insulating shell to a connecting device of a single floor element. Also, an insulation of the battery cells in the form of an adhesive tape is possible.

It is particularly expedient if a plastic foam is arranged between the cells of adjacent cell pairs and on the uppermost and lowermost cells of the battery module. Such a design presses - when the individual floor modules are placed in a housing - the individual elements of the stack together. As a result, the entire battery module is on the one hand uniformly mechanically stressed even with thermal strains and on the other hand protected against vibration.

Further, for fire prevention purposes, a sheet-like fire protection material may be provided for preventing the spread of cell fire between the connection means and the cells.

It is particularly advantageous if the cooling module composed of the floor elements is arranged in a housing which is made of plastic and which delimits the cooling module on at least three sides, which is equipped with at least one bursting area. So if an increased pressure in the battery module should arise for whatever reason, the housing will give way deliberately in the bursting area and reduce the pressure without exploding immediately.

Furthermore, the cooling module composed of the floor elements can be arranged in a plastic housing which delimits the cooling module on at least two mutually opposite sides, which sides are parallel to the planes of the floor elements, and the corresponding sides of the housing are designed with a concave curvature , As a result, the foam-biased cells counteract this curvature, preferably in such a way that the curvature of the corresponding sides of the housing is canceled. This not only exerts a desired pressing force on the individual cells, which ensures a uniform heat transfer and a mechanical fixation, but the battery module is given a fairly uniform shape in the form of a cuboid, which allows the accommodation of several similar modules in a narrow container ,

Furthermore, for this inventive design also many of the previous interpretation according to the WO 2012/028298 current benefits. For example, the side parts in the form of hollow profiles reproducible in a production plant can be produced inexpensively, and with very little material waste, since now simple hollow sections can be used, which have a cooling passage and can be prefabricated in an independent previous step to a desired length or in the mass production of cooling modules are made in the desired length, whereby a series production of cooling modules in larger quantities is possible.

However, in the present invention, the production of the hollow profiles as extruded parts is not limited only by the use of z. As aluminum or an Al alloy as a starting material, but also made of plastic and it can be produced with relatively thin wall thicknesses of the hollow profiles of about 0.5 to 5 mm, a rigid structure, since the walls of the hollow sections not only the leadership of coolant , but also serve to stiffen the cooling module. Furthermore, the thin-walled construction leads to a lightweight cooling module.

In the invention, but also the connecting means can be made as extruded parts, since the plurality of cooling channels favors the heat dissipation even in a material with low thermal conductivity. The use of plastic also promotes the reduction of weight. However, even light metals, such as. As aluminum or magnesium or their alloys, used as a starting material for the hollow sections.

Hollow sections can be made in longer lengths of several meters and the finished profile can, for. B. by a saw ("flying saw") are divided to a desired length as soon as a strand section is sufficiently solidified.

The fact that the individual floor elements can be stacked, a modular design of the cooling module can be accomplished, since a desired height of the cooling module can be achieved simply by selecting a vorgebaren number of floor elements. This means that different sizes of cooling modules can be easily produced in a production plant, since the same starting material can always be used for the individual battery modules, which can be cut to a desired length as required and simply varied in height by the required number of hollow profiles can be.

The distributor and the collector can be designed in the same way as described in the aforementioned WO document in the present invention and can also be produced as extruded parts.

Advantageous embodiments of the invention are described in the subclaims, the description and the figures.

The invention will be explained in more detail below on the basis of exemplary embodiments with reference to the drawing, in which:

1A to 1G Representations of a first cooling module, wherein the 1A a perspective view of the cooling module; the 1B a perspective view of a floor element of the cooling module, 1C a front view of the floor element of 1A ; the 1D an enlarged section corresponding to the section line CC of 1C ; the 1E an enlarged perspective view of one end of the hollow profile of the side part of the floor element of 1C ; 1F a possible configuration of a turbulator, and the 1G an attachment possibility of two side parts together,

2A to 2C Representations according to the 1B to 1D from another form of a floor element,

3A to 3C , Representations according to the 1B to 1D from another form of a floor element,

4A to 4C Representations according to the 1B to 1D from another form of a floor element,

5A & 5B Representations of other cooling modules, wherein the 5A a cooling module with installed cooling plates and 5B show a similar cooling module with integrated cooling wings,

6A & 6B Exploded views of the in the 5A & 5B used floor elements with two battery cells,

7 a perspective view of an insulating shell,

8th a perspective view of a floor element with two inserted battery cells and two inserted insulating shells,

9 a perspective view of a cooling module with inserted battery cells,

10 a perspective view of a floor element with inserted fire protection element,

11 a perspective view of a floor element with a foam pad,

12A to 12C a perspective view of a housing with a housing cover with concave curvature, it would be nice if the existing drawings of 12B and 12C could be made larger, so that the details are easier to see)

13A & 13B a perspective view of a side of the housing of 12A Seen from the inside or an enlarged sectional view of this page in the circled area,

14A & 14B 14A shows a representation of a battery module with an installed board of a battery management system and the 14B shows a schematic representation of the attachment of a board of a battery management system to battery cells of a cooling module,

15A & 15B schematic Dartstellungen a temperature or growth sensor between adjacent battery cells of a battery module.

Features having the same or a similar function will be denoted by the same reference numerals below, and it goes without saying that the description given for components or component functions in connection with an embodiment also apply to other embodiments the same reference numbers are used unless otherwise stated.

The 1A shows a perspective view of a battery module 1 with a cooling module according to the invention 10 , This in normal operation for cooling the battery cells 11 of the battery module 1 is used, but at low outside temperatures can also be used to the battery cells 11 to warm up.

The cooling module 10 has a substantially cuboid shape and has in its entrance area a manifold 12 and in its exit area a collector 14 on. The distributor 12 and the collector 14 each have a connection or spout 16 . 18 on, through which the coolant can be added or removed.

The cooling module 10 consists of several floor elements 20 together, in the example of the 1A six floor elements 20 stacked on each other to the cooling module 10 to build. The cooling module 10 is in particular a cooling module of a multi-cell rechargeable battery, such. B of a lithium ion battery, wherein the cells in 1 are not apparent. Specifically, it consists of the 1B to 1E visible every floor element 20 from a first and a second, at least one flow channel 21 respectively. 21 ' having side part 22 . 24 as well as from a cooling channels 26 having connecting means 28 whose cooling channels 26 between the flow channels 21 . 21 ' the side parts 22 . 24 extend. The side parts 22 and 24 , which are the same in cross section and can be cut from an extrusion, are in cross section in 1E shown.

The distributors mentioned above 12 and collectors 14 are frontally to the corresponding side panels 22 respectively. 24 attached, by screws 27 by suitable positions of the distributor and the collector in the passages 29 . 29 ' the side parts 22 and 24 intervene (see 9 ), where seals 25 between the distributor 12 and the side panel 22 and between the collector 14 and the side panel 24 are provided and the distributor 12 and the collector 14 Have openings that communicate with the flow channels 21 respectively 21 ' communicate. The flow channels 21 . 21 ' and the screwing passages 29 . 29 ' of the 1E are by respective elongated hollow passages of the extrusion of the 1E educated.

How out 1A can be seen at the manifold or the collector opposite backs 30 . 30 ' the side panels a continuous plate 31 by means of other screws (not shown) sealingly attached, which also in the screw passages 29 . 29 ' intervention. The plate 31 stiffens a so assembled cooling module 10 and seal the Rear sides of the flow channels 21 . 21 ' the side parts 22 . 24 from.

It is also conceivable interpretation in a respective side part 22 . 24 own collector 12 and its own distributor 14 at a respective end of the side part 22 . 24 has (not shown). Ie. that the cooling liquid only by a flow channel 21 . 21 ' each side part 22 . 24 between a own collector 14 and its own distributor 12 flows.

Furthermore, there is also the possibility that a side panel 22 at one end with the distributor 12 is connected and the collector 14 on the second side part 24 at the distributor 12 opposite end of the second side part 24 is attached (also not shown).

The design of the distributor 12 and the collector 14 can be done the same way as in the WO 2012/028298 described in detail and here in the 9 is shown. The content of this WO 2012/028298 is hereby made part of the present application.

The flow channels 20 . 20 ' the side parts 22 respectively. 24 in this example are on the backsides 30 . 30 ' the side parts 22 respectively. 24 by means of sealed strips (not shown) or glued-on or welded-on strips or individual plugs inserted into the flow channels 21 . 21 ' at the backs 30 . 30 ' be used or otherwise sealed fluid-tight.

The connection device 28 is approximately in the middle of each side part 22 respectively. 24 attached and forms, as from the 1B visible, depending on a free space 32 . 32 ' above and below the connection device 28 and between the sides 22 and 24 , To the cooling channels 26 the connection device 28 fluidly with the flow channels 21 . 21 ' the side parts 22 respectively. 24 To connect, either the wall areas of the side panels 22 respectively. 24 defining the flow channels, provided with a continuous slot in which the corresponding side of the connecting device 28 is used, or the flow channels 21 . 21 ' are made as all-round closed cavities and the side wall milled out to form a slot which is the corresponding side of the connecting device 28 receives. The latter is the preferred solution since it can then be more certain that a fluid-tight connection will be made at the conforming ends of the slots.

In the finished construction, as in the 1A Thus, a path for the cooling liquid is created, which proceeds as follows:
The cooling liquid is removed by means of a pump (not shown) a supply (also not shown) and via a line, not shown in the input grommet 16 of the distributor 12 fed. The internal cavity of the distributor 12 communicates with the six stacked side panels 22 , so that a uniform flow in each flow channel 21 the six side panels 22 he follows. From the flow channels 21 the coolant also flows evenly into the individual cooling channels 26 the connecting devices 28 over and through them. At the ends of the cooling channels 26 adjacent to the side panel 24 the coolant flows into the flow channels 21 ' the side parts 24 and from there into the inner cavity of the collector 14 , From there, the coolant leaves the collector 14 over the outlet grommet 18 and flows back via a line not shown and at least one heat exchanger, not shown, back into the reservoir.

In other words, the cooling module 10 designed so that the flow channels of each side panel on the input side of the cooling module with a coolant-carrying manifold 12 and the flow channels of each side part on the output side of the cooling module 10 with a coolant leading collector 14 in Fluiverbindung stands.

As can be seen, the floor elements 20 In plan view, preferably square or rectangular, but they could instead have a different shape such as a triangular shape in plan view.

The construction according to the 1A to 1E may consist of first and second extruded or injection molded side panels 22 . 24 in the form of plastic profiles, as well as an extruded or injection molded, thin-walled connection device 28 , with several compared to the cross-section of the flow channels 21 . 21 ' having smaller cross-sections cooling channels 26 , with the side parts 22 . 24 and the connection device 28 be secured together by hot gas or ultrasonic welding. The plastic that is used here for the side parts and the connecting device is, for example, polyamide.

The 2A to 2C show an alternative solution, which viewed from the form of the solution according to 1A to 1E is very similar. The difference is that here the first and second formed as extruded side panels 22 and 24 made of metal, z. Al, Cu, or Mg, or an Al, Cu, or Mg alloy, with a thin-walled, brazed, or welded joint 28 , also made of metal, preferably of the same metal, with several in comparison to the cross section of the flow channels 21 . 21 ' having smaller cross sections cooling channels 28 in which the side parts and the connection device are fastened to one another by soldering, welding or gluing. It would also be conceivable to have an injection-molded connecting device 28 , eg according to 1B , with side parts made of metal according to 2A to use or vice versa, to a floor element 20 to realize.

The connection device 28 could also consist of several preferably juxtaposed and parallel to each other arranged smaller extruded profiles having microchannels.

You can do the construction according to the 2A to 2C summarize as follows:
There are lateral extruded profiles 22 . 24 made of metal such. As aluminum before, with a thin-walled, brazed cooling plate 28 with microchannels 26 be connected to each other. The connection of the three parts 22 . 24 and 28 done by soldering, welding or gluing.

Again, the distribution takes place in the finished module 10 about manifolds 12 . 14 on one side of the module 10 while completing the profiles 22 . 24 by means of a plate 31 (not shown here) on the backs 30 . 30 ' the side parts 22 . 24 or the cooling module 10 is accomplished.

In a further variant, the floor element 20 as in the 3A to 3C shown to be realized as a diecast part, usually made of aluminum, an aluminum alloy such as LM 40 or magnesium or a magnesium alloy such as AlMg.

One can diecasting according to the 3A to 3C summarize as follows:
There is a heat sink 22 . 24 . 28 in die-cast design, with the main flow channels 21 respectively. 21 ' be realized via slide. Also the open cross channels 26 are made by sliders. As a slider, movable inserts of a die-casting mold are understood, which are inserted in the production of the die-cast part in the mold and pulled out to release the part of the die-casting mold.

The open cross channels 26 be on the top and the bottom in 3A to 3C closed by plate-shaped elements to form closed cooling channels. One possible embodiment of the plate-shaped elements is in the form of insulating shells 40 in the 7 described in more detail.

Again, the distribution of the cooling liquid takes place in the cooling module 10 about manifolds 12 . 14 on the front side, and it completes the profiles 22 . 24 with a plate 31 on the back, as described above.

The 4A to 4C show a construction similar to the 3A to 3C at the open areas 23 in the connection device 28 are provided ( 4 C). The open areas 23 the connection device 28 form open cooling channels of the connecting device 28 , To seal the open cooling channels up or down is z. B. an insulating shell 40 (please refer 7 ) from above or from below to the connecting device 28 glued by means of a suitable adhesive (see 4B and 4C for one with insulating shells 40 provided connecting device), also is a different connection of the insulating shells 40 conceivable with the connecting device. The insulating shell 40 is preferably a shell made of PET and the connecting device 28 is z. B. manufactured as an aluminum die-cast part.

In the 4C is also an optional, in particular made of GRP pipe 68 (see also the 10 ), which can be used to achieve a higher pressure load capacity of the cooling element (mechanical pressure).

Returning to the 1E It can be seen that the hollow profile on one longitudinal side of a groove 42 and on the other longitudinal side a spring 44 wherein, when forming a stack 45 the hollow profiles the spring 44 one side part 22 respectively. 24 of a floor element 20 in the groove 42 of the adjacent side part 22 respectively. 24 is inserted.

Furthermore, you can see from the 1E and 1G that's the side parts 22 and 24 forming hollow profile two lateral noses 46 and 48 each having a niche 50 . 52 form, in which the hook-shaped ends 54 . 56 the generally C-shaped spring clips 58 intervene to the pile 45 together. The spring clips, their preferred spatial arrangement and their holding function are also from the 1A seen.

• a) an einer Längsseite eine U-förmige Nut 42,
• b) an der anderen Längsseite eine Feder (bzw. einen Steg) 44, der in die U-förmige Nut eines benachbarten Seitenteils 22 bzw. 24 einpasst,
• c) einen hohlen Bereich, der einen Strömungskanal 21, 21' definiert mit einer seitlichen Öffnung oder mehreren seitlichen Öffnungen, die eine Fluidverbindung zu einem weiteren Fluid führenden Element in Form der Kühlkanäle 26 aufweisende Verbindungseinrichtung 28 ermöglicht bzw. ermöglichen,
• d) eine weitere sich in Längsrichtung des Seitenteils erstreckende Bohrung 29, 29' oder Passage zur Aufnahme eines Befestigungselements wie eine Schraube,
• e) mindestens eine und vorzugsweise zwei seitlich abstehende Nasen 46, 48 auf der der seitlichen Öffnung bzw. den seitlichen Öffnungen entgegengesetzten Seite des Hohlprofils, d. h. auf der äußeren Seite des Seitenteils, wobei die Nase bzw. Nasen 46, 48 Nischen 50, 52 bilden, die zur Aufnahme der Haken 54, 56 von Halterungsfedern 58 ausgelegt sind, wobei die, vorzugsweise blattfederartige, Halterungsfedern 58 benachbarte Seitenteile 22 bzw. 24 aneinder halten, beispielsweise derart, dass die Feder 44 des einen Seitenteils in die Nut 42 des oder eines benachbarten Seitenteils hineingedrückt ist.

The extrusion parts, which are in 1E and 1G are shown and side panels 22 respectively. 24 form all of the following characteristics:

• a) on one longitudinal side a U-shaped groove 42 .
• b) on the other longitudinal side a spring (or a web) 44 which is in the U-shaped groove of an adjacent side part 22 respectively. 24 fits,
• c) a hollow area, which has a flow channel 21 . 21 ' defined with a lateral opening or a plurality of lateral openings, which fluidly connects to a further fluid-carrying element in the form of the cooling channels 26 having connecting device 28 enable or enable
• d) another extending in the longitudinal direction of the side part bore 29 . 29 ' or passage for receiving a fastener such as a screw,
• e) at least one and preferably two laterally projecting noses 46 . 48 on the side opening or the side openings opposite side of the hollow profile, ie on the outer side of the side part, wherein the nose or noses 46 . 48 American 50 . 52 form, which take up the hook 54 . 56 of retaining springs 58 are designed, wherein the, preferably leaf spring-like, retaining springs 58 adjacent side parts 22 respectively. 24 hold on, for example, such that the spring 44 of a side part in the groove 42 of the or an adjacent side part is pressed.

In other words, the spring clips or retaining springs 58 Therefore, provided to the side panels 22 . 24 at least two stacked floor elements 20 to hold each other, with the retaining springs 58 hook-shaped ends 54 . 56 have that in shape-adapted niches 50 . 52 the side parts 22 . 24 the floor elements 20 intervention.

Furthermore, one sees so-called turbulators 60 in the flow channel 21 . 21 ' of the 1E , These are additional parts that are used in the channels of the cooling profiles to reduce the cross section. The goal is to get from a laminar flow to a turbulent flow and thus to increase the cooling performance. At least one turbulator may be provided in each flow channel on the input side and / or on the output side. The pressure drop due to the turbulator (s) must be taken into account during the design.

1F shows a possible configuration of a turbulator 60 , with alternately arranged spheroidal regions of larger diameter and cylindrical sections of smaller diameter. In particular, the turbulators are designed so that they perform a constant repetition between reduced and enlarged cross-section.

The 5A & 5B show illustrations of other cooling modules 10 , The 5A shows a cooling module 10 with installed cooling plates 62 and 5B a similar cooling module 10 with integrated cooling wings 64 whose construction according to WO 2012/028298 is. Every floor 20 comprises at least a first and a second, at least one flow channel 21 . 21 ' having side part 22 . 24 , which are formed by an U-bent extruded profile, so that a three-sided floor element 20 with a lingering flow channel 21 is formed, and at least one substantially planar element 28 that is between the side panels 22 . 24 extends. Between the adjacent at least one planar element 28 neighboring floors 20 is an inner space 32 . 32 ' formed and the rooms are for receiving the battery cells 11 , in particular of flat, rectangular or square battery cells, designed.

The 6A & 6B show exploded views of the in the 5A & 5B used floors with two einzusetzenden battery cells.

The in the 5A and 5B Although the construction shown is known per se, it can be modified with the means described here to provide an improved cooling module 10 to form, for. B. can the cooling modules 10 according to 5A & 5B floor-level, using side panels with corresponding noses 46 . 48 according to 1E are provided so that the individual floors 20 with retaining clips 58 can be held together.

An example of the above-mentioned insulating shells 40 is in the 7 shown. The insulating shells can on the one hand with the cooling module 10 according to one of 1A to 1G . 2A to 2C . 3A to 3C 4A to 4C in which cooling channels 26 having connecting panels 28 on the other hand, with cooling modules 10 according to 5A or 5B be used.

The insulating dishes 40 serve different purposes. For example, with a cooling module 10 according to 3A to 3C respectively. 4A to 4C they will be at the connection device 28 attached, z. B. by means of an adhesive, and thus serve as a wall of the cooling channels 26 the connection device 28 ,

When the insulating shells 40 with floor elements according to 3A to 3C respectively. 4A to 4C are used, the insulating shells 40 on the top and bottom of the side panels 22 . 24 integral connection device 28 glued, whereby the openings for the slide are sealed.

With these cooling modules 10 and in the other previously described cooling modules 10 of the 1A to 1G . 2A to 2C . 5A and 5B They form at least an additional electrical insulation between the battery cells 11 and the cooling module 10 ,

Furthermore, they can be used with all cooling modules 10 an additional protective function for the battery cells 11 take.

The insulating dishes 40 are preferably produced in a thermoforming process from PET film and are both against the cell and against the cooling, ie, for example, the connecting device 28 , or glued the cooling vanes or cooling plates. They should have the smallest possible wall thickness to minimize their influence on the cooling performance. They have a closed bottom with a peripheral edge, at the front recesses for the cell tabs by z. B. a punching process can be introduced.

The use of insulating shells 40 above in connection with the embodiments according to the 3A to 3C and 4A to 4C is not limited to this embodiment, but would be in each embodiment in question, in which a receiving space 32 . 32 ' above and below a connection device 28 is formed and in all other conceivable constructions that have receiving spaces for the battery cells.

The 8th For example, shows a drawing similar to the 12 of the WO 2012/028298 in which each one battery cell is glued on each plastic shell of a floor element. The stacked floor elements with insulating shells and battery cells are then according to the 9 to understand. How such battery cells are connected together to form a battery module is described in detail in the document WO 2010/121831 whose relevant content is made part of the content of the present description and will not be explained further here.

Instead of the battery cells in the individual floor elements (in their receiving spaces 32 and 32 ' ) and the floor elements then to a stack 45 It is also possible to assemble the stack 45 first train and the battery cells 22 after finishing the stack 45 to insert in its compartments, each by two receiving spaces 32 and 32 ' two adjacent floor elements are formed. It also allows more battery cells in the remaining uppermost receiving space 32 of the top floor element and in the lowest receiving space 32 ' the lowest floor element can be used.

No matter which procedure is chosen, the recording rooms 32 and 32 ' filled by the inclusion of particular flat rectangular or square battery cells.

• a) Herstellung mehrerer gleichartiger Etagenelemente 20, wobei jedes Etagenelement aus einem ersten und einem zweiten, je mindestens einen Strömungskanal 21, 21' aufweisenden Seitenteil 22, 24 sowie aus einer Kühlkanäle 26 aufweisenden Verbindungseinrichtung 28, deren Kühlkanäle 26 sich zwischen den Strömungskanälen 21, 21' der Seitenteile 22, 24 erstrecken,
• b) Bildung eines Stapels 45 aus den Etagenelementen 20,
• c) Einführung der Zellen in Räume 32, 32', die von den Verbindungseinrichtungen 28 und den Seitenteilen 22, 24 definiert sind,
• d) Anbringung eines Strömungsverteilers 12 auf der Eingangsseite des Stapels an den dortigen Seitenteilen 22 und Anbringung eines Sammlers 14 auf der Ausgangsseite des Stapels 45 an den dortigen Seitenteilen 24,
• e) Verschließen der Strömungskanäle 21, 21' der Seitenteile 22, 24 auf den dem Strömungsverteiler 12 bzw. dem Sammler 14 abgewandten Enden der Strömungskanäle 21, 21' der Seitenteile 22, 24 und
• f) Anbringung von Halteklammern 58 bzw. Haltefedern, um die Etagenelemente 20 aneinander zu halten.

The present invention also includes a method of manufacturing a cooling module 10 a battery module consisting of rechargeable cells with the steps:

• a) Production of several similar floor elements 20 wherein each floor element consists of a first and a second, at least one flow channel 21 . 21 ' having side part 22 . 24 as well as from a cooling channels 26 having connecting means 28 whose cooling channels 26 between the flow channels 21 . 21 ' the side parts 22 . 24 extend
• b) Formation of a stack 45 from the floor elements 20 .
• c) Introduction of the cells into rooms 32 . 32 ' coming from the connecting devices 28 and the side panels 22 . 24 are defined
• d) Attachment of a flow distributor 12 on the input side of the stack at the local side parts 22 and attaching a collector 14 on the output side of the stack 45 at the local side parts 24 .
• e) closing the flow channels 21 . 21 ' the side parts 22 . 24 on the flow distributor 12 or the collector 14 opposite ends of the flow channels 21 . 21 ' the side parts 22 . 24 and
• f) attachment of retaining clips 58 or retaining springs to the floor elements 20 to hold each other.

• g) jeweils eine Zelle auf jeder Seite jeder Verbindungseinrichtung 28 angebracht und die Etagenelemente 20 anschließend zu einem Stapel zusammengesetzt, oder
• h) die Etagenelemente 20 zu einem Stapel 45 zusammengesetzt und die Zellen erst nachträglich in von jeweils zwei benachbart angeordneten Etagenelementen 20 gebildete Räume 32, 32' eingeführt, grundsätzlich besteht auch die Möglichkeit eine oder mehrere Batteriezelle(n) in jeden Raum einzuführen, bevorzugt werden zwei Batteriezellen pro Raum 32, 32' eingeführt.

This procedure will / will be either

• g) one cell each on each side of each connector 28 attached and the floor elements 20 then assembled into a stack, or
• h) the floor elements 20 to a pile 45 composed and the cells only later in each of two adjacently arranged floor elements 20 educated spaces 32 . 32 ' In principle, it is also possible to introduce one or more battery cell (s) into each room, preferably two battery cells per room 32 . 32 ' introduced.

• j) der Anbringung von Isolierschalen 40 an den beiden Seiten der Verbindungseinrichtungen 28 und an den Flachseiten der Batteriezellen, wobei die Isolierschalen 40 vorzugsweise vor dem Zusammensetzen der Etagenelemente 20 zu einem Stapel 45 auf diese aufgebracht werden und die entsprechenden Batteriezellen erst dann auf die freiliegende Seite der Isolierschalen 40 aufgebracht werden oder die Isolierschalen 40 je eine auf einer Seite einer Zelle aufgebracht werden und anschließend die freie Seite der Isolierschale 40 auf eine Verbindungseinrichtung 28 eines einzelnen Etagenelements 20 oder zwei aneinander gelegten Zellen mit ihrer Isolierschalen 40 nach außen in einen zwischen zwei benachbarten Verbindungseinrichtungen 28 zweier benachtbarter Etagenelemente 20 gebildeten Raum 32, 32' eingeführt werden.

Preferably, the method also comprises the further step:

• j) the installation of insulating shells 40 on the two sides of the connecting devices 28 and on the flat sides of the battery cells, wherein the insulating shells 40 preferably before assembly of the floor elements 20 to a pile 45 be applied to this and the corresponding battery cells only then on the exposed side of the insulating shells 40 be applied or the insulating shells 40 one each applied to one side of a cell and then the free side of the insulating 40 to a connection device 28 a single floor element 20 or two adjacent cells with their insulating shells 40 to the outside in one between two adjacent connecting devices 28 two benhabbarter floor elements 20 formed space 32 . 32 ' be introduced.

10 shows a floor element 20 with cooling wings 64 according to the cooling module 20 to 5B , In the room, between the cooling wings 64 in the plane of the cooling wings 64 is formed, is a fire protection element 66 arranged. It is a non-flammable, thermally insulating material that is between the battery cells 11 a double cell arrangement consisting of the floor element 20 each with a battery cell 11 above and below the cooling wings 64 (here is only the upper battery cell 11 schematically indicated by dashed lines) is arranged.

In this context, even a flame-retardant material or a material which inflates under the influence of heat to thermally better isolate the cells from each other, between the battery cells 11 a double cell array are arranged.

Optionally, in such a floor element 20 two insulating shells (like 40 - not shown) between the battery cells 11 and the cooling feet 64 , or the fire protection element 66 to be ordered. The fire protection element 66 Should the fire of a cell fire spread between adjacent battery cells 11 In addition, it can prevent and additional mechanical fixation of the battery cells 11 serve.

As fire protection element 66 can z. As a silicate fiber plate, a plate of a foaming foam inflates when exposed to temperature, a mineral fiber plate, a Stahltplatte or an aluminum plate can be used.

Such fire protection elements 66 can also be between adjacent battery cells 11 , and / or between the uppermost battery cell and a lid of the cooling module 10 (please refer 12B ), and / or between the lowermost battery cell and a bottom of the cooling module 10 (not shown), and / or on the front of the cooling module 10 between the electrical connection rows consisting of the electrical connections of the battery cells 11 and the spacers, as well as outside these rows of leads on the battery cells 11 facing side of the battery management system supporting board.

Furthermore, the shows 10 a stabilizing element 68 between the opposite side panels 22 . 24 a floor element 20 angeordent is. Such a stabilizing element 68 prevents a spreading apart of the side parts 22 . 24 , Also, the (mechanical) compressive strength of a cooling module by the use of a stabilizing element 68 elevated.

It is particularly favorable if, as in the 11 shown, a made of plastic or silicone foam layer 70 between two cells, which are arranged in a receiving space, used, for reasons of clarity, only half of a receiving space shown and the upper or under cell is not shown.

Optionally, such a foam sheet may be applied to the top and bottom cells of the battery module (not shown). The foam layer, which can also be replaced by another type of damping element, which achieves a damping of the construction, serves for the additional mechanical fixation of the cells 11 , even with a possible vacuum loss of the battery cells 11 , For this purpose, z. As a silicone foam with a defined compression strength in a defined arrangement and size (area and thickness of the material) on the cells 11 applied to bias this with a defined force. It should be noted that the compression strength of the foam material must be chosen so that the battery cells are not damaged during assembly, but held together by the silicone foam so that no free space can occur, and the battery cells from external influences such. B. shocks to shooters.

The specific foam is applied in a defined arrangement and size (area and thickness of the material) on the cells to bias them with a defined force. The foam is between each double pack and on the top and bottom cell.

As a foam material can also be used, which also has a fire protection function, so that it is in the fire protection material 66 and the damping element 70 to be able to trade the same material.

When using a fire protection material 66 and / or a Dämpfungslement 70 , the space of a battery module is ideally not increased.

The foam 70 Also increases the ability of the battery to absorb pressure forces.

As in the 12A . 12B and 12C also shown is a housing 80 , a three-piece case with a front 84 (see eg 13A ), an inwardly bulging lid 82 (please refer 12B and 12C ) above the stack 45 and, optionally, arched inward Bottom (not shown) below the stack 45 used. As a result, a deflection of the housing plates is balanced when force application from the inside, so that when installed, the lid 82 and the bottom, ie the housing plates, after receiving the outgoing of the damping elements forces are no longer concave curved but flat.

The aim is that no deflection to the outside arises. Ideal design creates a smooth, non-curved outer surface.

Furthermore, as in the 13A and 13B shown in at least part of the case, here in the front 84 of the housing 80 , at least one defined weaker area 90 in the case 80 , ie a predetermined breaking point, are provided. This area opens due to material breakage in the battery module 10 excessive overpressure. This weakened area allows outgassing in a given area.

13A shows a rear view of the front 84 of the housing 80 with, from a planar outer side towards the inside of the cooling module 10 extending, horizontal and vertical stiffening ribs 86 , The stiffening ribs are provided in a crossed arrangement.

13B shows a section along the section line III-III of 13A , In this sectional drawing can be seen that some stiffening ribs 86 with notches 88 are provided to form the predetermined breaking points.

14A shows a representation of a battery module 1 with an installed circuit board 92 a battery management system. To the board 92 with the battery cells 11 electrically connect the board directly to the terminals of the battery cells 11 brought into contact and by means of screws 94 screwed with these.

14B shows a partial section through a screw 94 along the section plane IV-IV according to 14A , The screws 94 attach the board 92 at the spacers 96 the of spacers 96 and the battery cell terminals existing terminal rows by vertically extending clamping bolts 98 be compressed to a clamping composite. Such a battery management system and its connection to the battery cells 11 will be in the WO 2010/121829 described in detail.

Between the board 92 and the spacers are multiple spring contacts 100 intended. These are essentially in the form of hairpin feathers 100 with a nose 102 on a Schenckel 104 , the nose 102 that are in corresponding grooves 106 engage the spacers and secure contact between the spacers and the board accomplish.

Preferably, the spring contacts are with their second Schenckel 108 at conductive areas of the board 92 at. These additional spring contacts 100 in addition, to those through the screws 94 and the conductive paths formed measuring paths, redundant measuring paths of the battery management system.

The aim of the redundant measuring paths is to preserve the function of the measuring paths even if a screw connection (first measuring path) fails as the main measuring path. When making the board of the battery modules 1 can the spring contacts 100 be applied in a placement machine

The grooves 106 the spacers 96 make sure that the battery management system can rest on the clamping system in a planar manner.

The 15A & 15B show schematic Dartstellungen the attachment of a temperature and / or growth sensor 110 . 112 between adjacent battery cells 11 a battery module 1 ,

These allow a temperature measurement and / or growth measurement (thickness increase) directly to the battery cells 11 , For the purpose of temperature measurement, temperature sensors are used 110 on so-called flex conductors 114 between the battery cells 11 used. The flexible ladder (s) 114 will or will be in suitable places on the board 92 connected to the battery management system for the temperature and / or growth measurement.

For example, the temperature sensors 110 formed by so-called NTC resistors (in English: negative temperature coefficient thermistors). The temperature sensors 110 can on every battery cell 11 be provided. But are separated by means of an insulating foam thermal.

For growth measurement contact surfaces are provided with spacers made of compression foam. When cell growth occurs, the foam is compressed and thus the two contact surfaces are joined, which is communicated to the battery management system.

As growth sensors 112 can be used as an alternative pressure sensors. Also the growth sensors 112 be with appropriate flex conductors 114 in suitable places on the board 92 of the battery management system connected. The temperature sensors as well as the pressure sensors can also be fitted together on a flexible conductor.

Geometric expressions, such as. As above or below, are always used in relation to an embodiment shown here and their arrangement in the respective figure. It goes without saying that the embodiments can be changed in their geometric position.

LIST OF REFERENCE NUMBERS

1

battery module

10

cooling module

11

Cells, battery cells

12

distributor

14

collector

16

Connection, inlet grommet

18

Connection, outlet grommet

20

floor element

21, 21 '

flow channel

22

Side wall

23

open areas

24

Side wall

25

seals

26

cooling channels

27

screw

28

connecting device

29, 29 '

Hole, hole

30

back

31

plate

32, 32 '

free space

40

Insulation shells

42

groove

44

Spring, thigh, bridge

45

stack

46

nose

48

nose

49

holes

50

niche

52

niche

54

hook-shaped end

56

hook-shaped end

58

Halteklmmer

60

turbulator

62

heatsink

64

Kühlflügel

66

Fire protection elements

68

stabilizing element

70

foam

80

casing

82

cover

84

front

86

stiffening ribs

88

notch

90

weakened area, bursting area

92

circuit board

94

screw

96

spacers

98

clamping bolt

100

spring contacts

102

nose

104

Schenckel

106

groove

108

Schenckel

110

temperature sensor

112

growth sensor

114

Flex Head

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2012/028298 [0002, 0011, 0037, 0068, 0068, 0091, 0101]
• WO 210/2/028298 [0027]
• WO 2010/121831 [0101]
• WO 2010/121829 [0125]

Claims (23)

Floor element ( 20 ) for one of several floor elements ( 20 ) assembled cooling module ( 10 ), in particular a cooling module one of a plurality of cells ( 11 ) existing rechargeable battery, such. B is a lithium-ion battery, each floor element ( 20 ) of a first and a second, at least one flow channel ( 21 . 21 ' ) having side part ( 22 . 24 ) as well as from a cooling channels ( 26 ) connection device ( 28 ) whose cooling channels ( 28 ) between the flow channels ( 21 . 21 ) of the lateral parts ( 22 . 24 ). Floor element according to claim 1, wherein the connecting device ( 28 ) approximately in the middle of each side part ( 22 . 24 ) and a free space ( 32 . 32 ) 'above and below the connection device ( 28 ) and between the sides ( 22 . 24 ) is formed. Floor element according to claim 1 or 2, wherein the floor element ( 20 ) in plan view is preferably square or rectangular and in particular can be executed polygonal in plan view. Floor element according to one of the preceding claims, characterized in that it consists of at least one of the following constructions: a) first and second extruded or injection-molded side parts ( 22 . 24 ) in the form of plastic profiles and an extruded or injection-molded, thin-walled connecting device ( 28 ), preferably a connecting plate ( 28 ), with a plurality of smaller compared to the cross-section of the flow channels smaller cross-sections cooling channels ( 26 ), the side parts ( 22 . 24 ) and the connection device ( 28 ) by z. B. hot gas or ultrasonic welding are fastened together, or b) first and second formed as extruded side panels ( 22 . 24 ) made of metal with a thin-walled, to this brazed connection device ( 28 ), preferably a connecting plate ( 28 ), with several compared to the cross section of the flow channels ( 21 . 21 ' ) smaller cross-section cooling channels, wherein the side parts ( 22 . 24 ) and the connection device ( 28 ) are fastened together by soldering, welding or gluing, or c) a heat sink ( 22 . 24 . 28 ) in die-cast version Floor element according to one of the preceding claims in combination with two insulating shells ( 40 ), which on at least one, preferably on both side (s) of the connecting device ( 28 ) are glued. Floor element according to claim 5, wherein the cooling channels ( 26 ) are open on at least one side and by a glued insulating 40 ) are sealed. Floor element according to claim 6, wherein a respective battery cell is glued on each insulating shell. Cooling module consisting of several stacked floor elements ( 20 ) according to any one of the preceding claims. Cooling module according to one of the preceding claims, wherein between the adjacent connecting devices ( 28 ) of adjacent floor elements ( 20 ) an inner space ( 32 . 32 ' ) is formed and the spaces for receiving battery cells ( 11 ) are designed in particular of flat, rectangular or square battery cells. Cooling module according to claim 8 or 9, wherein retaining springs ( 58 ) are provided, which the side parts ( 22 . 24 ) of at least two stacked floor elements ( 20 ), the retaining springs ( 58 ) hook-shaped ends ( 54 . 56 ) in form-adapted niches ( 50 . 52 ) of the side parts ( 22 . 24 ) of the floor elements ( 20 ) intervene. Cooling module according to one of claims 8 to 10, wherein the flow channels ( 21 ) of each side part ( 22 ) on the input side of the cooling module ( 10 ) with a coolant leading distributor ( 12 ) and the flow channels of each side part ( 24 ) on the output side of the cooling module ( 10 ) with a coolant leading collector ( 14 ) in Fluiverbindung stands. Floor element or consisting of several floor elements cooling module ( 10 ), wherein at least one turbulator ( 60 ) in each flow channel ( 21 . 21 ' ) is provided on the input side and / or on the output side of the cooling module. Floor element or cooling module according to claim 12, wherein the turbulator ( 60 ) is designed so that there is a constant repetition between reduced and enlarged cross section. Side part for use in a floor element of a cooling module, but in particular not exclusively in a floor element ( 20 ) according to one of the preceding claims, wherein the side part ( 22 . 24 ) is realized as a hollow profile, which has the following features: a) on one longitudinal side a U-shaped groove ( 42 b) on the other longitudinal side a web ( 44 ), which is in the U-shaped groove ( 42 ) of an adjacent side part ( 22 . 24 ), c) a hollow region of a flow channel ( 21 . 21 ' ) defined with a lateral opening or a plurality of lateral openings which fluidly connect to a further fluid-carrying element, ie a cooling channels ( 26 ) having connecting means ( 28 ) enable or enable, d) another in the longitudinal direction of the side part ( 22 . 24 ) extending bore ( 29 . 29 ) or passage for receiving a fastener such as a screw, e) at least one and preferably two laterally projecting lugs ( 46 . 48 ) on the side opening or the side openings opposite side of the hollow profile, ie on the outer side of the side part ( 22 . 24 ), whereby the nose or noses ( 46 . 48 ) Niches ( 50 . 52 ) for receiving the hooks ( 54 . 56 ) of retaining springs ( 58 ), the adjacent side parts ( 22 . 24 ) hold, for example, such that the web ( 42 ) of the one side part ( 22 . 24 ) into the groove ( 44 ) of the or an adjacent side part ( 22 ), (24) is pressed in. Side part according to claim 14, wherein at least one turbulator ( 60 ) is provided in the hollow profile and is preferably designed so that there is a constant repetition between reduced and enlarged cross-section. Cooling module ( 10 ) consisting of several floors ( 20 ), whereby the cooling module ( 10 ) for receiving a plurality of battery cells ( 11 ), such. B lithium ion batteries, is designed, each floor ( 20 ) of at least a first and a second, at least one flow channel ( 21 . 21 ' ) having side part ( 22 . 24 ), as well as from at least one substantially planar element ( 28 ) that is planar between the side parts ( 22 . 24 ), wherein between flat elements ( 28 ) of adjacent floors ( 20 ) inner spaces ( 32 . 32 ' ) are formed and the spaces for receiving the battery cells ( 11 ), characterized in that retaining springs ( 58 ) are provided, the adjacent side parts ( 22 . 24 ) hold on. Cooling module ( 10 ) consisting of several floors ( 20 ), whereby the cooling module ( 10 ) for receiving a plurality of battery cells ( 11 ), such. B lithium ion batteries, the cooling module ( 10 ) of at least a first and a second, at least one flow channel ( 21 . 21 ' ) having side part ( 22 . 24 ), as well as of several substantially planar elements ( 28 ) which are planar between the side parts ( 22 . 24 ), wherein between adjacent planar elements ( 28 ) an inner space ( 32 . 32 ' ) is formed and the spaces for receiving the battery cells ( 11 ), are designed, characterized in that insulating shells between battery cells and sheet-like elements are provided. Cooling module ( 10 ) consisting of several floors ( 20 ), whereby the cooling module ( 10 ) for receiving a plurality of battery cells ( 11 ), such. B lithium ion batteries, the cooling module ( 10 ) of at least a first and a second, at least one flow channel ( 21 . 21 ' ) having side part ( 22 . 24 ), as well as of several substantially planar elements ( 28 ) which are planar between the side parts ( 22 . 24 ), wherein between adjacent planar elements ( 28 ) an inner space ( 32 . 32 ' ) is formed and the spaces for receiving the battery cells ( 11 ), characterized in that the cooling module on the upper side with an inwardly bulging lid ( 82 ) and / or provided on the lower side with an inwardly bulging floor. Cooling module ( 10 ) consisting of several floors ( 20 ), whereby the cooling module ( 10 ) for receiving a plurality of battery cells ( 11 ), such. B lithium ion batteries, the cooling module ( 10 ) of at least a first and a second, at least one flow channel ( 21 . 21 ' ) having side part ( 22 . 24 ), as well as of several substantially planar elements ( 28 ) which are planar between the side parts ( 22 . 24 ), wherein between adjacent planar elements ( 28 ) an inner space ( 32 . 32 ' ) is formed and the spaces for receiving the battery cells ( 11 ), characterized in that the cooling module is surrounded on at least three sides by a housing, which with at least one bursting area ( 90 ) Is provided. Cooling module ( 10 ) consisting of several floors ( 20 ), whereby the cooling module ( 10 ) for receiving a plurality of battery cells ( 11 ), such. B lithium ion batteries, the cooling module ( 10 ) of at least a first and a second, at least one flow channel ( 21 . 21 ' ) having side part ( 22 . 24 ), as well as of several substantially planar elements ( 28 ) which are planar between the side parts ( 22 . 24 ), wherein between adjacent planar elements ( 28 ) an inner space ( 32 . 32 ' ) is formed and the spaces for receiving the battery cells ( 11 ), characterized in that a turbulator is provided in at least one flow channel on the input side and / or on the output side. Method for producing a cooling module of a rechargeable cell battery module comprising the steps of a) producing a plurality of similar floor elements ( 20 ), wherein each floor element consists of a first and a second, at least one flow channel ( 21 . 21 ' ) having side part ( 22 . 24 ) and a cooling channels ( 26 ) Connection device ( 28 ) whose cooling channels ( 26 ) between the flow channels ( 21 . 21 ) of the side parts ( 22 . 24 ), b) formation of a stack ( 45 ) from the floor elements ( 20 ), c) Introduction of the cells ( 11 ) in rooms ( 32 . 32 ' ), which are defined by the connecting devices, d) attachment of a flow distributor ( 12 ) on the input side of the stack ( 45 ) at the local side parts ( 22 ) and mounting a collector ( 14 ) on the output side of the stack ( 45 ) at the local side parts ( 24 ), e) closing the flow channels ( 21 . 21 ) of the side parts ( 22 . 24 ) on the flow distributor ( 12 ) or the collector ( 14 ) opposite ends of the flow channels ( 21 . 21 ' ) of the side parts ( 22 . 24 ) and f) connection of the floor element ( 20 ) by attaching retaining clips ( 58 ) or holding springs and / or an adhesive and / or by means of welding or ultrasonic welding, to the floor elements ( 20 ) to hold together. The method of claim 21, wherein g) either one cell each ( 11 ) on each side of each connection device ( 28 ) and the floor elements ( 20 ) then to a stack ( 45 ) or h) the floor elements ( 20 ) to a stack ( 45 ) and the cells ( 11 ) later in each of two adjacently arranged floor elements ( 20 ) formed spaces ( 32 . 32 ' ). A method according to claim 21 or 22, further comprising the step of: j) mounting insulating shells ( 40 ) to at least one, preferably on both sides of the connecting devices ( 28 ) and on the flat sides of the battery cells ( 11 ), the insulating shells ( 40 ) preferably before assembly of the floor elements ( 20 ) to a stack ( 45 ) are applied to this and the corresponding battery cells ( 11 ) only on the exposed side of the insulating shells ( 40 ) or the insulating shells are each applied to one side of a cell and then the free side of the insulating ( 40 ) to a connection device ( 28 ) of a single floor element ( 20 ) or two adjacent cells ( 11 ) with their insulating shells ( 40 ) to the outside in a between two adjacent connecting devices ( 28 ) of two neighboring floor elements ( 20 ) space ( 32 . 32 ' ) is introduced.

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