DE102021104276A1 - Battery module arrangement, battery module and motor vehicle - Google Patents

Abstract

The invention relates to a battery module arrangement (10, 12) with a first battery module (18, 18a, 18c) with a plurality of first battery cells (22) arranged one above the other in a first direction (z) in a first module housing (24, 24a, 24c) and a second Battery module (18, 18b, 18d) with a plurality of second battery cells (22) arranged one above the other in the first direction (z) in a second module housing (24, 24b, 24d), the first and the second module housing (24, 24a, 24b, 24c, 24d) are arranged next to one another in a third direction (y) perpendicular to the first and a second direction (z, x), the first module housing (24, 24a, 24c) and the second module housing (24, 24b, 24d) being arranged in such a way can be coupled to one another in that at least one first intermediate space (36, 36a, 36b) for receiving a cooling device (40) for cooling the first and / or second battery cells (22) is provided.

Description

The invention relates to a battery module arrangement with a first battery module which has a first cell stack with a plurality of first battery cells which are arranged one above the other in a first direction, the first battery module having a first module housing in which the first cell stack is arranged, the first module housing has a longitudinal extent in a second direction perpendicular to the first direction. In addition, the invention also relates to a battery module for such a battery module arrangement and a motor vehicle with such a battery module arrangement.

The present invention is essentially in the field of high-voltage batteries for motor vehicles, in particular electric or hybrid vehicles. In order to provide a high-voltage voltage, multi-cell battery cells are usually required and, accordingly, a very large amount of space is required in the motor vehicle to accommodate these battery cells. Currently, battery systems almost always consist of cells that are geometrically and electrically identical. As a rule, there is little scope for vehicle integration in order to efficiently use the different installation spaces that are available. As a rule, there is always a conflict between battery geometry and dimensional concept or ergonomics. It is therefore desirable that the installation space can be better used and that good ergonomics and an adapted design and dimensional concept are still made possible.

In order to be able to accommodate batteries or battery modules in a vehicle in a space-efficient manner, modular battery concepts are already known from the prior art. For example, describes the DE 10 2017 200 479 A1 a modular energy storage device. At least two separate energy storage modules of the same type are stacked next to one another along a longitudinal direction, so that the respective adjacent energy storage modules are electrically connected to one another via coupling elements. Each of the energy storage modules has a module housing designed as a hollow body for accommodating one or more energy storage cells, which is also designed as a crash support with regard to mechanical effects occurring transversely to the longitudinal direction. The coupling elements arranged between the energy storage modules can each have a projection and a recess which can be brought into engagement with one another, similar to a clip mechanism. When connecting the coupling elements, cooling channels of the individual energy storage modules are also automatically connected to one another. In this way, however, only one battery with a plurality of such energy storage modules can be provided, which is only scalable in the longitudinal direction according to the number of modules used.

Furthermore, the DE 10 2017 211 365 A1 an energy storage device for a motor vehicle, which is intended to be arranged under the front hood of the motor vehicle. This has a plurality of energy storage devices, which are arranged as an energy storage device stack and each have an energy storage device housing. Furthermore, the energy storage device has a housing enclosing the energy storage devices. At least one housing wall of the housing also has on its inside a deformation element arrangement designed for deformation in the event of a crash. In this case, several energy stores can be stacked in such a way that their number can be flexibly adapted to the installation space available in the motor vehicle. A temperature control device is also arranged on the side walls of the energy storage housing, which is formed from a number of elements, each of which has a fluid channel and is joined together by means of coupling elements. The temperature control device should be able to be flexibly adapted to the number of energy stores to be temperature-controlled, in that the elements are plugged together in a modular manner by means of the coupling elements.

However, such an energy storage device is not suitable for constructing a large high-voltage battery from a number of such units. Even the plug-in connections required for the provision of the temperature control device require an enormous number of seals and sealing concepts, which could not be implemented at all for a large high-voltage battery, or only with enormous effort.

When accommodating battery cells in the motor vehicle as adaptably and flexibly as possible, it is also important to note that other components associated with such a high-voltage battery, such as cooling, crash structures, cell connectors, cables, degassing options or the like, can also be accommodated as space-efficiently as possible should.

The object of the present invention is therefore to provide a battery module arrangement, a battery module and a motor vehicle that make it possible to provide a battery module arrangement in a simple and cost-effective manner that can be adapted as flexibly as possible to the installation space available in a motor vehicle.

This object is achieved by a battery module arrangement, a battery module and a motor vehicle having the features according to the respective independent patent claims. Advantageous configurations of the invention are the subject matter of the dependent patent claims, the description and the figures.

A battery module arrangement according to the invention has a first battery module with a first cell stack with a plurality of first battery cells which are arranged one above the other in a first direction, the first battery module having a first module housing in which the first cell stack is arranged, the first module housing having a longitudinal extension in has a second direction perpendicular to the first direction. Furthermore, the battery module arrangement comprises a second battery module, which comprises a second cell stack with a plurality of second battery cells arranged one above the other in the first direction, and a second module housing, in which the second cell stack is arranged, the second module housing having a longitudinal extension in the second direction. The first and second module housings are arranged next to one another in a third direction perpendicular to the first and second directions, with the first module housing having a first coupling wall facing the second module housing and the second module housing having a second coupling wall facing the first module housing, with the first module housing and the second module housing can be coupled to one another in such a way that at least a first intermediate space for accommodating a cooling device for cooling the first and/or second battery cells is provided between the first and second coupling wall.

The invention is based on the finding that scalability of a battery module arrangement for a motor vehicle is advantageous above all in the vertical direction of the motor vehicle and also in the longitudinal direction of the motor vehicle, but less so in the transverse direction of the motor vehicle. Typically, high-voltage batteries are arranged in an underbody area of the motor vehicle, in particular in an arrangement area that extends in the vehicle transverse direction from side sill to side sill and in the vehicle longitudinal direction at least up to the front wheel axle and the rear wheel axle and possibly also beyond. The installation space available in the transverse direction of the motor vehicle remains essentially constant, in particular not only in the longitudinal direction of a vehicle, but also across different vehicle models. On the other hand, the installation space available in the longitudinal direction of the vehicle can differ. Above all, however, there is a different amount of space available in the vertical direction of the vehicle within the same motor vehicle, especially in the vertical direction of the vehicle, depending on the position, specifically depending on the position in the longitudinal direction of the vehicle. For example, there is more installation space below the vehicle seats, especially below the back seat of a vehicle, than, for example, in the footwell area of the front passengers. This installation space available in a motor vehicle can now be used in a particularly efficient manner by the battery module arrangement according to the invention. This is due to a variety of special features of the battery module arrangement, which in a synergetic manner enable particularly simple scaling in the vertical direction of the vehicle as well as in the longitudinal direction of the vehicle. On the one hand, this is due to the fact that cell stacks are provided which have a plurality of battery cells which are arranged one above the other in the first direction and are therefore lying, so to speak. The first direction corresponds in particular to the vertical direction of the vehicle. The height of such a cell stack, ie in the vertical direction of the vehicle, can be adapted to the structural conditions of the motor vehicle in a particularly simple manner by simply varying the number of battery cells comprised by the cell stack accordingly. In particular, the battery cells can be stacked one on top of the other in a lying position, so that the thickness of each battery cell points in the first direction and represents the smallest dimension of the battery cell, i.e. smaller than its width in the third direction and its length in the second direction . This provides a particularly high degree of flexibility with regard to the design of the height of such a battery module, since this can be adjusted in particularly small incremental steps. Because the battery modules, i.e. in this case the first and the second battery module, are also arranged next to one another in the third direction, in which in particular any number of such battery modules can be arranged next to one another, this third direction, which preferably allows corresponds to a vehicle longitudinal direction, adjust the dimensions of the battery module arrangement in a particularly simple manner to the geometric space conditions. This advantageously provides particularly simple scalability of the battery module arrangement both in the first direction and in the third direction. A major advantage of the invention, however, is that an intermediate space, here the first intermediate space, is arranged between the two module housings for accommodating a cooling device. The cooling device runs vertically, so to speak, between two battery modules. In particular, the cooling device can extend over the entire first and/or second coupling wall of the relevant module housing. This allows such a cooling device on the one hand, cool all the first battery cells of the first battery module at the same time, in a particularly homogeneous manner, since the cooling device can also extend in the stacking direction due to its arrangement. On the other hand, both the first battery module and the second battery module can be cooled by the cooling device. Conversely, a cyclic continuation of these components, ie battery module, cooling device, battery module, cooling device and so on, in the third direction provides cooling on both sides in the third direction for each battery module. This is also particularly efficient with regard to homogeneous cooling of the battery cells. Since the cooling device is also located between two battery modules, it can also be easily scaled in the first direction to match the height of the battery module in question. For example, the cooling device can be designed in such a way that it extends over almost the entire coupling wall of the larger battery module, for example, viewed in the first direction. This geometric scaling allows the cooling capacity to be automatically adjusted to the different geometries of the individual battery modules. In addition, this can be achieved in a simple manner without the need for a complex plug-in system for connecting cooling channels. For example, a common cooling plate, or an even more efficient and later described flexible bag cooling, or the like can be used for the several first and also second battery cells of the first and second battery module, which does not have to be composed of individual channels plugged together. Such a cooling system can thus be implemented in a particularly simple manner at the overall battery level, even for particularly large batteries, as is the case with high-voltage batteries. The special feature of the battery module arrangement is that the modular concept, which enables easy scaling of the battery height and battery length, also includes a modular concept for extremely efficient cooling of the battery cells. Overall, a battery module arrangement can thus be provided which can be adapted to the given installation space requirements in a motor vehicle in a particularly simple and efficient manner.

The battery cells, that is to say both the first and the second battery cell, can be in the form of lithium-ion cells, for example. The first and the second battery module can also be designed identically, for example, except for their height in the first direction and the number of battery cells comprised by the battery module. However, the first and the second battery module can also be of the same design with regard to the number of battery cells they comprise and their height in the first direction. As will be explained in more detail later, it is particularly advantageous if the respective module housings are designed as extruded profiles. Correspondingly, these can be open, for example, at the front and rear viewed in the second direction. In other words, the module housings can be open on the sides that delimit the battery modules in their direction of longitudinal extent. By being designed as an extruded profile, such a module housing has a cross section that is translationally invariant in the second direction, perpendicular to this second direction. This simplifies the design and the manufacturing process of such a module housing. The design of the module housing as an extruded profile also has the great advantage that such an extruded profile can above all provide very high stability in the second direction and thus a high degree of crash safety. The module housings are also preferably formed from a metal or an alloy, for example aluminum or steel, and can therefore be made particularly robust in a simple manner, even with relatively small wall thicknesses. Such a module housing can also be subjected to subsequent processing steps, for example in order to partially cut out a central cable duct, as will also be explained in more detail later. At the location of such a recess, the above-mentioned translational invariance of the cross-sectional geometry is then interrupted.

In addition, the battery module arrangement can also have other battery modules of this type, depending on the available installation space, in particular in the third direction. As described, the battery modules can differ in terms of their height. The height in turn depends on how many battery cells are included in the battery module or in the cell stack of the battery module. The more battery cells are included in the cell stack, the higher the corresponding battery module is in the first direction. Otherwise, however, the descriptions given for one battery module can apply analogously to each additional battery module. This means, for example, that the first battery module can also have a second coupling wall opposite the first, via which the first battery module can be analogously coupled to a third battery module, which is arranged opposite the third direction next to the first battery module. Analogously, the second battery module can also have a first coupling wall on the side opposite the second coupling wall, via which the second battery module can be coupled to a fourth battery module, which is then arranged correspondingly in the third direction next to the second battery module, and so on. With others In other words, each battery module can have two coupling walls which limit the width of the battery module in question on both sides in the third direction and via which the battery modules in question can be coupled to adjacent battery modules, so that at least one such gap is formed between each two battery modules in the third direction is. If, in particular, two battery modules of the same height are arranged next to one another in the third direction, a single intermediate space is preferably formed between them. If two battery modules arranged next to one another differ in terms of their height, it is advantageous if an adapter plate, which will be explained in more detail later, is also arranged between them. In this case, an intermediate space is formed between the adapter plate and an adjacent battery module in each case, which means that in this case two intermediate spaces are formed between the battery modules arranged next to one another, i.e. one intermediate space between the first battery module and a first side of the adapter plate and one Space between a second side of the adapter plate and the second battery module.

If there is no adapter plate between the two battery modules, in this example the first and the second battery module, e.g. if they are the same height, the two battery modules are coupled in such a way that they are in direct mechanical contact with one another via a coupling mechanism provided on the respective coupling walls. The coupling mechanism can also limit the space in the first direction up and down. For example, the space may be configured to be open at the front and bottom rear as viewed in the second direction.

In addition to the possibility of being able to accommodate a cooling device in the space formed between two battery modules, this configuration has the enormous additional advantage that flexible cooling can be used in this way, as will be explained in more detail below.

It represents a particularly advantageous embodiment of the invention when the battery module arrangement has the cooling device through which a coolant can flow, the cooling device being designed flexibly in such a way that when the cooling device is in a state in which the coolant is flowing through, at least part of a coolant pressure is applied to the first Coupling wall of the first module housing and / or the second coupling wall of the second module housing is transferrable.

Such a flexible, deformable cooling device has the great advantage that it can nestle against the first coupling wall and/or second coupling wall, as a result of which the heat transfer from the battery modules to the cooling device can be increased. In particular, inclusions between the relevant coupling wall and the cooling device can be reduced or completely avoided as a result. The cooling device can be inflated like an air mattress by the coolant pressure and thus cling to the first coupling wall and/or second coupling wall. The cooling device rests against both the first and the second coupling wall if only one space is provided between the first and second battery module, in which the cooling device is accommodated, which is the case in particular when the first and second battery modules are the same are high. Otherwise, for example, if the adapter plate described above is also arranged between the two battery modules, the cooling device rests either only on the first battery module, ie on its first coupling wall, or on the second coupling wall of the second battery module.

Such a flexible cooling device can advantageously function at the same time as a tolerance compensation device, since the distances between the battery modules cannot always be identical due to production-related tolerances. Smaller tolerances in the millimeter range, for example in the range of 0.5 mm, can be easily compensated for by the flexible cooling device. The distances between two battery modules or their coupling walls are preferably between 4.5 and 5 mm. A particularly space-efficient, but at the same time effective, cooling of the battery modules can thus be provided.

Because the cooling device is clamped between two walls, that is to say either two module walls or a module wall and a wall of the adapter plate, it is only possible to align such a flexible cooling device vertically. This is because these two walls, which are located on both sides of the cooling device in the third direction, can provide sufficient support to prevent the flexible cooling device from collapsing like a bag under the influence of gravity and the coolant pressure. Because the walls mentioned can be used as supporting walls, any webs for stabilizing the cooling device can be dispensed with, which significantly simplifies its construction.

It is therefore a further advantageous embodiment of the invention if the cooling device has a flexible cooling bag through which a cooling medium can flow, the cooling bag having a first bag wall and a second bag wall opposite the first bag wall in the third direction, the first bag wall in a state of the cooling bag through which a cooling medium is flowing rests against the first coupling wall and/or the second bag wall rests against the second coupling wall, in particular over an area related to at least a large part of the first and/or second coupling wall. Such a bag can also have intermediate webs, for example, which fasten the first bag wall to the second bag wall, for example in a central region of the bag, but this is not necessary due to the supporting effect of the module walls described above. The shape of the bag can, so to speak, be kept stable by these walls, ie the first and/or second coupling wall, when a coolant flows through it. The bag or, in general, the cooling device can be made of a plastic, such as a plastic film, for example. In addition, in order to provide the flexibility mentioned above, the cooling device can have a very small wall thickness, for example in the range of 0.3 mm and 0.6 mm. In other words, the cooling device can be provided, for example, as a plastic bag made of two plastic films welded together, which have such a wall thickness. A supply connection and a discharge connection for supplying and discharging the relevant coolant can also be provided on such a bag. These are preferably arranged on an end face of the bag in relation to the second direction. As a result, the connections are particularly easy to access, since the module housings, which are preferably manufactured as extruded profiles, are also open in this direction.

In a further, very advantageous embodiment of the invention, the first and second battery cells are pouch cells. This is particularly advantageous because pouch cells have a very small thickness, which means that the height can be scaled in particularly small steps in the first direction. A respective height of such a pouch cell in the first direction can be, for example, between 5 mm and 20 mm inclusive, for example between 12 mm and 13 mm inclusive. The height can thus be adapted particularly flexibly to the installation space conditions in the motor vehicle. Nevertheless, the first and second battery cells can also be prismatic battery cells, for example. However, pouch cells not only have the advantage that they are particularly small in terms of their height, ie their thickness, but that they also provide a particularly high degree of flexibility with their other dimensions and, above all, with their other dimensions very well with the others Motor vehicle conditions are adaptable. For example, such a pouch cell can have a width in the third direction of between 80 mm and 150 mm, in particular for example 100 mm. The battery module arrangement can thus also be scaled very well in the third direction, namely by steps of the order of approx. 10 cm. This also provides a particularly high degree of flexibility. In addition, such a pouch cell can have a length in the second direction of between 500 mm and 600 mm, for example 550 mm. It is precisely this large length of such a pouch cell that is particularly well suited to providing very long cell stacks. As will also be explained later in more detail, it is preferred that a battery module has not just one cell stack, but rather two cell stacks arranged next to one another in the second direction. With a pouch cell length of 550 mm, this corresponds to a total cell stack length of 1.1 m, if various spaces for cable guides or the like are initially left out. This can be accommodated particularly easily in a typical motor vehicle, which means that almost the entire vehicle width or that in the transverse direction of the vehicle can be accommodated at the same time available space can be utilized. In addition, with such pouch cells, the poles or pole connections in question can be provided in a simple manner on the end face with respect to the second direction, which in turn simplifies accessibility and their interconnection, since they then point in the direction of the open sides of the extruded profiles through which the module housings are provided , demonstrate.

In a further, very advantageous embodiment of the invention, the first coupling wall of the first module housing has two first webs that protrude in the third direction and are at a first distance from one another in the first direction, with the first module housing having a second coupling wall opposite the first coupling wall, in particular for coupling to a third battery module, wherein the second coupling wall has two second webs protruding in the third direction, which have a second distance from one another in the first direction, which differs from the first distance. Furthermore, it is preferred that the first and second webs are arranged in an edge region of the first and second coupling side with respect to the first direction.

The coupling mechanism is therefore less based on a tongue and groove principle, but rather on a pen-and-pen principle. If the two battery modules, i.e. the first and the second battery module, are two battery modules of the same size with regard to their height in the first direction, the distances between the respective pairs of bars on the corresponding coupling sides facing one another are dimensioned in such a way that the first Webs abut the second webs and, for example, the second webs are arranged with respect to the first direction inside or outside of the first webs. Furthermore, the respective webs protrude the same distance from their respective coupling side. This therefore means that the end faces of the respective webs rest against the respective opposite coupling side in the third direction. Due to the fact that the webs protrude, an intermediate space is automatically formed between the relevant coupling sides, in which space the cooling device described above is arranged. Furthermore, it is preferred that the webs have the same height in the first direction, which simplifies production but does not necessarily have to be the case in theory. In this case, for example, the first webs can be arranged directly at the edge in relation to the first direction and the second webs can have a distance to the edge of the relevant coupling side, both upwards and downwards in relation to the first direction, which is equal to the web width in the corresponds to first direction. Then these pairs of bars can simply be joined together so that they interlock, so that the insides of the first bars touch the outsides of the second bars, so to speak. A respective pair of a first and a second web then delimits the intermediate space located between the two coupling sides upwards and downwards in relation to the first direction. If two battery modules are coupled to one another in this way, they cannot move against one another in the first direction. In other words, the coupling mechanism on the respective coupling sides is designed in such a way that two module housings of the same height can be plugged or pushed together and separated or pulled apart again in the third direction, while in the plugged-in state they cannot be displaced in relation to one another in and counter to the first direction , at least not non-destructively. This in turn has the great advantage that a very high and good flexural torsional rigidity can be achieved for the battery module arrangement as a whole by this housing arrangement. In the case of crossing a bollard, in which a local force is applied to the motor vehicle from bottom to top, this flexural torsional rigidity can provide very good force distribution of a locally acting force over the entire housing, formed by the individual module housings, which increases the likelihood of Local damage to the battery module assembly is greatly reduced.

If, for example, the first and second battery modules are two modules with different heights in the first direction, the corresponding webs can likewise be arranged as described on a respective region of the relevant coupling side in the first direction. In this case, however, the two coupling sides cannot be coupled directly via the webs. It is therefore a further, very advantageous embodiment of the invention if the first battery module has a different height than the second battery module in the first direction, and the battery module arrangement has an adapter plate which is arranged between the first and second battery module and which is arranged in such a way is coupled to the first coupling side of the first module housing and the second coupling side of the second module housing, the first intermediate space is formed between the adapter plate and the first coupling side, and a second intermediate space for accommodating a second cooling device is formed between the adapter plate and the second coupling side of the second module housing is. This adapter plate can also have, for example, pairs of webs on the respective sides, which have distances from one another that are adapted to the respective pairs of webs on the coupling sides with which the adapter plate is to be coupled. In other words, the adapter plate can have a pair of ridges on one side that couples to the first ridges of the first coupling side of the first battery module as described above, and on the other side the adapter plate can have another pair of ridges that couple to the second ridges of the second coupling side of the second battery module as described above. Such an adapter plate has the great advantage that the extruded profiles, through which the battery module housings are provided, can always be of the same design with regard to their coupling mechanism and the arrangement of the webs described, regardless of their height. In other words, the webs on the relevant coupling sides of a module housing can always be arranged in such a way that they are always located directly on the edge on one coupling side in relation to the first direction and on the opposite coupling side of the same module housing are at a distance from this edge that is greater than their Web width in the first direction corresponds. Corresponding adapter plates can then be provided in order to then be able to easily couple battery modules of different heights to one another. As a result, production can be simplified enormously. In the area of such an adapter plate, one can also more efficient cooling can be provided since a cooling device can be arranged in both intermediate spaces.

In a further advantageous embodiment of the invention, the first module housing has two opposite open sides in the second direction, in particular with the first module housing being designed as an extruded profile, with the first battery cells having cell poles which are arranged on a respective end face of a respective first battery cell, wherein the first battery cells are arranged in the first module housing in such a way that the end faces point in the second direction. As already described, this has the great advantage that the cell poles are more easily accessible and can be easily connected to one another. This also simplifies the connections and routing of the high-voltage lines and sensor lines or the like.

In a further advantageous embodiment of the invention, the first battery module has a third cell stack with a plurality of third battery cells, the third cell stack being arranged in the first module housing in the second direction next to the first cell stack, in particular the battery module arrangement having a cable duct extending in the third direction comprises, which is arranged at least in part between the first and third cell stack. As already mentioned, it is very advantageous to provide two cell stacks in a battery module, which are arranged next to one another in the longitudinal direction, ie the second direction that corresponds to the transverse direction of the vehicle. Correspondingly, a cable duct can also be provided between two such pairs of cell stacks. As described, it is preferred that this is not arranged in the first direction above the cell stack and in particular above the module housing, but rather is at least partially or completely integrated into the battery modules in relation to the first direction. This can be achieved in that, for example, the module housings have a central or central notch in relation to the second direction. The two cell stacks arranged in the same cell module can also be at a distance from one another in relation to the second direction, as a result of which installation space is provided for this cable duct between these two cell stacks. The cable duct thus advantageously requires no installation space in the first direction. The great advantage of the front-side arrangement of the cell poles of the respective cell stack in the second direction is also evident here, since in this way the connections of the high-voltage lines can also easily be routed to at least two cell poles. Other lines, such as sensor lines or the like, as well as various electrical or electronic components and sensors, can also be arranged in this cable duct. With such an embedding, no additional space has to be taken into account, which would possibly complicate the modular concept.

The invention also relates to a battery module for a battery module arrangement, in particular a battery module arrangement according to the invention, the battery module being designed as the first battery module of the battery module arrangement according to the invention or the battery module arrangement according to an exemplary embodiment of the invention. The advantages described for the battery module arrangement according to the invention and its configurations therefore apply in the same way to the battery module according to the invention.

Furthermore, the invention also relates to a motor vehicle with a battery module arrangement according to the invention or one of its embodiments. Here, too, the advantages mentioned for the battery module arrangement according to the invention and its embodiments apply in the same way to the motor vehicle according to the invention. Furthermore, it is preferred that the first direction runs in the direction of a vehicle vertical axis, the second direction in the direction of a vehicle transverse axis and the third direction in the direction of a vehicle longitudinal axis. In this way, the installation space available in the motor vehicle can be optimally flexibly utilized by the battery module arrangement.

The motor vehicle according to the invention is also preferably designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle. In addition, the motor vehicle is preferably designed as an electric vehicle and/or hybrid vehicle.

The invention also includes the combinations of features of the described embodiments. The invention also includes implementations that each have a combination of the features of several of the described embodiments, unless the embodiments were described as mutually exclusive.

• 1 eine schematische Querschnittsdarstellung eines Kraftfahrzeugs mit einer Hochvoltbatterie gemäß einem Ausführungsbeispiel der Erfindung;
• 2 eine schematische Querschnittsdarstellung einer Hochvoltbatterie für ein Kraftfahrzeug mit einer Modulanordnung gemäß einem Ausführungsbeispiel der Erfindung;
• 3 eine schematische Querschnittsdarstellung eines Teils der Batteriemodulanordnung aus 2 zur Veranschaulichung des Kopplungsmechanismus zwischen den Batteriemodulen; und
• 4 eine schematische und perspektivische Darstellung einer Batteriemodulanordnung gemäß einem weiteren Ausführungsbeispiel der Erfindung.

Exemplary embodiments of the invention are described below. It shows:

• 1 a schematic cross-sectional view of a motor vehicle with a high-voltage battery according to an embodiment of the invention;
• 2 a schematic cross-sectional view of a high-voltage battery for a motor vehicle with a module arrangement according to an embodiment of the invention;
• 3 a schematic cross-sectional representation of a part of the battery module arrangement 2 to illustrate the coupling mechanism between the battery modules; and
• 4 a schematic and perspective view of a battery module arrangement according to a further embodiment of the invention.

The exemplary embodiments explained below are preferred embodiments of the invention. In the exemplary embodiments, the described components of the embodiments each represent individual features of the invention that are to be considered independently of one another and that each also develop the invention independently of one another. Therefore, the disclosure is also intended to encompass combinations of the features of the embodiments other than those illustrated. Furthermore, the described embodiments can also be supplemented by further features of the invention that have already been described.

In the figures, the same reference symbols designate elements with the same function.

1 shows a schematic cross-sectional illustration of a motor vehicle 10 with a high-voltage battery 12 according to an exemplary embodiment of the invention. The high-voltage battery 12 has in particular a battery module arrangement 14 according to an exemplary embodiment of the invention. The battery module arrangement 14 is divided into several sections 16a, 16b, 16c, 16d, which have a different height in a first direction, here the z-direction shown. The respective sections 16a, 16b, 16c, 16d can in turn contain one or more battery modules 18 (cf 2 ), which in turn have a plurality of battery cells 22 (cf 2 ) as will be described later in more detail. Furthermore, these sections 16a, 16b, 16c, 16d are arranged next to one another in the y-direction shown here. The y-direction corresponds to the direction of a vehicle longitudinal axis of the motor vehicle 10, the z-direction to the direction of a motor vehicle vertical axis and the x-direction to the direction of a motor vehicle transverse axis.

The invention and its embodiments provide a modular concept that makes it possible to provide such sections 16a, 16b, 16c, 16d with different heights in the z-direction in a particularly simple and efficient manner and to couple them to one another, as is shown below with reference to 2 until 4 is explained in more detail. This advantageously makes it possible to use the installation space available in a motor vehicle 10 for accommodating a battery, such as the present high-voltage battery 12, in a particularly advantageous and efficient manner. Due to the typical size of a high-voltage battery 12, it is often installed in an underbody area, as in 1 shown, housed. With conventional high-voltage batteries, a compromise always has to be made between ergonomics, design and the range to be provided. As in 1 As can be seen, there is often more installation space available in the z-direction below the seating areas of passengers 19 than, for example, in a foot area 21. However, conventional high-voltage batteries are designed with a constant height in the z-direction. This then means either that the installation space available under the seating area of the passengers 19 cannot be fully utilized if comfortable space is to be provided for the occupants 19 in the foot area 21 . Conversely, if the battery is designed in such a way that the entire installation space below the seating area of the passengers 19 is used in the z-direction, this results in a very uncomfortable position in the foot area 21, which would then also be filled with battery modules. The invention and its embodiments, on the other hand, make it possible to provide different sections 16a, 16b, 16c, 16d with different heights in the z-direction in a particularly simple and efficient manner, so that efficient use of space is reconciled with an ergonomic design of the battery 12 can be. In addition, there is advantageously not only the possibility of scaling the battery 12 in the z-direction, but also, for example, in the y-direction through the number of battery modules 18 installed 2 until 4 described.

2 FIG. 1 shows a cross-sectional view of a battery module arrangement 14, which is in turn designed as a high-voltage battery 12, according to a further exemplary embodiment of the invention. This in 2 The coordinate system shown corresponds in particular to that shown in FIG 1 . In this example too, the battery module arrangement 14 again has sections 16e, 16f, 16g which are arranged next to one another in the y-direction and have different heights in the z-direction. Each of these sections 16e, 16f, 16g in turn has at least one battery module 18, in this example a plurality of battery modules 18 respectively. A respective battery module 18 comprises at least one cell stack 20 each with a plurality of battery cells 22 arranged one above the other in the z-direction, which are preferably designed as pouch cells. For reasons of clarity, in 2 per section 16e, 16f, 16g only one cell stack 20 and one battery cell 22 are provided with a reference number. In addition, each battery module 18 has a module housing 24 which is designed as an extruded profile and has an essentially rectangular cross section in a cross-sectional plane perpendicular to the x-direction shown.

By using pouch cells as battery cells 22, the height of the respective cell stacks 20 can be adapted particularly flexibly to the available space, since pouch cells 22 generally only have a very small height in the range of, for example, 12 mm to 13 mm. In this example, sections 16e and 16g have more pouch cells 22 than battery modules 18 in section 16f. In addition, a respective battery module 18 can also have a plurality of such cell stacks 20 next to one another in the x-direction, preferably a total of two. A cable duct 26 can be formed between these two cell stacks 20 in the x-direction, which is at least partially recessed in the z-direction relative to an upper side of the respective battery modules 18 . This has the great advantage that no additional installation space needs to be provided in the z-direction, for example for the routing of high-voltage cables or the like. The extruded profiles that provide the respective module housing 24 can be correspondingly notched, that is to say have a notch that extends in the y-direction and is located, for example, in the middle of the respective housing 24 with respect to the x-direction. Such a cable duct 26 is, for example, in 4 in the form of such a notch in the extruded profile which the housing 24 provides.

The housing sides of the battery housing 24 facing one another in the y-direction are also referred to as coupling sides 28, 30, some of which are also referred to below as coupling walls 28, 30. For reasons of clarity, these coupling sides 28, 30 are shown in 2 illustrated only for some battery modules 18. An enlarged section is shown for better visibility 2 once again in 3 shown.

3 14 thus shows a schematic cross-sectional illustration of a part of the battery module arrangement 14 2 , especially in the area of the left section 16e.

For simplification, a first battery module 18 is denoted by 18a, and the battery module 18 arranged next to it in the y-direction is denoted by 18b as the second battery module. Correspondingly, the first battery module 18a has a first module housing 24a and the second battery module 18b has a second module housing 24b. Nevertheless, both battery modules 18a, 18b can be of identical design, and in this example they are. This means that they also have the same height in the z-direction. The first module housing 24a has a first coupling side 30 which faces the second battery module 18b. The second module housing 24b of the second battery module 18b also has a second coupling side 28 which faces the first battery module 18a. Both coupling sides 28, 30 have coupling elements 32, 34 in the form of webs protruding from the respective coupling sides 28, 30 in the y-direction. First webs 34 are arranged on the first coupling side 30 and second webs 32 are arranged on the second coupling side 28. The first webs 34 are at a first distance from one another in the z-direction, which differs from a second distance, which the second webs 32 in z-direction to each other, differs, in particular by a web width in the z-direction. In this way, it can advantageously be achieved that these pairs of webs 32, 34, as in 3 shown, interlock when the first battery module 18a is placed on the second battery module 18b. Furthermore, the respective webs 32, 34, as in 3 can also be seen, arranged in an edge region of the respective coupling side 28, 30 in relation to the z-direction. Furthermore, the respective webs 32, 34 can be elongate in the x-direction and accordingly extend over the entire housing width of the respective module housing 24.

Such a coupling ensures that the battery modules 18 cannot be displaced relative to one another in the z direction in the coupled state. This promotes the flexural torsional rigidity of the overall housing, which is composed of the individual module housings 24, which is particularly advantageous with regard to crossing a bollard, i.e. a local force acting on the battery 12 from below in the z-direction, since this causes such a local force to act can be very well distributed over the entire housing, reducing the likelihood of localized damage to the battery 12. Due to the design as extruded profiles, the module housings 24 also have a particularly high level of protection against crushing in other directions, in particular in the x-direction.

However, a particularly great advantage of this coupling mechanism, which is provided by the corresponding design of the respective module housing 24, is that a gap 36 is provided between the first battery module 18a and the second battery module 18b or between the respective facing coupling sides 28, 30, in which a cooling device 40 can be included and is included in the present example. This cooling device 40 is used as a flexible heat exchanger carrier formed, that is, as a flexible cooling device 40 with walls that have no dimensional stability without support. Such a flexible cooling device 40 can be provided, for example, in the manner of an air mattress arranged in this intermediate space 36, which, however, cannot be filled with air but with a coolant, and such a coolant can flow through it. The cooling device 40 can be provided, for example, in the form of a film bag, which is arranged in this intermediate space 36 and is supported on both sides by the respective coupling walls 28, 30. A particularly efficient heat dissipation can be provided by such a flexible cooling device 40, since such a flexible bag can cling to the respective coupling walls 28, 30 in a form-fitting manner, as a result of which gaps and thus a reduction in heat transfer can be avoided. By providing the module housing 24 as extruded profiles, which can have a wall thickness in the area of the coupling walls 28, 30 of 2 to 3 mm, for example, it is advantageously possible to provide sufficient support for such a flexible cooling device 40. In order to keep such a flexible cooling device 40 in shape, very high contact forces are required, which cannot be provided with conventional battery systems in order to ensure a vertical arrangement of such a cooling device 40, as in 3 shown to allow. For example, such supporting forces cannot be applied by battery cells themselves without running the risk of damaging the cells, since their cell housings typically do not provide sufficient stability, especially when it comes to pouch cells. The battery module arrangement 14 according to the invention and its embodiments can thus kill several birds with one stone. The coupling mechanism described, which is provided by the respective coupling walls 28, 30, can therefore not only provide a particularly flexible and adaptable coupling mechanism, but at the same time a particularly advantageous functional integration of a vertical and flexible cooling device 40 is made possible. This cooling device 40 arranged between the respective battery modules 18 can accordingly be used simultaneously for cooling all of the cells 22 arranged in the respective modules 18 . A particularly efficient cooling over the entire height of the stack in the z-direction can advantageously be provided in this way. Nevertheless, a further cooling device can also be provided below the entire battery module arrangement 14 in the z-direction in order to further increase the cooling efficiency. Such a cooling device 40 can advantageously simultaneously function as a tolerance compensation device, since the distances between the battery modules 18 cannot always be identical due to production-related tolerances, for example also the respective webs 32, 34. Smaller tolerances in the millimeter range, for example in the range of 0.5 mm, can thus easily be compensated for by the flexible cooling device 40. The distances between two battery modules 18 or their coupling walls 28, 30 are preferably between 4.5 and 5 mm. A particularly space-efficient but at the same time effective cooling of the battery modules 18 can thus be provided.

In order to create a transition between battery modules 18 of different heights in the z-direction that is particularly efficient and above all effective for production, an adapter plate 41 can also be arranged between such battery modules 18 of different heights, as is now the case in connection with FIG 4 is explained in more detail.

4 14 again shows a schematic and perspective view of a battery module arrangement 14 with two battery modules 18, which are now referred to here as the third battery module 18c and the fourth battery module 18d for better differentiation. The third battery module 18c includes a module housing 24, referred to herein as the third module housing 24c, and the fourth battery module 18d includes a corresponding fourth module housing 24d. Both module housings in turn have corresponding coupling walls 28, 30 with the webs 32, 34 described above. Since the two battery modules 18c, 18d now have different heights in the z-direction, the corresponding pairs of webs 32, 34 cannot couple to one another as described above if the module housings 24c, 24d were to be arranged directly next to one another. If, on the other hand, the first webs 34 of the third battery module 18c on its first coupling side 30 were to be arranged at a smaller distance from one another, so that they could couple to the second webs 32 of the fourth battery module 18d, this would in turn require a special production of a respective module housing 24. Above all, however, this would result in the intermediate space directly adjoining the first coupling side 30, which in 4 denoted by 36a, are thereby interrupted. This could no longer be a continuous cooling device 40, such as 3 described, arranged. Accordingly, it is now particularly advantageous to arrange such an adapter plate 41 between two such battery modules 18c, 18d of different heights, as is shown in 4 is shown. This points to a third battery module 18c side facing a first pair of webs 42, which protrudes from the adapter plate 41 against the illustrated y-direction and with the pair of webs 34 of the third module housing 24c as in 4 shown and for example to 3 described can couple. Correspondingly, the adapter plate 41 also has a second pair of webs 44, which protrudes in the y-direction, the webs 44 in question being at a smaller distance from one another in the z-direction than the webs 42, so that this second pair of webs 44 can be connected to the pair of webs 32 of the fourth module housing 24d can couple, in particular as in 4 shown and also already closed 3 described. An adapter plate 41 designed in this way now provides two intermediate spaces 36a, 36b between the two battery modules 18c, 18d, specifically a first intermediate space 36a between the adapter plate 41 and the third battery module 18c, and a second intermediate space 36b between the adapter plate 41 and the fourth battery module 18d. In both spaces 36a, 36b is preferably in turn a cooling device 40 as for 3 arranged as described, although these in 4 are not shown. This can also advantageously provide a large-area cooling over the complete coupling sides 28, 30 of the respective battery modules 18 away, even if battery modules 18 adjoining one another do not have the same height in the z-direction.

Furthermore, in 4 , as already mentioned above, the cable duct 26, for example for the routing of HV lines that can be coupled to the battery cells 22 to see. This is arranged recessed in the battery module arrangement 14 in the z-direction, so that it does not require any additional installation space in the z-direction. Accordingly, a battery module 18 can have two cell stacks 20, which are 4 are designated as 20a and 20b for better distinguishability. These are arranged next to one another in the x-direction, with the second cell stack 20b in 4 is covered by the module housing 24c. Two cell stacks 20 can also be accommodated in the fourth module housing 24d, which are not explicitly shown here as an example. Furthermore, the cell poles 46 of the respective battery cells 22 are preferably arranged on the front side in relation to the x-direction, in particular partly pointing away from the cable duct 26 and partly pointing towards the cable duct 26, for example one pole 46 pointing away to the cable duct 26 and the other of the two Poles 46 of a cell 22 pointing towards the cable channel 26. This enables a particularly simple interconnection, for example by means of cell connectors 48, since this interconnection can take place at least partially in the area of the open sides of the housing 24. In addition, with this arrangement, the two poles pointing in the same direction of two cells 22 lying one above the other in a cell stack 20 can simply be connected by a cell connector 48 .

Furthermore, the extruded profiles that are open on one or both sides and that provide the module housing 24 can also provide a simple exhaust gas discharge for gases escaping from battery cells 22 in the event of a thermal runaway, which is not explicitly shown. Such a gas duct can be used, for example, by means of an exhaust manifold between a respective module 18, in particular on the outside in relation to the x-direction, and a frame profile 50 (cf 2 ) take place. Such a frame profile 50 can, for example, run below the battery modules 18 and, for example, also act as a carrier for the battery modules 18 . Such a frame profile 50 can also be designed as a hollow space or also be provided as an extruded profile, as a result of which exhaust gas discharge is possible in a simple manner inside such a profile. It is thus advantageously possible to conduct gases escaping from the battery cells 22 out of the entire battery 12 along the y-direction shown.

Overall, the examples show how a “tailored battery” can be provided by the invention, ie a battery in the form of a battery module arrangement that can be tailored to the installation space available in a motor vehicle in a particularly simple and efficient manner.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was 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.

Patent Literature Cited

• DE 102017200479 A1 [0003]
• DE 102017211365 A1 [0004]

Claims (10)

Battery module arrangement (10, 12) with a first battery module (18, 18a, 18c), - wherein the first battery module (18, 18a, 18c) has a first cell stack (20) with a plurality of first battery cells (22), which are in a first Direction (z) are arranged one above the other, - wherein the first battery module (18, 18a, 18c) has a first module housing (24, 24a, 24c), in which the first cell stack (20) is arranged, - wherein the first module housing (24 , 24a, 24c) has a longitudinal extent in a second direction (x) perpendicular to the first direction (z), characterized in that - the battery module arrangement (10, 12) has a second battery module (18, 18b, 18d), - the one second cell stack (20) with a plurality of second battery cells (22) arranged one above the other in the first direction (z), - and a second module housing (24, 24b, 24d), in which the second cell stack (20) is arranged, - wherein the second module housing (24, 24b, 24d) a longitudinal extension in the two th direction (x), - wherein the first and the second module housing (24, 24a, 24b, 24c, 24d) in a third direction (y) perpendicular to the first and second direction (z, x) are arranged next to each other, - wherein the first module housing (24, 24a, 24c) has a first coupling wall (30) facing the second module housing (24, 24b, 24d) and the second module housing (24, 24b, 24d) has a first module housing (24, 24a, 24c) facing second coupling wall (28), - wherein the first module housing (24, 24a, 24c) and the second module housing (24, 24b, 24d) can be coupled to one another in such a way that between the first and second coupling wall (30, 28) at least one first intermediate space (36, 36a, 36b) for receiving a cooling device (40) for cooling the first and/or second battery cells (22) is provided. Battery module arrangement (10, 12) after claim 1 , characterized in that the battery module arrangement (10, 12) has the cooling device (40) through which a coolant can flow, wherein the cooling device (40) is designed so flexibly that when the coolant is flowing through the cooling device (40) at least part of a coolant pressure can be transmitted to the first coupling wall (30) of the first module housing (24, 24a, 24c) and/or the second coupling wall (28) of the second module housing (24, 24b, 24d). Battery module arrangement (10, 12) after claim 2 , characterized in that the cooling device (40) has a flexible cooling bag through which a cooling medium can flow, the cooling bag having a first bag wall and a second bag wall lying opposite the first bag wall in the third direction (y), the first bag wall in when the cooling bag is in a state in which a cooling medium is flowing through it is in contact with the first coupling wall (30) and/or the second bag wall is in contact with the second coupling wall (28), in particular over an area related to at least a large part of the first and/or second coupling wall (30, 28) . Battery module arrangement (10, 12) according to one of the preceding claims, characterized in that the first and second battery cells (22) represent pouch cells (22) and in particular a respective height in the first direction (z) between 5 mm and 15 mm (12 to 13), a width in the third direction (y) between 80 mm and 150 mm and a length in the second direction (x) between 500 mm and 600 mm. Battery module arrangement (10, 12) according to one of the preceding claims, characterized in that the first coupling wall (30) of the first module housing (24, 24a, 24c) has two first webs (34) protruding in the third direction (y), which in have a first distance from one another in the first direction (z), the first module housing (24, 24a, 24c) having a second coupling wall (28) opposite the first coupling wall (30), in particular for coupling to a third battery module (18), wherein the second coupling wall (28) has two second webs (32) protruding in the third direction (y) and having a second distance from one another in the first direction (z) which differs from the first distance, in particular wherein the first and second Webs (34, 32) are arranged in an edge region of the first and second coupling wall (30, 28) with respect to the first direction (z). Battery module arrangement (10, 12) according to one of the preceding claims, characterized in that the first battery module (18, 18c) has a different height in the first direction than the second battery module (18, 18d), the battery module arrangement (10, 12) has an adapter plate (41) which is arranged between the first and second battery module (18, 18c, 18d) and which is connected in this way to the first coupling wall (30) of the first module housing (24, 24c) and the second coupling wall (28) of the second module housing (24, 24d) is coupled in that the first intermediate space (36a) is formed between the adapter plate (41) and the first coupling wall (30) and between the adapter plate (41) and the second coupling wall (28) of the second module housing ( 24, 24d) a second intermediate space (36b) for receiving a second cooling device (40) is formed. Battery module arrangement (10, 12) according to one of the preceding claims, characterized in that the first module housing (24, 24a, 24c) has two opposite open sides in the second direction (x), in particular wherein the first module housing (24, 24a, 24c ) is designed as an extruded profile, the first battery cells (22) having cell poles (46) which are arranged on a respective end face of a respective first battery cell (22), the first battery cells (22) being mounted in the first module housing (24, 24a, 24c) are arranged such that the end faces point in the second direction. Battery module arrangement (10, 12) according to one of the preceding claims, characterized in that the first battery module (18, 18a, 18c) has a third cell stack (20b) with a plurality of third battery cells (22), the third cell stack (20b) in the first Module housing (24, 24a, 24c) is arranged next to the first cell stack (20, 20a) in the second direction (x), in particular wherein the battery module arrangement (10, 12) has a cable duct (26) extending in the third direction (y). which is arranged at least in part between the first and third cell stacks (20a, 20b). Battery module (18, 18a, 18b, 18c, 18d) for a battery module arrangement (10, 12), the battery module (18, 18a, 18b, 18c, 18d) being the first battery module (18, 18a, 18c) of the battery module arrangement (10 , 12) according to one of the preceding claims. Motor vehicle (10) with a battery module arrangement (10, 12) according to one of Claims 1 until 8th , The first direction (z) running in the direction of a vehicle vertical axis, the second direction (x) in the direction of a vehicle transverse axis and the third direction (y) in the direction of a vehicle longitudinal axis.

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