Abstract:
The invention relates to a method for manufacturing a battery ( 10 ) in which at least one battery module ( 12 ) having a plurality of battery cells ( 14 ) is provided. A cooling device ( 26 ) is selected depending on whether liquid cooling or cooling by a gaseous medium is intended for the at least one battery module ( 12 ). Depending on the selection, at least one first heat sink ( 26 ), through which a cooling liquid can flow, or at least one second heat sink, through which a gaseous medium can flow, is arranged on the at least one battery module ( 12 ) as the cooling device. The invention further relates to a battery arrangement and a modular system for producing a battery ( 10 ).

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is the U.S. National Stage of International Application No. PCT/EP2012/004881, filed Nov. 27, 2012, which designated the United States and has been published as International Publication No. WO 2013/083241 and which claims the priority of German Patent Application, Serial No. 10 2011 120 234.3, filed Dec. 5, 2011, pursuant to 35 U.S.C. 119(a)-(d). 
     BACKGROUND OF THE INVENTION 
     The invention relates to a method for manufacturing a battery, wherein at least a battery module is provided and has a plurality of battery cells, and wherein a cooling device is arranged to which at least a battery module. Furthermore, the invention relates to a battery arrangement, and a modular system for manufacturing a battery. 
     Electrically powered vehicles receive the energy, required for the drive, from a battery. To ensure a long battery life, heat is dissipated from the battery during operation to thus cool it. It is known hereby to use a liquid medium or a gaseous medium for cooling. 
     For example, DE 10 2009 037 012 A1 describes a battery unit for a hybrid vehicle, in which the battery unit has a battery channel. The battery channel has a first channel, in which an exhaust pipe of the hybrid vehicle and a cooling channel are arranged. The cooling channel is hereby arranged between the channel for the exhaust pipe and a bottom side of the battery unit. For controlling a temperature of the battery unit, air or a cooling liquid can be conducted through the cooling channel. 
     DE 10 2009 058 808 A1 describes a vehicle drive battery arrangement having a battery cell group, and a cooling apparatus. The cooling apparatus includes a carrier member which is configured as a ribbed hollow body in which reinforcing ribs and U-shaped brackets for a coolant duct are formed. Locking lugs on both sides of the coolant duct provide a formfitting attachment of the coolant duct on the carrier member. A spring elastic contact plate is arranged on the carrier member and maintained under tension against an underside of the battery cell group, when the cooling apparatus is attached to the battery cell group. 
     DE 10 2009 058 810 A1 also discloses a vehicle drive battery with a battery cell group and a cooling apparatus. A heat transfer member of the cooling apparatus is hereby configured to be resilient and extends convexly to a flat side when in a state in which it is not secured to the flat side of the battery cell group. The heat transfer member is screwed onto the flat side of the battery cell group and maintained hereby under elastic tension. Coolant ducts are in contact with the heat transfer member. 
     US 2008/0251246 A1 describes a cooling structure for batteries and electrical components such as control units and a converter. The batteries and the electrical components are hereby arranged in a receiving space in the vehicle floor of a hybrid vehicle. Two fans are used to cool the batteries, with cooling ribs of the electrical components being arranged in the cooling air flow downstream of the batteries. 
     Furthermore, EP 2 017 919 A1 describes a battery having a plurality of battery cells which are arranged in a housing. The housing forms cooling channels through which cooling air or cooling water can selectively flow. 
     In particular, when the battery is arranged in a vehicle, the specific installation space conditions must be considered. This means that depending on the vehicle type and the cooling provided for the vehicle type—such as liquid cooling or gas cooling—different cooling devices have to be provided. 
     As a consequence of the different configuration of the cooling devices, a great number of variants are needed, so that the manufacture becomes comparatively laborious and cost-intensive. In addition, depending on the shape of the battery modules and the cooling devices, appropriate receiving systems must be provided, which also has a negative effect on the complexity and costs during manufacture. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide a method of the afore-mentioned type as well as a battery arrangement and a modular system to enable a particularly simple and cost-effective manufacture. 
     The According to one aspect of the invention, the object is achieved by a method for manufacturing a battery used in particular in a vehicle, including the following steps:
     a) providing at least one battery module having a plurality of battery cells;   b) determining demands from a cooling device for the battery, depending on whether liquid cooling or a cooling system with a gaseous medium is intended to be used for the battery;   c) selecting the cooling device in dependence on whether the liquid cooling or the cooling with a gaseous medium is provided for the at least one battery module;   d) arranging at least a first heat sink, through which a cooling liquid can flow, or at least a second heat sink, through which the gaseous medium can flow, on the at least one battery module as cooling device in dependence on the selection made in step b).   

     Depending on the desired type of cooling, the appropriate type of heat sink is arranged on the at least one battery module. This allows the use of a uniform battery module, even when different types of cooling of this battery module are provided. Such a modular design of the battery allows implementation of a simple and cost-efficient manufacture. Thus, depending on the posed cooling demands, the appropriate heat sink is chosen. The first heat sink may hereby in particular differ from the second heat sink such as to conform to the type of medium guided there through. 
     The use of a uniform battery module, especially useable for different vehicle types, enables a reduction in development costs and manufacturing cost for the battery. 
     The cooling medium used for cooling the battery may also be used for initial heating of the battery module, when the ambient temperature is low and thus when the battery is cold, so that the battery module reaches its desired capability particularly rapidly. For this purpose, the cooling medium used in the cooling mode for cooling the battery can be heated and then supplied to the still comparatively cold battery module. The cooling liquid or the gaseous cooling medium can therefore also provide heating of the battery module. 
     Preferably the first or the second heat sink is brought into contact with the at least one battery module to ensure in the cooling mode a particularly efficient removal of heat from the battery module. 
     When the selection of the cooling device is executed in dependence on the provision of a liquid cooling or a cooling with the gaseous medium by using a computing unit, a particularly efficient manufacture of the battery can be achieved. 
     A further advantage has been shown when the at least one first or second heat sink is placed in a receiving space which is formed between a support device and the at least one battery module. As a result, the support device and the battery module can be provided as unitary structures, useful in particular for different types of vehicle, regardless of the provided type of cooling. In this way, the battery can be manufactured with particularly low development costs and manufacturing costs. 
     The receiving space has defined cooling surfaces, at which heat can be removed from the battery module during the cooling mode, after placement of the first or second heat sink in the receiving space. The receiving space itself is, however universal, i.e. independent on whether it accommodates the heat sink for liquid cooling or the heat sink for cooling with a gaseous medium. The introduction of the particular heat sink in the receiving space results in a vehicle-specific battery, when the battery is used for a vehicle. 
     According to a further advantageous configuration, the at least one second heat sink through which the gaseous medium can flow, forms at least one cooling channel which is bounded by the support device at least on one side. As a result, efficient heat dissipation is realized, without the need to take particular measures to seal the at least one cooling channel. 
     It has been shown as a further advantage, when the at least one first heat sink, through which the cooling liquid can flow, is formed as a hollow body which is closed about the outer circumference and on which a battery module is arranged. As a result, the heat sink is particularly well designed to realize a liquid cooling, regardless of situations at hand at an installation site. 
     It is furthermore preferred when the at least one first or second heat sink is formed as a profile part which is formed through extrusion and on which at least one battery module is arranged. As a result, the respective heat sinks can be easily and inexpensively produced, and they can be especially easily brought to a length intended for cooling the battery module. 
     When the at least one first or the at least one second heat sink is made of an aluminum alloy, heat can be dissipated especially well via the latter. This is particularly true when cooling is provided by a gaseous medium. Such a cooling can be assisted in particular when leading the gaseous medium past a plurality of cooling ribs of the heat sink during the cooling mode. 
     Advantageously, the at least one first heat sink, through which the cooling liquid can flow, is arranged on the at least one battery module, when the battery is provided for an electric vehicle. In an electric vehicle, it is, in fact, of particular importance that even relatively large amount of heat can be dissipated very rapidly. In addition, demands of cooling capacity for liquid cooling can be complied with particularly easily or met with particularly accuracy. 
     Preferably, the at least one second heat sink, through which the gaseous medium can flow, is arranged on the at least one battery module, when the battery is provided for a hybrid vehicle. Using a gas cooling—and especially air cooling—the desired cooling capacity can easily and safely be realized in hybrid vehicles in a simple and for the type of application sufficient manner. 
     Finally, it has shown to be advantageous when at least two battery modules are arranged in the battery as viewed in flow direction of a cooling medium through the respective heat sink, together with the at least one heat sink associated to a respective one of battery modules in successive and/or side-by-side and/or superimposed relationship. By providing uniform battery modules and heat sinks respectively associated therewith, there is no need to provide particular cooling devices depending on the arrangement of the battery modules. Rather, the battery modules with their associated heat sinks can be flexibly coupled with one another. 
     When the battery modules are arranged behind one another, as viewed in flow direction, the heat sinks can also be very easily fluidly coupled with one another. In an arrangement of the battery modules with their associated heat sinks above one another or side-by-side, respective feed lines to inlets into the corresponding heat sinks are provided and branches which are connected to respective outlets of the heat sinks. 
     According to another aspect of the invention, the object is achieved by a battery arrangement, provided in particular for a vehicle, including at least a battery module having a plurality of battery cells. A support device of the battery arrangement is configured to hold the at least one battery module. The at least one battery module and the support device form a receiving space for at least one heat sink. The support device or the battery module includes at least one guide by means of which the at least one heat sink is brought into contact at least during introduction in the receiving space. The guide facilitates the insertion of the heat sink, provided for a respectively desired type of the cooling being a liquid cooling or a cooling with a gaseous medium, into the receiving space, so that the battery arrangement can be provided with a heat sink, provided for the application at hand, depending on the desired cooling. 
     In this way, a heat sink through which a cooling liquid can flow can be easily placed into the receiving space, when a liquid cooling system of the battery module is provided. As an alternative, also a heat sink through which a gaseous cooling medium can flow can be placed in the receiving space, when the at least one battery module is cooled by the gaseous medium. A simple and cost-effective production of a battery can be realized, when the heat sink provided for the particular application is guided along the at least one guide into the receiving space. 
     The support device preferably includes two rails substantially of L-shape in cross section for support of the at least one battery module. Thus, the rails maintain integrity of the battery module from below and to the side, when the battery module is arranged on the rails. 
     When being formed through extrusion, the two rails can be provided in a particularly easy manner with the intended length for support of the at least one battery module. As a robust and yet lightweight material, aluminum alloy in particular can hereby be used for the rails. 
     It has been shown as further advantageous, when the support device includes a support plate to connect the two rails, with the receiving space for the at least one heat sink being provided by the support plate, the two rails, and a bottom of the at least one battery module. In this way, the standardized receiving space can be formed in a simple way with components that are cost-effective and readily available, and can selectively accommodate the heat sink through which the cooling liquid can flow or the heat sink through which the gaseous medium can flow. The support plate can be formed in particular from: plastic. 
     Finally, it has been shown to be advantageous when the at least one guide is configured as a guide bar. Then, the at least one heat sink does not only contact the guide bar when introduced into the receiving space. Rather, the guide bar secures also the heat sink, placed into the receiving chamber, easily and reliably like a stop. This is especially true when the heat sink is surrounded on each of both sides by a guide bar. The at least one guide rail is especially easy to provide when configured in one piece with the support plate. 
     According to still another aspect of the invention, the object is achieved by a modular system for manufacturing a battery, including at least one battery module having a plurality of battery cells. Further provided is a support device for holding the at least one battery module, and at least one cooling device which can be arranged on the at least one battery module. The at least one cooling device includes hereby a first heat sink through which a cooling liquid can flow and/or a second heat sink through which a gaseous medium can flow. The at least one battery module and the support device can define a receiving space for at least one of the heat sinks, with the receiving space being universally configured for arrangement of the first or the second heat sink. Thus, either the modular system can be used for manufacturing a battery with liquid cooling, or the modular system for manufacturing a battery with a gas or air cooling, or the modular system may include both heat sinks, so that the desired heat sink can be selectively arranged on the battery module. 
     The advantages described for the method according to the invention and the battery arrangement according to the invention and preferred embodiments also apply for the modular system according to the invention, and vice versa. 
     The foregoing features and feature combinations mentioned in the description and the features and feature combinations mentioned hereinafter in the figure description and/or shown alone in the figures are applicable not only in the respectively indicated combination, but also in other combinations or taken alone, without departing the scope of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       Further advantages, features and details of the invention will become apparent from the claims, the following description of preferred embodiments, and from the drawings, in which like or functionally same elements are provided with identical reference signs. It is shown in: 
         FIG. 1  a sectional view of a portion of a battery with liquid cooling; 
         FIG. 2  a sectional view of a portion of a battery of identical construction, but with air cooling; and 
         FIG. 3  a flow diagram illustrating the manufacture of a battery in which liquid cooling or gas cooling is selectively used. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       FIG. 1  shows a section of a battery module  12  of a battery  10 , which can be configured as vehicle battery in particular, with the battery module  12  having a plurality of battery cells  14 . The battery cells  14  are electrically isolated from each other by so-called separators or spacers  16 . The battery module  12  is bounded to the side by respective side plates  18  which are also referred to as binders. The side plates  18  fix the spacers  16  relative to one another and connect (here not shown) end plates of the battery module  12  with one another to close the battery module  12  towards its end faces. 
     The battery  10  also includes a support device  20  having two rails  22  of L-shape in cross section, which are preferably formed as extrusions from an aluminum alloy. The rails  22 , which are arranged at respective corners of the battery module  12 , support the battery module  12  from below and embrace the battery module  12  to the sides. 
     The two rails  22  are connected to one another by a support plate  24  having ends which—as shown here by way of example—engage longitudinal grooves formed in the two rails  22 . In alternative embodiments, other types of connection of the support plate  24  to the rails  22  can be realized. 
     The support plate  24  bounds to the lower side a receiving space  25  which is bounded at the top by a bottom of the battery module  12 . In the battery  10  shown in  FIG. 1 , two heat sinks  26  formed as closed hollow bodies are placed in this receiving space  25  and in contact with both the support plate  24  and the bottom of the battery  12 . 
     These heat sinks  26  are provided for liquid cooling of the battery module  12 , i.e. a cooling liquid flows there through during cooling mode. In this way, especially large amounts of heat can be removed from the battery module  12 . Therefore, such a cooling device can be provided especially when the battery  10  is to be used in an electric vehicle which utilizes the electric energy solely made available by the battery  10  for propulsion. Cooling channels  28  of the respective heat sink  26  may be separated from each other by a partition wall  30  or by a plurality of partition walls. 
     Formed in one piece with the support plate  24  are guide rails  32  which laterally embrace here the two heat sinks  26  and facilitate insertion of the heat sinks  26  into the receiving space  25 . When being placed into the receiving space  25 , the respective heat sinks  26  contact the two guide rails  32  that laterally embrace them. In addition, the guide rails  32  secure the heat sinks  26  in their place in the receiving space  25 . 
     Particularly in conjunction with  FIG. 2 , it becomes clear that the same battery module  12  and the same support device  20  of the battery  10  may use as an alternative air-cooling or gas cooling. In the embodiment of the battery  10  shown in  FIG. 2 , two heat sinks  34  are placed in the receiving space  25  in respective regions laterally bound by the two guide rails  32  for cooling the battery module  12  by air or such a gaseous medium. 
     The two heat sinks  34 , just like the heat sinks  26  provided for the liquid cooling, are also arranged between the support plate  24  on one hand and the battery module  12  on the other hand and contact the battery cells of the battery module  12 . The two heat sinks  34  are formed in the battery  10  shown in  FIG. 2  as profile parts which are open towards the bottom side and have a plurality of cooling ribs  36 . The cooling ribs  36  define cooling channels that separated from each other and bounded downwardly by the support plate  24 . 
     While the heat sinks  26 ,  34  and the rails  22  are preferably made from an aluminum alloy through extrusion, plastic can be used in particular for the support plate  24 . 
     The battery  10  (see  FIG. 2 ) having air cooling can be used especially in a hybrid vehicle which poses less demands on the cooling of the battery  10  as opposed to a purely electrically powered vehicle. 
     The battery  10  can therefore selectively be equipped with heat sinks  26  provided for liquid cooling (see  FIG. 1 ) or heat sinks  34  provided for air cooling (see  FIG. 2 ), wherein the standardized receiving space  25  is provided for each of the two types of heat sinks  26 ,  34 . 
     The guide bars  32  are also provided in the receiving space  25  to facilitate insertion of the heat sink  26 ,  34  intended for the respectively desired type of cooling and to fix the respective heat sink  26 ,  34  in place. 
     Thus, a standardized battery module  12  and a standardized support device  20  are made available which can be provided with the appropriate heat sink  26 ,  34  depending on the desired cooling of the battery  10 . Therefore, there is no need to provide cooling devices that are specifically tailored to the particular shape of the battery  10 , but, depending on the desired type of cooling, the appropriate heat sink  26 ,  34  can be introduced into the receiving space  25 . 
       FIG. 3  illustrates a flow diagram  38  of a method to provide in dependence on the desired cooling for a battery  10  a suitable heat sink  26 ,  34  for the battery  10  that is specific for the vehicle. 
     In step  40 , the uniform battery module  12  and the uniform support device  20  are provided. Thereafter, in step  42 , demands on the cooling system for the desired battery  10  are determined. Subsequently, in step  44 , a selection of the cooling system is made depending on whether liquid cooling or air or gas cooling is to be used for the battery  10 . 
     When a liquid cooling is provided for the battery  10 , the heat sink  26 , through which a cooling liquid can flow, is placed in step  46  into the receiving space  25  formed between the support device  20  and the bottom of the battery module  12 . 
     When, on the other hand, air cooling system is selected for the battery  10  in step  44 , then the heat sink  34  through which gas or air can flow is arranged in step  48  into the receiving space  25  formed between the support device  20  and the bottom of the battery module  12 . 
     In both cases, a battery  10  is provided in step  50  which is suited to the vehicle-specific cooling requirements and which is modular in construction and thereby greatly reduces development costs and manufacturing costs. 
     The battery  10  provided for the particular vehicle may have a plurality of battery modules  12 . When these battery modules  12  are arranged behind one another, the support device  20  and the heat sinks  26 ,  34  can be provided with the intended length appropriate for several battery modules  12  in a particularly simple manner. 
     The battery modules  12  may, however, also be arranged side-by-side, in which case each battery module  12  is being provided preferably with a support device  20  having the appropriate length. Also the heat sinks are then preferably provided with the length appropriate for the respective battery module  12 . The battery  10  can then be cooled by merely connecting the respective cooling liquid conduits or cooling air conduits to the particular heat sink  26 ,  34 . This applies in a similar manner, when the battery modules  12  with their associated support devices  20  and heat sinks  26 ,  34  are stacked above one another in the vehicle.