DE102022114794B3 - Battery device for an at least partially electrically driven motor vehicle with a cooling device for the direct cooling of battery cells - Google Patents

Abstract

Battery device (1) for an at least partially electrically driven motor vehicle, comprising at least one cooling device (10) for direct cooling of battery cells (2) and at least one battery housing (4) and a plurality of battery cells (2) arranged next to one another and accommodated in the battery housing (4). a plurality of intermediate elements (3) accommodated in the battery housing (4) and arranged in a sandwich-like manner between adjacent battery cells (2), the intermediate elements (3) being provided by cooling elements (13) and/or compression elements (23) and the battery cells (2) each have two opposite end sections (12), on each of which a cell tab structure (22) is formed, the intermediate elements (3) at least in part at their end regions (33) arranged adjacent to the end sections (12) of the battery cells (2) each having at least are equipped with a compressible sealing foam body (5) and wherein the sealing foam body (5) seals off the adjacent battery cells (2) with at least one sealing geometry (35) in each case in order to create defined flow paths (11) for a coolant of the cooling device (10) within the battery housing ( 4), characterized in that the sealing geometry (35) comprises at least one positioning contour (85) which corresponds to a housing component (14) of the battery housing (4) in order to position the intermediate element (3) by means of the positioning contour (85) on the housing component (14) to align.

Description

The present invention relates to a battery device for an at least partially electrically driven motor vehicle with at least one cooling device for the direct cooling of battery cells. The battery device comprises at least one battery case and a plurality of battery cells accommodated in the battery case and arranged next to one another and a plurality of intermediate elements accommodated in the battery case and arranged sandwiched between adjacent battery cells. The intermediate elements are provided by cooling elements and/or compression elements.

In the case of batteries with directly cooled battery cells, it is usually necessary to seal off the battery housing from the environment. In order to ensure reliable and effective cooling, however, it is also necessary to provide flow paths within the battery housing and to seal them off from one another in a targeted manner.

A battery device for an electrically powered motor vehicle with directly cooled battery cells is from DE 10 2020 101 266 B3 known. The battery cells are equipped with molded seals that rest against the walls of the housing and adjacent battery cells to form a seal.

A generic battery device is in DE 20 2010 016 259 U1 shown.

In contrast, it is the object of the present invention to further improve such a battery device. In particular, the battery device should be structurally uncomplicated and economical to produce using industrial methods. At the same time, the battery device should enable particularly reliable direct cooling of the battery cells.

This object is achieved by a battery device having the features of claim 1. Preferred developments of the invention are the subject matter of the dependent claims. Further advantages and features of the present invention result from the general description and the description of the exemplary embodiment.

The battery device according to the invention is intended for an at least partially electrically driven motor vehicle. The battery device includes at least one cooling device for the direct cooling of battery cells. The battery device comprises at least one battery housing and a plurality of battery cells arranged next to one another and accommodated in the battery housing. The battery device comprises a plurality of intermediate elements accommodated in the battery housing and arranged in a sandwich-like manner (or in a multi-layered stacked manner) between adjacent battery cells. The intermediate elements are provided in particular by cooling elements and/or compression elements. The battery cells each have two opposite end sections. A cell flag structure is formed on each of the end sections. The intermediate elements are at least partially and preferably all equipped with at least one compressible sealing foam body at their end regions arranged adjacent to the end sections of the battery cell. The sealing foam body seals the (two) adjacent battery cells with at least one sealing geometry. In particular, the sealing foam body is in sealing contact with the adjacent battery cells, each with at least one sealing geometry. In particular, this provides defined flow paths for a coolant of the cooling device within the battery housing. The sealing foam body preferably also provides a seal with respect to other components accommodated inside the battery housing, which are necessary to create the flow paths. The sealing geometry includes at least one positioning contour, which corresponds to a housing component of the battery housing, in order to align the intermediate element on the housing component by means of the positioning contour.

The present invention offers many advantages. Equipping the intermediate elements with the sealing foam body offers a considerable advantage. This enables a particularly targeted and reliable sealing of the intended flow paths. It has been shown that equipping the intermediate elements with the sealing foam body offers significant advantages compared to a molded seal arranged on the battery cells. One advantage is that there is no need for very complex or dangerous handling of the battery cells during the manufacture of the molded seal. A further advantage is that with the invention, tolerances and, for example, material distortions or material protrusions on the battery cells can be compensated for much better and therefore do not lead to undesirable leaks in the coolant flow. Overall, the assembly of the battery device can be carried out much more easily and with less susceptibility to errors.

It is preferred and advantageous that the sealing foam body is produced by attaching, in particular spraying and/or foaming, a shapeless material to the (respective) intermediate element. In particular, the attachment takes place using a molding tool. In particular, the sealing foam body by attaching at the same time firmly connected to the intermediate element. In particular, an injection molding process and/or a suitable dosing technique for the targeted application of the material is provided for this purpose. The sealing foam body is preferably attached to the intermediate element at the same time as its original shaping. As a result, the intermediate elements can be equipped with the sealing foam body in a particularly uncomplicated and economical manner. A further advantage is that the intermediate elements with the attached sealing foam body can be handled as a unit. In particular, at least one sealing foam body is attached to each end area of the intermediate elements. In particular, the sealing foam body is not detachably connected to the intermediate element in a non-destructive manner.

The sealing geometry preferably extends at least over the entire width of the intermediate element (at the end region of the intermediate element). In the context of the present invention, a width relates in particular to the extent transverse to the extent between the end regions or the end sections. A length corresponds in particular to the extension between the end areas or the end sections.

In particular, the sealing geometry includes at least one first sealing structure. The sealing geometry with the first sealing structure preferably rests (sealing) on the cell lug structure. The sealing geometry with the first sealing structure preferably bears against at least one section of the cell lug structure which extends between a cell shoulder and a connection unit. In particular, the cell lug structure of a battery cell lies between the sealing geometries of adjacent intermediate elements. In particular, the first sealing structure extends at least over the entire width of the cell lug structure. The first sealing structure preferably extends over the entire width of the battery cell (and not just over the entire width of the cell tab structure).

In particular, the sealing geometry includes at least one second sealing structure. The sealing geometry with the second sealing structure preferably rests (sealing) on a cell shoulder of the battery cell. In particular, the cell plume structure is arranged in a projecting manner between two cell shoulders. In particular, the cell shoulders each extend from the cell lug structure to a main cell side running transversely to the cell shoulders. It is possible for the second sealing structure to also bear against the main side of the cell, at least in sections. In particular, the second sealing structure is in contact with a main side of the cell where the main side of the cell is not yet in contact with the intermediate element.

In an advantageous and preferred development, the second sealing structure comprises at least one wave geometry with a plurality of wave crests and wave troughs. At least the crests of the waves are in sealing contact with the cell shoulder. In an intended assembly state, the wave crests are pressed in particular against the cell shoulder, so that the second sealing structure is compressed. The longitudinal axis of the wave geometry runs in particular along the width of the cell shoulder.

It is advantageous and preferred that the second sealing structure provides at least one positioning aid for aligning the battery cell relative to the intermediate element. In particular, the positioning aid is designed as a compressible stop. In particular, the cell shoulder of the battery cell can be placed against the positioning aid. In particular, the battery cell is pushed with its cell shoulder against the positioning aid during assembly and the positioning aid is partially compressed in the process. The positioning aid is preferably provided by the shaft geometry. In particular, the wave crests serve as a compressible stop.

At least one targeted free cut is preferably formed in the sealing geometry and particularly preferably at least in the first sealing structure. In particular, the cutout is suitable and designed to at least partially accommodate material distortions and/or material protrusions of the battery cell and in particular a cell foil of the battery cell. In an intended assembly state, a material distortion and/or a material overhang is at least partially accommodated in the free cut. Such material distortions or material protrusions can be caused, for example, by folding or joining (e.g. weld seams) the cell foil. Additionally or alternatively, at least one targeted free cut can also be formed on the second sealing structure and/or at another point of the sealing geometry.

According to the invention, the sealing geometry comprises at least one positioning contour. According to the invention, the positioning contour corresponds to at least one housing component of the battery housing, so that the intermediate element can be aligned on the housing component by means of the positioning contour. The positioning contour can also be referred to as an outer contour or at least includes one. In particular, the positioning contour enables the sealing geometry together with the intermediate element attached to it to fit in a form-fitting manner on the housing component. The housing component is in particular an end plate and/or a wall component.

The battery cells are preferably arranged between the sealing foam bodies of adjacent (different) intermediate elements. The sealing geometries are in sealing contact with the battery cells. It is possible for terminating intermediate elements to be arranged at the ends of the battery cells stacked in a sandwich-like manner, in which case the sealing foam body has a sealing geometry only on one main side of the intermediate element. In particular, the sealing foam body then only seals to an adjacent battery cell with the sealing geometry.

The cooling elements preferably each have at least one coolant routing system. The coolant routing system allows the coolant to flow between adjacent battery cells in direct contact with the battery cells. In particular, the cooling elements are designed to be incompressible. In particular, the cooling element has a plurality of cooling channels. The cooling channels are preferably arranged between two layers. In particular, the cooling channels are arranged between at least one carrier layer and/or at least one cover layer. In particular, the cooling channels are not sealed off from the battery housing. The cooling channels are fluidly connected in particular to a housing space of the battery housing.

The compression elements are preferably suitable and designed to compensate for operational deformations of the battery cells. In particular, the compression elements can compensate for swelling and swelling of the battery cells. The compression elements are designed to be compressible at least in sections and, in particular, to be elastic.

The cooling elements and the compression elements are preferably arranged alternately between two adjacent battery cells in each case. It is also possible for a compression element to be arranged only on the outermost battery cells. Then the remaining intermediate elements are designed in particular as cooling elements.

In all of the configurations, it is particularly preferred that the battery cells are configured as pouch cells. In particular, the electrochemical components of the pouch cells are housed in a cell film that is closed like a bag. In particular, the cell film forms a film bag. The cell flag structure can also be referred to as a cell tab or cell tab or can include one. In particular, the sealing geometry rests against the welded cell foil. In particular, the first sealing structure seals the cell foil. In particular, the second sealing structure also seals the cell foil. In particular, the entire battery cell is covered by a cell foil. In particular, the outside of the battery cell is provided by the cell foil.

At least one of the two cell lug structures of a battery cell includes a connection unit (+/- pole) for making electrical contact with the battery cell. In particular, the first sealing structure bears against the connection unit at least in sections and preferably only in sections or not at all. The sealing foam body can also leave the connection unit uncovered at least in sections. In particular, the sealing foam body has at least one recess around the connection unit, at least in sections. The connection units are also cooled particularly effectively in this way.

The battery device is designed in particular as a traction battery or part of one. The battery device is preferably designed as a battery module. The battery module is in particular part of a battery arrangement with a plurality of battery modules connected to one another. The battery arrangement can be designed as a traction battery. The battery assembly may include a main housing in which the battery modules are housed.

The battery device stores the electrical energy, in particular on an electrochemical basis. Additionally or alternatively, the battery device can also store the electrical energy in an electrical field. The battery device is then designed, for example, as a capacitor device or as a hybrid capacitor. The battery cells are designed in particular as electrochemical cells and/or as capacitors. The battery cells can then also be referred to as capacitor cells or hybrid cells. The battery device is in particular rechargeable.

A coolant can flow directly around the battery cells, at least in sections. In particular, the battery cells are fixed floating in the coolant in the battery housing. In particular, the cooling device also includes sealing of the battery housing from the environment or from the outside. In particular, the coolant flows in a defined direction along the battery cells. In particular, the coolant flows transversely to a longitudinal axis which extends from one end section to the other end section. The sealing foam body can also be attached, at least in sections, to the battery housing and/or at least one other component (component) accommodated in the battery housing. seal. Adjacent sealing foam bodies (of adjacent intermediate elements) can at least partially lie against one another in a sealing manner.

In particular, an intermediate element has two sealing foam bodies. In particular, an intermediate element has a sealing foam body at each end region. In particular, the sealing foam body has at least two sealing geometries. In particular, the sealing geometries are each assigned to a different battery cell. In particular, the sealing geometries are arranged on opposite main sides of the intermediate elements. In particular, two sealing geometries are arranged on the main sides of the intermediate elements. The sealing geometries on a main side each belong to a different sealing foam body. In particular, the sealing geometry has a defined geometric shape. In particular, the sealing geometry provides a shaped seal or can also be referred to as such. In particular, the sealing geometry is not shapeless.

Further advantages and features of the present invention result from the exemplary embodiments which are explained below with reference to the enclosed figures.

• 1 eine rein schematische Darstellung einer erfindungsgemäßen Batterieeinrichtung in einer geschnittenen Seitenansicht;
• 2 eine stark schematisierte Darstellung einer erfindungsgemäßen Batterieeinrichtung in einer geschnittenen Vorderansicht;
• 3 eine rein schematische Detaildarstellung einer erfindungsgemäßen Batterieeinrichtung in einer perspektivischen Ansicht; und
• 4 eine Detaildarstellung eines Zwischenelements der Batterieeinrichtung der 3
• 5 eine Detaildarstellung des Zwischenelements der 4; und
• 6 eine rein schematische Detaildarstellung der Batterieeinrichtung der 3 in einer Seitenansicht.

In the figures show:

• 1 a purely schematic representation of a battery device according to the invention in a sectional side view;
• 2 a highly schematic representation of a battery device according to the invention in a sectional front view;
• 3 a purely schematic detailed representation of a battery device according to the invention in a perspective view; and
• 4 a detailed view of an intermediate element of the battery device 3
• 5 a detailed view of the intermediate element of 4 ; and
• 6 a purely schematic detailed representation of the battery device 3 in a side view.

The 1 and 2 show highly schematic diagrams to illustrate the structure of the battery device 1 according to the invention. The battery device 1 is designed here as a battery module of a traction battery for supplying energy to a traction drive of an at least partially electrically powered motor vehicle. A plurality of battery cells 2 and intermediate elements 3 are accommodated in a battery housing 4 . The intermediate elements 3 are sandwiched between adjacent battery cells 2 and are provided by cooling elements 13 and compression elements 23 . Here, a cooling element 13 and a compression element 23 are alternately arranged between adjacent battery cells 2 .

The one in the 1 The sectional view shown is cut along a cooling element 13 so that the battery cells 2 and the compression elements 23 are not visible. In the 2 the battery device 1 is transverse to the sectional view of FIG 1 cut. The battery cells 2 and intermediate elements 3 arranged in a sandwich-like manner can be seen particularly well here. The battery case 4 is equipped here with an insertion aid 24 in order to be able to better insert the battery cells 2 and the intermediate elements 3 into the battery case 4 .

The battery device 1 includes a cooling device 10 for direct cooling of the battery cells 2, so that the battery cells 2 have direct contact with a coolant or swim in it. The coolant flows into the battery housing 4 via an inlet 20 . The coolant is discharged from the battery housing 4 again via a drain 30 .

Defined flow paths 11 are formed within the battery housing 4, which are outlined here by block arrows. The inflowing coolant runs along the bottom of the battery housing 4 and flows from there through the individual cooling elements 13 and thus directly up along the battery cells 2 and from there back to the outlet 30. The battery cells 2 and the intermediate elements 3 run in the battery housing 4 in such a way that the end sections 12 of the battery cells 2 or the end regions 33 of the intermediate elements 3 face either the side with the inlet 20 or the side with the outlet 30 .

In order to ensure effective and reliable cooling, the flow paths 11 are sealed off from one another in a targeted manner. Sealing foam bodies 5 are provided for sealing the flow paths 11 and are formed on the intermediate elements 3 . The sealing of the flow paths 11 is in front of or behind the plane of the drawing 2 , So that the sealing foam body 5 are not visible there.

In an alternative embodiment, the battery cells 2 and the intermediate elements 3 can also be stacked in two or more rows in a sandwich-like manner. Then the individual rows can also be sealed to one another via sealing foam bodies 5 .

Related to the 3 until 6 the sealing of the flow paths 11 by means of the sealing foam body 5 will now be described in more detail. The 3 shows two battery cells 2 designed as pouch cells 52 in the area of their end sections 12. Between the battery cells 2 is shown an intermediate element 3 with a sealing foam body 5 attached thereto, which is equipped with a sealing foam body 5 in each case at the end regions 33. The opposite end region 33, which is not shown here, is preferably equipped with a sealing foam body 5 in an analogous manner (also compare 4 ). The battery cells 2 are also preferably designed and arranged in an analogous manner on the opposite end section 12 .

The pouch cells 52 are surrounded by a cell film 62 that is closed in the manner of a bag. Inside the cell foil, electrochemical components are arranged, which are not visible here. A cell flag structure 22 is formed on each of the end sections 12 and is located between two cell shoulders 42 . A connection unit 32 protrudes from the cell foil 62 in a distal region of the cell lug structure 22, via which the battery cell 2 can be electrically contacted. The connection unit 32 extends here like a bow from the cell lug structure 22 of one battery cell 2 to a cell lug structure 22 of the adjacent battery cell 2.

The intermediate element 3 is designed here, for example, as a cooling element 13 which includes a coolant routing system 130 . The coolant routing system 130 includes z. B. a plurality of cooling channels, which are arranged between a carrier layer and a cover layer. The cooling element 13 is designed here in the form of a plate or as a cooling plate.

Like in the 3 is clearly visible, the sealing foam body 5 is equipped with two sealing geometries 35. The sealing geometries 35 are each in sealing contact with a battery cell 2 . The sealing geometry 35 comprises a first sealing structure 15 and a second sealing structure 25. The first sealing structure 15 bears against the cell lug structure 22 in a sealing manner. The second sealing structure is in sealing contact with the cell shoulder 42 .

Adjacent to those in the 3 Battery cells 2 shown can be installed in a specified assembly arrangement (as is shown, for example, in 2 is outlined) in each case an intermediate element 3 designed as a compression element 23 can be arranged. The sealing foam body 5 is then in sealing contact with the sealing geometry 35 on the cell shoulder 42 which is still free here and the cell flag structure 22 . Battery cells 2 are then arranged again on the compression elements 23 and cooling elements 13 on them again, and so on.

The sealing foam body 5 is produced here by injecting a shapeless material onto the intermediate element 3 . At the same time, this results in a firm connection between the sealing foam body 5 and the intermediate element 3.

The 4 shows a single intermediate element 3 each with a sealing foam body 5 at its end regions 33. The intermediate element 3 is designed as a cooling element 13 here. However, it is also possible for the intermediate element 3 shown here to be designed as a compression element 23 . The compression element 23 comprises, for example, a compressible plate and, for example, a foam or the like. As a result, tolerances and swelling forces of the battery cells 2 can be accommodated or compensated for. In the case of the compression element 23 too, the sealing foam body 5 is produced by injection molding and is firmly connected to the compression element 23 .

In the 5 it is easy to see that the sealing geometry 35 extends over the entire width 43 of the intermediate element 3 . The second sealing structure 25 is equipped here with a wave geometry 45 with a plurality of wave crests 55 and 65 wave troughs. It can also be clearly seen here that the sealing geometry 35 is equipped with cutouts 95 in the area of the first sealing structure 15 . Material distortions and excess material of the cell foil 62 can be accommodated in the cutouts 95 .

In the 6 it is easy to see how the sealing foam body 5 with the sealing geometry 35 is arranged within the battery housing 4 in the intended assembly state. The intermediate element 3, to which the sealing foam body 5 is attached, is not shown here in order to be able to show the arrangement of the sealing geometry 35 better.

The corrugated geometry 45 runs here with its longitudinal axis parallel to the cell shoulder 42. Since the cell foil 62 has a rather undefined outer contour, particularly in this area, the corrugated geometry 45 results in a particularly high level of reliability of the seal. The wave geometry 45 has 7 wave crests 55 here, for example, so that there is seven times the certainty that at least one sealing surface is in sealing contact with the battery cell 2 . In addition, a force reduction or force distribution on the sensitive cell shoulder 42 is thereby realized. Due to the assembly of the battery cell 2, the crests 55 are partially compressed.

The second sealing structure 25 provides a positioning aid 75 for aligning the battery cell 2 relative to the intermediate element 3 . The positioning aid 75 serves as a compressible stop against which the battery cell 2 can be pushed with its cell shoulder 42 . In the example shown here, the positioning aid 75 is provided by the shaft geometry 45 . The battery cell 2 is thus oriented to the positioning aid 75 of the sealing foam body 5 during assembly or pressing.

The sealing geometry 35 is formed here with a positioning contour 85, which corresponds to a housing component 14 of the battery housing 4 and here, for example, to an end plate. As a result, the intermediate elements 3 or the battery cells 2 can be aligned particularly easily during assembly. The positioning of the housing component 14 or the end plate is possible here in two spatial directions due to the positioning contour 85 . In the area of the positioning contour 85, cutouts 95 are also formed here on the sealing geometry 35.

Reference List

1

battery setup

2

battery cells

3

intermediate element

4

battery case

5

sealing foam body

10

cooling device

11

flow path

12

end section

13

cooling element

14

housing component

15

sealing structure

20

Intake

22

cell plume structure

23

compression element

24

insertion aid

25

sealing structure

30

Sequence

32

connection unit

33

end area

35

sealing geometry

42

cell shoulder

43

Broad

45

wave geometry

52

pouch cell

55

wave crest

62

cell foil

65

trough

75

positioning aid

85

positioning contour

95

free cut

130

coolant management system

Claims (13)

Battery device (1) for an at least partially electrically driven motor vehicle, comprising at least one cooling device (10) for direct cooling of battery cells (2) and at least one battery housing (4) and a plurality of battery cells (2) arranged next to one another and accommodated in the battery housing (4). a plurality of intermediate elements (3) accommodated in the battery housing (4) and arranged in a sandwich-like manner between adjacent battery cells (2), the intermediate elements (3) being provided by cooling elements (13) and/or compression elements (23) and the battery cells (2) each have two opposite end sections (12), on each of which a cell tab structure (22) is formed, the intermediate elements (3) at least in part at their end regions (33) arranged adjacent to the end sections (12) of the battery cells (2) each having at least are equipped with a compressible sealing foam body (5) and wherein the sealing foam body (5) seals off the adjacent battery cells (2) with at least one sealing geometry (35) in each case in order to create defined flow paths (11) for a coolant of the cooling device (10) within the battery housing ( 4), characterized in that the sealing geometry (35) comprises at least one positioning contour (85) which corresponds to a housing component (14) of the battery housing (4) in order to position the intermediate element (3) by means of the positioning contour (85) on the housing component (14) to align. Battery device (1) according to the preceding claim, wherein the sealing foam body (5) is produced by attaching a shapeless material to the intermediate element (3) using a mold and is firmly connected to the intermediate element (3). Battery device (1) according to one of the preceding claims, wherein the sealing geometry (35) extends at least over the entire width (43) of the intermediate element (3). Battery device (1) according to any one of the preceding claims, wherein the sealing geometry (35) rests with a first sealing structure (15) on the cell lug structure (22). Battery device (1) according to one of the preceding claims, wherein the sealing geometry (35) bears against a cell shoulder (42) of the battery cell (2) with a second sealing structure (25). Battery device (1) according to the preceding claim, wherein the second sealing structure (25) comprises at least one wave geometry (45) with a plurality of wave crests (55) and wave troughs (65) and wherein at least the wave crests (55) on the cell shoulder (42) fit tightly. Battery device (1) according to one of the two preceding claims, wherein the second sealing structure (25) provides a positioning aid (75) for aligning the battery cell (2) relative to the intermediate element (3). Battery device (1) according to one of the preceding claims, wherein at least one targeted free cut (95) is formed in the sealing geometry (35), in which material distortions and/or material protrusions of the battery cell (2) are at least partially accommodated. Battery device (1) according to one of the preceding claims, wherein the battery cells (2) are each arranged between the sealing foam bodies (5) of adjacent intermediate elements (3). Battery device (1) according to one of the preceding claims, wherein the cooling elements (13) each have a coolant guide system (130) through which the coolant can flow between adjacent battery cells (2) in direct contact with the battery cells (2). Battery device (1) according to one of the preceding claims, wherein the compression elements (23) are suitable and designed to compensate for operational deformations of the battery cells (2). Battery device (1) according to one of the preceding claims, wherein the cooling elements (13) and the compression elements (23) are arranged alternately between two adjacent battery cells (2). Battery device (1) according to one of the preceding claims, wherein the battery cells (2) are designed as pouch cells (52) in which electrochemical components are accommodated in a cell film (62) sealed in the manner of a pouch.

Images