CN107154470B

CN107154470B - Battery pack and vehicle with such a battery pack

Info

Publication number: CN107154470B
Application number: CN201710123989.9A
Authority: CN
Inventors: A.韦伯; F.格劳比茨
Original assignee: Volkswagen AG
Current assignee: Volkswagen AG
Priority date: 2016-03-03
Filing date: 2017-03-03
Publication date: 2020-06-19
Anticipated expiration: 2037-03-03
Also published as: DE102016203553A1; CN107154470A

Abstract

The invention particularly relates to a battery assembly (3) having a battery housing (4), the battery housing (4) having a pot-shaped battery carrier (5) made of plastic or fiber-reinforced plastic having a carrier base (5a) and a carrier wall (5b) and a battery cover (6) covering the battery carrier (5), wherein at least one battery module (10) is arranged and fixed within the battery housing (4), wherein the battery carrier (5) has a metallic insert (13) formed integrally therewith and/or a metallic mounting (14) arranged within the battery carrier (5), and wherein at least a part of the inserts (13) and/or the mounts (14) are connected to each other and to the earth connection (28) in an electrically conductive manner in such a way that the EMV protection is assisted in the scope of a dual function.

Description

Battery pack and vehicle with such a battery pack

Technical Field

The present invention relates to a battery pack. The invention further relates to a vehicle, in particular an electric or hybrid vehicle, having a battery assembly of this type.

Background

From document FR 2986374 a1, a battery pack of an electric vehicle with a self-supporting battery housing for accommodating a plurality of battery cells is known, which has a plurality of walls and/or a base made of a composite structure. The composite structure is formed by a plurality of fiber-reinforced plastic layers. At least one layer made of a non-conductive material is arranged on the inner side of the wall. The battery housing has an upwardly directed opening which is closed by the cover. Document DE 102011011432 a1 describes a battery for an electric vehicle having a dc cell, which cell is associated with a carrier at least partially surrounding the cell in order to protect against mechanical and thermal influences and damage. The carrier comprises at least one bending-resistant molded part made of metal or plastic, an electrically insulating filling material which at least partially fills the gap between the electrical core and the molded part, and a connecting contact. A threaded sleeve or threaded bushing for receiving the bolt is embedded in the filling material. Components, such as, for example, connectors, stabilizing elements or insulators, are to be fastened to the support via screw connections. Document EP 2332761 a1 describes a battery housing with a housing bottom and side walls and a battery cover. The battery case is made of plastic and has a separation wall inside. In order to increase the strength and rigidity of the battery case, a metal frame is associated therewith. The battery housing furthermore has a blind nut which is inserted into the battery housing and a threaded sleeve for an associated fastening screw. Document DE 102011052515 a1 describes a trough-shaped or trough-shaped battery carrier of a battery housing of a traction battery of an electric vehicle. The battery carrier consists of a plastic material and has at least one planar element made of an electrically conductive material in order to provide EMV protection (EMV = electromagnetic compatibility). According to the european EMV standard, electromagnetic compatibility (EMV) is understood to be essentially the ability of an instrument, a device or a system to operate satisfactorily in an electromagnetic environment without causing unacceptable electromagnetic interference in this case for all instruments, devices or systems present in the environment. Document DE 102011052515 a1 proposes providing the surrounding area of the battery carrier with shielding against electromagnetic radiation from the traction battery and/or providing the traction battery with shielding against electromagnetic radiation from a radiation source in the environment of the traction battery by means of the planar element. The planar elements consist of metal films, nonwovens and/or fabrics and/or polymeric foams with an electrically conductive coating, metallic meshes or metal layers applied by electroplating. All the surface-mounted elements can be connected in an electrically conductive manner to a ground connection, which is formed by the chassis ground of the electric vehicle, more precisely the body or the frame thereof.

By means of the planar elements, a so-called faraday cage is accordingly implemented in order to protect the internal functional units (Innenleben) of the battery, in particular the control unit and the low-voltage lines, from interfering electromagnetic radiation from the environment. However, in practice, this measure has proved to be inadequate, and in order to achieve a shielding of the internal functional mechanisms of the battery which is as defect-free as possible, it is necessary to ground all metallic inserts and mountings. If the insert and the mounting are not grounded, there is a risk that electrical capacity and electrical load are formed, whereby the transmission of electrical signals within the battery may be disturbed. This is a particular challenge since little structural space is available within the battery housing. Here, the invention described below is proposed.

Disclosure of Invention

The object of the invention is to provide a battery assembly which, while retaining the advantages of the prior art, improves the EMV protection by means of simpler and more cost-effective measures. According to a further aspect of the invention, the crash safety of the battery assembly is additionally to be improved. The invention also relates to a vehicle, in particular an electric or hybrid vehicle, having a battery assembly of this type.

The object is achieved by a battery assembly having a battery housing with a pot-shaped battery carrier made of plastic or fiber-reinforced plastic with a carrier base and a carrier wall and a battery cover covering the battery carrier, wherein at least one battery module is arranged and fixed within the battery housing, wherein the battery carrier has a metallic insert part formed integrally therewith and/or a metallic mounting part arranged within the battery carrier, and wherein at least some of the insert parts and/or mounting parts are connected to one another and to an earth ground in an electrically conductive manner in order to assist the EMV protection in the dual-function range.

As already explained above, a defect-free shielding of the internal functional mechanisms of the cell cannot be ensured merely by means of a conventional outer lining or casing of the cell housing with a metal foil or the like. The battery pack according to the invention accordingly differs from the prior art (DE 102011052515 a1) essentially in that the existing metallic insertion and/or mounting parts of the battery housing are connected both to one another and to the ground, as a result of which the formation of negative effects of capacitive or electrical loads in the metal part is effectively prevented, in particular for the control unit and the low-voltage line.

The metallic insert is then advantageously formed by means of an existing threaded sleeve, a reinforcement and/or more alike. The metallic mounting is formed by existing structural elements, retaining elements, connecting elements, fastening elements and/or other metallic elements. Preferably, the insert and/or the mounting are conductively connected to each other by direct contact. However, if direct contact cannot be achieved due to, for example, distorted (verzeichend) distances, electrical lines are alternatively provided which ensure an electrically conductive connection between the metallic insert and/or the mounting. In order to configure the battery carrier as crash-safe, at least one tab-shaped reinforcing element is associated with the battery carrier, which reinforcing element is at least partially made of metal and is supported on the support structure of the battery carrier. The support structure can be formed by a carrier wall section of the battery carrier, a carrier base, a battery channel formed integrally with the carrier base and/or by at least one tie rod (zugstree) which is also supported on the battery carrier. Preferably, the at least one tie rod extends transversely to the longitudinal extent of the web-shaped reinforcing element, as a result of which a grid-shaped reinforcing structure of the battery carrier can be realized. More preferably, the tie rods are also made of metal. In an advantageous development of the invention, at least one stiffening element, which likewise assists the EMV protection, is integrated into the electrically conductive composite of the insert and/or the mounting. If the tie rods are made of metal, they are preferably likewise incorporated into the electrically conductive composite of the insert and/or the mounting. A particularly simple and functionally reliable embodiment of the invention is achieved in that the at least one reinforcing element is connected in an electrically conductive manner to a battery cover, which is likewise made at least partially of metal and advantageously serves as a medium for the grounding. In order to achieve a high impact resistance of the at least one reinforcing element and the correspondingly reinforced battery carrier or battery housing, the reinforcing element is formed by a long, elongated hollow profile made of metal with an internal rib structure. In order to further increase the impact resistance, in a development of the invention at least one reinforcing element is formed by a metal-plastic hybrid component with the elongated hollow profile made of metal having an internal rib structure, wherein the hollow profile is filled and/or coated with plastic or fiber-reinforced plastic.

The invention also relates to a vehicle, in particular an electric or hybrid vehicle, having a battery assembly of the type described above.

Drawings

The invention will be explained in detail below on the basis of embodiments which are schematically shown in the drawing. However, the present invention is not limited to this embodiment. Wherein:

figure 1 very schematically illustrates a vehicle equipped with a battery assembly constructed in accordance with the present invention,

figure 2 shows the battery assembly in a perspective exploded view,

figure 3 shows a perspective internal view of a battery housing of the battery assembly,

figure 4 shows a detail "Z" according to figure 3,

figure 5 shows a perspective detail view of the mounting of the battery housing,

figure 6 shows a perspective sectional view of a battery housing in the region of its wall,

figure 7 shows a detail of a reinforcing element of a battery housing,

figure 8 shows a battery housing according to a first advantageous embodiment of the invention in a plan view,

fig. 9 shows a detail "Y" according to fig. 3 according to an advantageous development of the invention, an

Fig. 10 shows a battery housing according to an advantageous second embodiment of the invention in a plan view.

List of reference numerals

1 vehicle

2 electric motor

3 Battery pack

4 Battery case

5 Battery carrier

5a bottom of the Carrier

5b carrier wall

5c Battery channel

6 Battery cover

7 end side

8 fixed bolt

9 Battery pack

10 cell module

11 Battery cell

12 heat exchanger

13 insert

13a thread bush

13b thread bush

14 mounting part

14a Module Carrier

15 fixing bolt

16a stiffening element

16b stiffening element

17 carrier wall section

18a traction rod

18b traction rod

19 Rib Structure

20 electric wire

21 connecting section

22 thread bolt

23 nut

24 gasket

25 supporting plate

26-angle reinforcement

27 fixing bolt

28 grounded part

29 are connected to the pressure plate.

Detailed Description

Fig. 1 shows a vehicle 1, in this case a passenger vehicle, having an electric motor 2 as a drive motor and a battery assembly 3 forming a traction battery. According to this exemplary embodiment, the electric vehicle is thus accordingly a purely electrically operated vehicle 1. The invention obviously also comprises a so-called hybrid vehicle 1 which, in addition to one or more electric motors 2, also has a known internal combustion engine, which is not illustrated.

According to fig. 2, the battery assembly 3 has a battery housing 4 with a battery carrier 5, the battery carrier 5 being configured here in the form of a basin with a carrier bottom 5a and a surrounding upwardly directed carrier wall 5 b. This shape of the battery carrier 5 corresponds to a preferred shape with respect to the waterproof battery case 4. According to this exemplary embodiment, the carrier bottom 5a of the battery carrier 5 furthermore has a so-called battery channel 5c, which is formed integrally therewith and in the form of a long, elongate recess which projects into the pot-shaped battery carrier 5, which battery channel 5c allows for the arrangement of the battery assembly 3 in particular in the vehicle 1, i.e. above a ventilation device which is not illustrated.

The battery carrier 5 has associated therewith a battery cover 6 which is or can be placed on a free end face 7 of the pot-shaped battery carrier 5, specifically of the carrier wall 5b, and can be screwed together with this end face by means of a fastening screw 8. For sealing the joint, an annular seal, not shown in the drawing, is preferably provided. The battery carrier 5 is made of plastic or fiber-reinforced plastic, for example glass fiber or carbon fiber-reinforced plastic, and is preferably made according to a plastic injection molding method. The battery cover 6 is made of metal, for example, aluminum or an aluminum alloy.

A battery component 9 is or can be arranged within the battery housing 4. According to this exemplary embodiment, the battery assembly 9 is composed of eight battery modules 10 which are electrically coupled to one another, the battery modules 10 being formed on their part by a plurality of battery cells 11 (see in particular fig. 2,3, 5). In each case, two battery modules 10, which are designed as a module stack, are associated with a plate-shaped heat exchanger 12, which is preferably made of metal, for example aluminum or an aluminum alloy, and is integrated into a fluid circuit, not shown, in particular a cooling circuit of vehicle 1. Fig. 3 shows a battery carrier 5 of the battery housing 4, which is only equipped with module groups, for better visibility. For the other three module groups, only the associated heat exchangers 12 are shown separately for better understanding. Two module groups which are arranged one behind the other and each have two battery modules 10 are arranged on both sides of the battery channel 5c, viewed in the longitudinal direction thereof.

As can also be seen from fig. 3, the battery carrier 5 has a plurality of metallic inserts 13, in particular in the form of threaded sleeves 13a, which are associated with the fastening screws 8 described for fastening the battery cover 6 to the free end face 7 of the pot-shaped battery carrier 5. Furthermore, the insert 13 comprises a metal reinforcement (not shown). The above-described metal insert 13 may be a threaded

sleeve

13a,13b and/or a reinforcement, preferably embedded in plastic according to the plastic injection molding method during the manufacture of the battery carrier 5. According to this embodiment, a further metal threaded sleeve 13b is provided for fixing a plurality of, in particular metal, mounting pieces 14.

The metallic mounting 14 is required to be essentially different structural, retaining, connecting and/or fastening elements. Fig. 3 to 5 show an exemplary mounting 14 in the form of a module carrier 14a, which has a largely X-shaped profile. The module carrier 14a serves to combine two battery modules 10 in each case together with the heat exchanger 12 into a module stack and to hold and fix the module stack formed on the battery carrier 5 by means of the fixing screws 15 by the fixing screws 15 being received by threaded sleeves 13b (fig. 4) embedded in the plastic of the battery carrier 5.

According to fig. 3 and 5, tab-shaped reinforcing

elements

16a,16b are arranged on both sides of the cell channel 5c between two directly adjacent module groups. The reinforcing

elements

16a,16b are each supported on a support structure of the battery carrier 5, here at one end on a carrier wall section 17 of the carrier wall 5b and at the other section on the battery channel 5c, downward on the carrier floor 5a and upward on the

tie rods

18a,18 b.

The

tie rods

18a,18b extend here transversely to the longitudinal extent of the respective tab-shaped

reinforcement element

16a,16b and are fixed at both ends to the cell carrier 5 in the region of the free end face 7 of the pot-shaped cell carrier 5, specifically of the carrier wall 5 b. Thereby, a grid-shaped reinforcing structure of the battery carrier 5 can be obtained. According to this embodiment, the

tie rods

18a,18b are likewise made of metal, for example of aluminum or an aluminum alloy.

According to fig. 3,5-7, the

respective stiffening element

16a,16b is formed by a long, elongated hollow profile made of metal with an internal, preferably elongated, rib structure 19, which extends in the direction of elongation, whereby it is advantageously achieved that it is made according to an extrusion method (fig. 7). The hollow profile is here configured as a T-profile, for example, wherein the profile flange rests on the carrier base 5 a. Advantageously, a tubular through-hole formed extending along the hollow profile allows the passage of an electric wire 20 or the like (see fig. 3, 5). In the direction of the

tie rods

18a,18b, specifically upwards, the respective reinforcing

element

16a,16b forms a connecting section 21, in which connecting section 21 a threaded bolt 22 is fastened. During assembly, the threaded bolts 22 pass through-holes not only in the

tie rods

18a,18b but also in the battery cover 6. A nut 23 with a washer 24 is associated with the threaded bolt 22 for fixedly connecting the reinforcing

elements

16a,16b with the respectively associated

tie rods

18a,18b and the battery cover 6. The threaded bolt 22 and the nut 23 together with the washer 24 are metal parts, thereby causing an electrically conductive connection between the

reinforcement elements

16a,16b, the

tie rods

18a,18b and the battery cover 6.

In order to ensure good force introduction into the reinforcing

elements

16a,16b in the event of a crash, they have, at their ends pointing toward the associated carrier wall section 17, support plates 25 extending transversely to the longitudinal extent of the reinforcing

elements

16a,16b and parallel to the carrier wall section 17, the support plates 25 being connected to the respective reinforcing

elements

16a,16b in a form-fitting, force-fitting and material-fitting manner, but preferably by welding. By means of the preferably welded-on corner reinforcement 26, a particularly stable composite is obtained between the

relevant reinforcement element

16a,16b and the associated support plate 25. The angle reinforcement 26 can be provided as a separately produced component or can be an integral component of the

reinforcement elements

16a,16b, which are formed as extrusions. The angle reinforcement 26 is configured here merely by way of example in the form of a plate. The fastening screws 27 are received by corresponding metal thread sleeves 13b (fig. 6) embedded in the plastic of the cell carrier 5, so that the

reinforcement elements

16a,16b are fastened to the cell carrier 5 and to the adjacent module carrier 14a on the carrier wall side by means of the fastening screws 27, with the corner reinforcements 26 being connected.

The opposite ends of the reinforcing

elements

16a,16b are connected to the adjacent module carrier 14a via the profile flanges by means of fixing screws (not shown) by receiving the fixing screws by corresponding metal thread sleeves 13b (see fig. 9 for this purpose) embedded in the plastic of the battery carrier 5.

The invention is not, however, restricted to the reinforcing

elements

16a,16b described above in the form of long, elongated hollow profiles, but also encompasses reinforcing

elements

16a,16b formed by metal-plastic hybrid components with said long, elongated hollow profiles made of metal, wherein the hollow profiles are filled and/or coated with plastic or fiber-reinforced plastic (not shown). By this measure, the impact resistance of the reinforcing

elements

16a,16b can be further increased.

In order to integrate all, but at least a large part, of the metallic insert 13 and mount 14, as already described above, into the EMV protection, they are conductively connected to one another and to the ground 28 (fig. 8, 10). The ground connection 28 is formed here by the chassis ground of the vehicle 1, more precisely the body or frame thereof. The metallic insert part 13 and the mounting part 14 thus fulfill a dual function in an advantageous manner, namely, on the one hand, the original structural, holding, connecting and/or fixing function according to the regulations, and, on the other hand, the EMV protection function by the grounding connection 28 effectively preventing the negative formation of capacitive or electrical loads in the metal part.

If, for example, due to an excessive distance, no direct contact is made between the metallic insert 13 and the mounting 14, electrical connecting lines, not shown, can be provided, which are preferably embedded in the plastic of the battery carrier 5, in particular with regard to the insert 13. As already indicated above, the electrically conductive connection between the insert 13 and the mounting 14 and the grounding 28 is realized via the metal parts of the respective reinforcing

elements

16a,16b and the coupled metal battery cover 6.

Referring to fig. 8, the metallic battery cover 6 is connected in an electrically conductive manner to the reinforcing

elements

16a,16b of the two battery housings 4 shown in fig. 3 as a medium relative to the ground connection 28. Each

stiffening element

16a,16b has for this purpose the connecting section 21 together with a threaded bolt 22, a nut 23 and a washer 24.

In contrast, according to fig. 10, the metallic battery cover 6 is connected in an electrically conductive manner to only one of the reinforcing

elements

16a,16b of the battery housing 4 shown in fig. 3, in this case the reinforcing element 16b, as a medium relative to the ground connection 28. Only the reinforcing element 16b has the connecting section 21 together with the threaded bolt 22, the nut 23 and the washer 24 for this purpose. A further reinforcing element 16a, which is not illustrated here, has no connection section 21 or is not connected to the battery cover 6 in an electrically conductive manner.

However, in order to also integrate the reinforcing element 16a and the adjacent insertion and mounting

parts

13,14 into the electrically conductive composite of the metallic insertion part 13 and mounting part 14 and thus into the EMV protection, more precisely the ground connection (grounding part 28), the module carrier 14a of the adjacent battery module 10, which is directly conductively joined to the reinforcing element 16a, is conductively connected to the module carrier 14a of the oppositely arranged battery module 10 and thus also to the reinforcing element 16b by means of a connecting web 29 which extends over the battery duct 5c provided there (see fig. 9).

In order to obtain an electromagnetic shielding that is as free of defects as possible both with respect to the housing exterior and with respect to the housing interior, the measures described above are preferably combined with the conventional outer lining or casing of the battery housing 4 already described above, with, for example, a metal foil (not shown).

Claims

1. A battery assembly (3) having a battery housing (4), the battery housing (4) having a pot-shaped battery carrier (5) made of plastic or fiber-reinforced plastic having a carrier base (5a) and a carrier wall (5b) and a battery cover (6) covering the battery carrier (5), wherein at least one battery module (10) is arranged and fixed within the battery housing (4), wherein the battery carrier (5) has a metallic insert (13) formed integrally therewith and/or a metallic mounting (14) arranged within the battery carrier (5), and wherein at least a part of the insert (13) and/or the mounting (14) are connected electrically conductively to each other and to a ground (28) and fulfill a dual function, that is, on the one hand, the original function according to the regulations is satisfied and, on the other hand, the electromagnetic compatibility protection function is satisfied.

2. A battery assembly (3) according to claim 1, characterized in that the insert (13) is formed by a threaded sleeve (13a,13b) and/or a reinforcement.

3. A battery assembly (3) as claimed in claim 1 or 2, characterized in that the mounting (14) is formed by a structural element.

4. A battery assembly (3) according to any of claims 1-2, characterized in that the insert (13) and/or the mounting (14) are interconnected by direct contact and/or by means of electrical leads.

5. A battery assembly (3) as claimed in any one of claims 1 to 2, characterized in that at least one tab-shaped reinforcing element (16a,16b) is associated with the battery carrier (5), the reinforcing element (16a,16b) being at least partially made of metal and being supported at a support structure of the battery carrier (5).

6. Battery assembly (3) according to claim 5, characterized in that the support structure is formed by a carrier wall section (17) of a battery carrier (5), a carrier bottom (5a), a battery channel (5c) which is constructed integrally with the carrier bottom (5a) and/or by at least one tie rod (18a,18b) which is also supported at the battery carrier (5).

7. A battery assembly (3) according to claim 5, characterized in that the at least one reinforcement element (16a,16b) is also incorporated into the electrically conductive composite of the insert (13) and/or the mounting (14) in such a way that an electromagnetic compatibility protection function is fulfilled.

8. The battery assembly (3) according to claim 7, characterized in that the at least one reinforcing element (16a,16b) is connected in an electrically conductive manner with a battery cover (6), the battery cover (6) likewise being made at least partially of metal and serving as a medium with respect to an earth connection (28).

9. A battery assembly (3) according to claim 5, characterized in that the at least one reinforcement element (16a,16b) is formed by a long, elongated hollow profile made of metal with an internally located rib structure (19).

10. A battery assembly (3) according to claim 5, characterized in that the at least one reinforcement element (16a,16b) is constituted by a metal-plastic hybrid component with a long, extended hollow profile formed of metal with an internally located rib structure (19), wherein the hollow profile is filled and/or coated with plastic or fiber-reinforced plastic.

11. A battery assembly (3) as claimed in claim 1 or 2, characterized in that the mounting (14) is formed by a retaining element.

12. A battery assembly (3) as claimed in claim 1 or 2, characterized in that the mounting (14) is formed by a connecting element.

13. A battery assembly (3) as claimed in claim 1 or 2, characterized in that the mounting (14) is formed by a fixing element.

14. A vehicle (1) with a battery assembly (3) according to any one of claims 1 to 13.

15. Vehicle (1) according to claim 14, characterized in that the vehicle (1) is an electric or hybrid vehicle.