DE102018116312A1 - Battery system for a motor vehicle - Google Patents

Abstract

The invention relates to a battery system for a motor vehicle, in particular with an electrical, preferably purely electrical, drive, comprising at least one rechargeable battery (13) and at least one active component, in particular at least one compressor (4), of a cooling device (12) for active use Cooling the at least one battery (13), the active component, in particular the compressor (4), forming a structural unit (14) together with the at least one battery (13).

Description

The invention relates to a battery system for a motor vehicle, in particular with an electrical, preferably purely electrical, drive, and to the use of such a system, a motor vehicle with such a system, a method for producing a motor vehicle and a method for operating a battery system or motor vehicle.

Particularly in vehicles with a purely electric drive (purely electric drive train) without an internal combustion engine (in particular no hybrid or without a range extender), comparatively large electrical accumulators (hereinafter also referred to as rechargeable batteries or only briefly: batteries) are required to provide the energy for the Provide drive. Especially when charging the battery quickly, especially in a power range above 150 kW, high currents can occur that generate a corresponding amount of heat.

The waste heat from an electrical supply line of a charging station is usually dissipated (at least partially) via an internal water cooling system in a power cable. This is a cooling circuit on the charging station side. Waste heat in the vehicle (after an electrical contact or after an electrical contact terminal) is not dissipated by the charging station cooling, but may have to be cooled by an in-vehicle cooling system. This requires comparatively high cooling capacities and (particularly in charging mode) can lead to considerable vibrations and noises in the vehicle cabin or the vehicle surroundings. Conventional air conditioning compressors, particularly in the front body area, are particularly problematic in this regard.

In US 2017/0096073 A1 describes an alternative cooling method to compensate for the (in-vehicle) waste heat when charging the battery quickly. Water is sprayed onto the underbody of the vehicle so that the waste heat from the battery (or the battery pack) can be carried away from the underbody of the vehicle without having to provide cooling power inside the vehicle. This prevents noise and vibrations from operating the vehicle refrigeration circuit. This in US 2017/0096073 A1 The proposed cooling method is comparatively complex and can only be used to a limited extent. Furthermore, in US 2017/0096073 A1 mentions that a "coolant loop" can be implemented between the battery cells for cooling a battery pack.

It is an object of the invention to propose a battery system for a motor vehicle, in particular with an electric, preferably purely electric drive, which can be used easily and with as little impairment of the environment as possible, in particular during a charging, especially quick-charging process. Furthermore, it is an object of the invention to propose a corresponding use, a corresponding motor vehicle, a corresponding method for producing a motor vehicle and a corresponding method for operating a battery system or motor vehicle.

In particular, the object is achieved by a battery system for a motor vehicle, in particular with an electrical, preferably purely electrical, drive, comprising at least one (rechargeable) battery (accumulator) and at least one (in particular active) component, in particular at least one compressor, of a cooling device for (in particular active) cooling of the at least one battery. The at least one active component, in particular the at least one compressor, of the cooling device preferably forms a structural unit with the at least one battery.

A structural unit is to be understood in particular to mean that the at least one active component, in particular the at least one compressor, and the battery can be assembled and / or disassembled together (without having to be separated from one another). During assembly or disassembly, the at least one battery and the at least one active component, in particular the at least one compressor, are preferably still connected to one another. Specifically, the battery and the at least one active component, in particular the at least one compressor, can be supported by a common frame and / or within a common housing.

A distance between the at least one active component, in particular the at least one compressor, and the at least one battery (or in the case of a plurality of batteries: at least one of the batteries) is preferably less than 50 cm, more preferably less than 20 cm. An active component is to be understood in particular as a component (such as in particular a compressor, possibly a blower or a pump) that is supplied with (electrical and / or mechanical) energy in order to effect cooling. An energy conversion preferably takes place in the active component during operation, in particular from electrical (and / or mechanical) energy to pressure and / or kinetic energy of a fluid, in particular cooling fluid. In general, a cooling device for the active cooling of the at least one battery is preferably to be understood as a cooling device which has such an active component. In particular, an active component is not to be understood as a purely passive component (such as, for example, a fluid channel and / or a cooling fin). In other words, the at least one active component of the cooling device for active cooling is in particular not a (pure) heat exchanger (through which a fluid can possibly flow).

Possibly. the entire cooling device can form a structural unit with the at least one battery or at least with one or more (further) component (s) of the cooling device, such as in particular with an evaporator and / or with a cooling circuit (at least partially), in particular with at least one tube and / or at least one heat exchanger (or heat exchanger).

The at least one active component, in particular the at least one compressor, and the at least one battery are preferably immovably connected to one another. A connection can in principle be detachable or non-detachable. The at least one active component, in particular the at least one compressor, and the at least one battery are thus, for example, not (only) connected to one another via fluid lines or cooling lines (such as cooling hoses or the like). The at least one active component, in particular the at least one compressor, can be arranged (within the motor vehicle) at a height which (at least approximately) corresponds to a height of the at least one battery. An upper end of the at least one active component, in particular the at least one compressor, can optionally be arranged below an upper end of the at least one battery (in the case of a plurality of batteries: the upper end of the uppermost battery).

A total of a plurality of at least 2 or at least 5 or at least 10 or at least 20 batteries can be present, which are preferably combined in one or more battery pack (s). The at least one active component, in particular the at least one compressor, is preferably not arranged in an engine compartment of the motor vehicle (or not in a corresponding front and / or rear vehicle area). In general, the at least one active component, in particular the at least one compressor, is preferably not installed in a space placed next to a passenger cell and enclosed by the motor vehicle body.

The cooling device or the at least one active component, in particular the at least one compressor, is preferably provided exclusively for the active cooling of the at least one battery. Alternatively, another or more other vehicle areas, such as a passenger compartment or a vehicle interior, can be cooled via the cooling device or the at least one active component, in particular the at least one compressor.

According to the invention, it was also recognized, in particular, that when the battery is operated, in particular when charging, considerable vibrations and noise emissions, e.g. B. can occur in the vehicle cabin or the vehicle environment, which are generated by an in-vehicle refrigeration circuit (with an in-vehicle compressor). Insulating or damping or shielding these vibrations or noise effects (vibro-acoustic excitations) and switching them off is problematic in configurations according to the prior art in several respects, since the (air conditioning) compressor is usually installed in the front body area, where rigidity and The mass (weight) of the abutments is particularly low in vehicles without a heavy internal combustion engine. This makes it difficult to decouple structure-borne noise. The invention can now (even with higher electrical outputs, such as when quickly charging the at least one battery, in particular of drive train accumulators of electric vehicles, in particular in the power class above 150 kW to 350 kW or above), internal heat generated by an internal vehicle Cooling system are discharged without significant noise and / or vibrations, especially in the vehicle cabin, and / or noise radiation, especially in the vehicle environment, occurs. Furthermore, external cooling of vehicle components during rapid charging by a charging station is not necessary (or is not necessary to the same extent). Overall, a (significant) improvement with regard to unwanted vibration or noise development can be achieved by the structural unit according to the invention.

The cooling device preferably comprises at least one cooling generator. The refrigeration generator in turn preferably comprises at least one (air conditioning) compressor. Alternatively or additionally, the air conditioning device can have at least one fluid flow generator, preferably comprising (at least) one blower and / or at least one pump. Likewise, the air-conditioning device can include a plurality of evaporators, of which, for example, at least one effects an air heat exchange and at least one further causes a water heat exchange. Vibration or noise emissions from such refrigeration generators and / or fluid flow generators can be suppressed or reduced particularly effectively by suitable design of the structural unit.

In preferred embodiments, at least one support device, in particular a support frame, is provided, by which the at least one battery, in particular an accumulator package, is held. The at least one active component, in particular the at least one compressor, is preferably (in particular predominantly or exclusively) arranged on the at least one support device. A predominant arrangement of the at least one active component, in particular of the at least one compressor, on the support device is to be understood in particular to mean that at least 50% by weight, preferably at least 80% by weight, of the at least one active component, in particular of the at least one compressor , on which at least one support device is arranged. A (air-conditioning) compressor of the cooling device is particularly preferably located on / on the support frame, which is also provided for carrying the at least one battery (in particular a battery pack). It is therefore outsourced from other (traditional) vehicle components. A support device, in particular a support frame, offers good prerequisites for improved vibroacoustic decoupling, since such a support device must be designed to be comparatively rigid anyway (in order to fulfill its function) and, together with the at least one battery (in particular with the battery packs), it is comparatively high Weight (mass) and has a few (possibly only two, especially front and rear) defined connection points to the vehicle.

In general, there may be a maximum of 10, preferably a maximum of 4, further preferably a maximum of 2 connection points (or connection points) of the structural unit according to the invention relative to the vehicle. Furthermore, if necessary, all connection points (or connection points) of the structural unit according to the invention with respect to the vehicle can extend over a contact area (to the other components of the vehicle) of at most 1000 cm ² , preferably at most 100 cm ² .

A plurality of batteries (accumulators) are preferably arranged around the at least one active component, in particular the at least one compressor. Such an arrangement is to be understood in particular to mean that at least two batteries (completely) are arranged on different sides of a plane that intersects the active component (and preferably runs vertically when the battery system is installed). Projections of these two batteries on the level mentioned preferably overlap with a projection of the active component on the same level mentioned. At least one battery can be arranged on at least two sides (in the installed state) of the active component (for example in front and behind and / or left and right). The two sides mentioned are in particular a first side and a side of the cooling device (or active component thereof) opposite the first side.

If individual batteries (or accumulator packs) are grouped around the at least one active component, in particular the at least one compressor, a sound-absorbing effect can be supported by components (assemblies) which are present anyway.

The at least one active component, in particular the at least one compressor, can be arranged in a corresponding housing. As an alternative or in addition, the at least one battery (or if there are several batteries, if necessary all of the batteries) is arranged in a housing. The respective housing can be a common housing that is common to the at least one active component, in particular the at least one compressor, and the at least one battery. Alternatively, the at least one active component, in particular the at least one compressor, or the at least one battery can each be assigned to a (separate) housing, which may only have the at least one active component, in particular the at least one compressor (or no battery). or only contains the at least one battery (or no active component). Furthermore, the at least one active component, in particular the at least one compressor, and at least one battery can each be arranged in separate housings, which in turn are arranged in a (superordinate) common housing. In any case, a compact structural unit can be implemented in a simple manner.

The compressor, which may be placed in an acoustically insulating housing, is preferably connected to a cooling circuit by at least one line guide, in particular in such a way that at least outer parts of the compressor (in addition to its internal cooling) are cooled separately.

The at least one active component, in particular the at least one compressor, can be at least partially mounted on at least one sound-absorbing and / or sound-damping, in particular structure-borne sound-damping and / or - damping, preferably passive and / or switchable and / or (vibro-acoustically) active storage device, and / or a pneumatic bearing. Specifically, the active component (the compressor) can sit in an airborne sound-absorbing housing and / or on structure-borne noise-decoupling bearings. The storage facilities (storage) can have a fixed characteristic have or be designed as switchable bearings or as (air) bearings with adjustable pressure

One, several or all lines (s) of the control and / or power electronics and / or all, one, several or all fluid-carrying lines (n) (e.g. for refrigerant through a compressor, as well as for water , Air or the like, in particular by cooling coils on or within the at least one active component or at least inside the sound-insulated housing), which can connect the at least one active component placed in a preferably sound-insulated housing to components outside the (sound-insulated) housing / can preferably be attached individually or in groups to stiff and / or massive points, preferably to the above supporting device, preferably by means of (body) sound-absorbing and / or -damping coupling elements.

In general, one, several or all of the lines which connect the active component (the compressor) placed in the soundproof housing to components outside the soundproof housing can preferably be fastened individually or in groups at stiff and / or massive points. This is preferably carried out on the carrying device by means of (body) sound-absorbing and / or damping coupling elements, so that all transmission paths in addition to the (body) sound decoupling of the active component (the compressor) and its airborne sound radiation are also damped. This connection preferably affects all lines of the control and power electronics as well as fluid-carrying lines.

The fluid-carrying lines can additionally be equipped with passive or active pulsation dampers (mufflers). Fluid-carrying lines are to be understood in particular as the refrigerant lines and also fluid lines for any additional cooling of the compressor, which, if necessary, bring in additional cooling by another fluid in addition to its internal cooling by the conveyed refrigerant. This can be done through (water or fluid) channels in the active component (in the compressor) and / or through cooling channels (cooling coils) attached to the outside of the compressor. (Water) cooling is also possible via a cooling fluid guide (cooling coil) placed inside the sound-absorbing housing next to the compressor. Furthermore, air cooling with a supply line and, if necessary, sound-damped exhaust air can take place. The above-mentioned preferably apply to all these fluid lines. Connection and decoupling methods.

In embodiments, at least one control electrical system is provided for the at least one battery, preferably as part of the structural unit. The at least one active component, in particular a compressor, is preferably arranged at least partially between the at least one battery and the control electronics, in particular a housing of the control electronics. This also makes it possible to reduce the generation of vibrations or sound emissions in a simple manner.

Overall, the unit, specifically by blocking with the battery unit provided anyway (preferably having a support frame), can achieve a cooling capacity that is required during rapid charging and possibly also during driving operation in a simple manner and without (major) complications. Such a construction unit (including the integrated cooling) can be configured as a (complete) module. An implementation in a (new) vehicle can (significantly) be simplified by such a modularity.

The cooling device can be configured exclusively for cooling the battery or can also cool other components and / or areas of the vehicle, such as in particular a vehicle cabin. It was recognized that the cooling requirement for a vehicle cabin is usually less than a cooling requirement for a (quick) charge of the vehicle battery.

The above-mentioned object is further achieved by using a system of the above type for a motor vehicle, in particular with an electric, preferably with a purely electric drive.

The above-mentioned object is further achieved by a motor vehicle, in particular with an electrical, preferably with a purely electrical, drive, comprising a system of the above type.

The object is further achieved by a method for producing a motor vehicle of the above type, wherein in a first step the structural unit comprising the at least one active component, in particular the at least one compressor, and the at least one battery is prepared or manufactured and in one subsequent step the (entire) structural unit is connected to the other components of the motor vehicle.

The above-mentioned object is further achieved by a method for operating a battery system of the above type or a motor vehicle of the above type or a vehicle manufactured in accordance with the above type, the at least one battery being charged and / or discharged, in particular during the operation of the motor vehicle, by which at least one cooling device is cooled.

The (active) cooling of the battery (at least or in particular during rapid charging) is preferably carried out exclusively via the cooling device.

Further embodiments result from the subclaims.

The invention is also described below with respect to further features and advantages using an exemplary embodiment which is explained in more detail with reference to the figures.

• 1 eine schematische Darstellung eines konventionellen elektrisch angetriebenen Kraftfahrzeuges; und
• 2 eine schematische Darstellung eines erfindungsgemäßen elektrisch angetriebenen Fahrzeugs.

Here show:

• 1 a schematic representation of a conventional electrically powered motor vehicle; and
• 2 is a schematic representation of an electrically powered vehicle according to the invention.

In the following description, the same reference numbers are used for the same and equivalent parts.

1 shows a schematic representation of a conventionally driven vehicle with a conventional battery unit.

The vehicle includes a vehicle cabin 1 , a trunk 2 (optional), an engine compartment (or aggregate compartment) 3 and a (air conditioning) compressor 4 (preferably electrically powered). A battery pack 8th is on a (main) support frame 5 for (carrying) the battery pack 8th arranged. The support frame 5 is about a front body mount 6 and a rear body mount 7 attached.

The (air conditioning) compressor 4 is part of a cooling device 12 among other things for (active) cooling of the battery pack 8th , The battery pack 8th includes a variety of batteries 13 , as in 1 (and also 2 ) indicated schematically.

It is also located on the support frame 5 a control electronics 9 , An (optional) steering column is identified by the reference symbol 10 symbolizes.

The electric vehicle driven according to the invention 2 can basically according to the vehicle 1 be constructed, but with the following (invention) differences in the battery system. In the embodiment according to the invention 2 becomes the (air conditioning) compressor 4 through the (main) support frame 5 of the battery pack 8th held (supported). Specifically, this (air conditioning) compressor can 4 through an (inner) support frame 11 or a corresponding housing can be held (or included in it), this (inner) supporting frame 11 or the housing is in turn supported on the (main) supporting frame.

The solution according to the embodiment therefore includes a battery pack 8th and compressor 4 Part of a (common) structural unit 14 ,

LIST OF REFERENCE NUMBERS

1

cabin

2

trunk

3

Engine compartment (aggregate compartment)

4

(Air conditioning) compressor

5

(Main) support frame

6

Front body mounting

7

Rear body mounting

8th

Battery pack

9

Electrical control

10

steering column

11

(Inner) support frame or housing

12

cooling device

13

battery

14

unit

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included 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.

Patent literature cited

• US 2017/0096073 A1 [0004]

Claims (12)

Battery system for a motor vehicle, in particular with an electrical, preferably purely electrical, drive, comprising at least one rechargeable battery (13) and at least one active component, in particular at least one compressor (4), a cooling device (12) for actively cooling the at least one Battery (13), the active component, in particular the compressor (4), forming a structural unit (14) together with the at least one battery (13). System according to Claim 1 , characterized in that at least one support device, in particular a support frame (5), is provided, by which the at least one battery (13), in particular at least one battery pack (8), is held, the being the active component , in particular the compressor (4), preferably, in particular predominantly or exclusively, is arranged on the at least one support device. System according to Claim 1 or 2 , characterized in that several batteries (13) are arranged around the at least one active component, in particular the at least one compressor (4). System according to one of the preceding claims, characterized in that the at least one active component, in particular the at least one compressor (4), and / or the at least one battery (13) are arranged in a housing is a housing that is common to the at least one at least one active component, in particular the at least one compressor, and the at least one battery (13) or is an, in particular acoustically sound-absorbing and / or sound-absorbing, housing that only which contains at least one active component, in particular the at least one compressor, or only the at least one battery (13). System according to one of the preceding claims, in particular according to Claim 4 , characterized in that the compressor, which may be placed in an acoustically insulating housing, is connected to a cooling circuit by at least one line routing, such that at least outer parts of the compressor are additionally cooled in addition to its internal cooling. System according to one of the preceding claims, characterized in that the at least one active component, in particular the at least one compressor (4), at least partially on at least one sound-absorbing and / or sound-absorbing, in particular structure-borne sound-absorbing and / or -damping, preferably passive and / or switchable and / or vibro-acoustically active, bearing device, or a pneumatic bearing is arranged. System according to one of the preceding claims, characterized in that one, more or all of the line (s) of the control and / or power electronics and / or one, more or all of the fluid-carrying line (s) which follow the at least one Claim 4 Connect the active component placed in a preferably sound-insulated housing with components outside the sound-insulated housing, preferably individually or in groups at stiff and / or massive points, preferably on the support device Claim 2 , are preferably attached by means of structure-borne sound-absorbing and / or damping coupling elements. System according to one of the preceding claims, characterized in that at least one control electronics (9) for the battery (13), preferably as a component of the structural unit (14), is provided, the at least one active component, in particular the at least one compressor (4 ), preferably at least partially between the at least one battery (13) and the control electronics (9), in particular a housing of the control electronics. Use of a system according to one of the preceding claims for a motor vehicle, in particular with an electrical, preferably purely electrical drive. Motor vehicle, in particular with an electric, preferably purely electric drive, comprising a system according to one of the preceding Claims 1 to 7 , Method of manufacturing a motor vehicle according to Claim 10 , wherein in a first step the assembly (14) comprising the at least one active component, in particular the at least one compressor (4), and the at least one battery (13) is prepared or manufactured and in a subsequent step the assembly (14 ) is connected to the other components of the motor vehicle. Method for operating a battery system according to one of the Claims 1 to 9 or a motor vehicle according to claim 19 or a motor vehicle manufactured according to Claim 11 , wherein the at least one battery (13) and / or the vehicle cabin during the charging and / or discharging thereof, in particular during the operation of the Motor vehicle through which at least one cooling device (12) is cooled.

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