Battery housing assembly with a housing cover for a motor vehicle battery, battery assembly, motor vehicle and method for mounting a battery assembly on a body-in-white of a motor vehicle.

Abstract

The invention relates to a battery housing arrangement (12) for a motor vehicle, which has a housing cover (18) designed for arrangement on a housing tray (20) including an interior space (22) which has a circumferential fastening area (74) for fastening the housing cover (18) to the housing tray (20), comprising an outer surface (18a) and an inner surface (18b) opposite the outer surface (18a) with respect to a first direction (z).It is provided that the battery housing arrangement (12) comprises a first structural element (24, 26), at least one connection area (80) of the outside (18a) which is different from the fastening area (74) is directed towards the first structural element (24, 26) and rests flat against the first structural element (24, 26), and the housing cover (18) comprises a through-opening (66) arranged in the connection area (80) and is attached to the structural element (24, 26) by means of a fastening element (62) passed through the through-opening (66) to the first structural element (24, 26).

Description

[0001] The invention relates to a battery housing assembly for a motor vehicle, wherein the battery housing assembly comprises a housing cover designed for mounting on a housing tray, including an interior space which has a circumferential mounting area for attaching the housing cover to the housing tray, and which comprises an outer surface and an inner surface opposite the outer surface with respect to a first direction. The invention further relates to a battery assembly, a motor vehicle, and a method for mounting a battery assembly.

[0002] Batteries, especially automotive batteries, such as high-voltage batteries, typically have a battery housing in which one and / or more battery modules, each containing one or more battery cells, can be arranged. With conventional designs, such a battery housing must generally be very rigid and robust to withstand crash loads and provide the best possible protection for the battery cells within, while also supporting the typically very high weight of these battery cells, which in the case of a high-voltage battery can amount to several hundred kilograms, for example, up to 500 kg. To further enhance the protection of the battery cells, an underride guard with a protective plate is often positioned beneath the battery. This guard can be mounted on the underside of the battery housing or on another supporting structure of the vehicle.This design of the battery, particularly the battery housing, as well as optional additional protective components such as the underbody protection, typically results in a very high weight. It would therefore be desirable to design such a housing to be lighter and / or less robust without compromising the protection of the battery cells.

[0003] CN 113889709 A describes a storage device designed to suppress the expansion of a cooling water jacket. The storage device comprises a storage module with a plurality of storage cells, the storage module being cooled by the cooling water oils. A mounting plate with clamps for securing the storage module is also provided. The cooling water jacket is positioned between the storage module and the mounting plate, and elastic elements are arranged on the underside of the cooling water jacket, which can be engaged by clamps on the mounting plate.

[0004] DE 10 2018 211 470 A1 describes a battery housing with a bottom section and an underride guard connected to it, wherein the underride guard and the bottom section are spaced apart from each other by a spacer which has a lower thermal conductivity than the bottom section and the underride guard.

[0005] DE 10 2019 214 920 A1 describes a battery pack for an electric vehicle, wherein a cooling medium jacket is formed between the underside of the bottom wall and the top of the cover element by attaching a cover element to a plurality of fastening sections provided on a bottom wall of the battery housing.

[0006] WO 2020 / 011680 A1 describes a battery housing with a lid section and a bottom section, which define a receiving space for one or more energy storage devices, and with an underride guard arranged below the bottom section, wherein the lid section, the bottom section and the underride guard are connected to each other by several fastening devices, each fastening device comprising a sleeve with a longitudinal bore arranged between the lid section and the bottom section, and a fastening element with a shaft and a bearing head formed on one side, guided through the longitudinal bore, wherein a sealing ring through which the shaft passes is arranged in the longitudinal bore, and a sealing device through which the shaft passes is provided between the underride guard and the bottom section, sealing the transition area of ​​the bottom section to the sleeve.

[0007] The problems mentioned above still remain.

[0008] The object of the present invention is to provide a battery housing arrangement, a battery arrangement, a motor vehicle and a method which makes it possible to design at least part of a battery housing in a simpler and / or less robust manner, and in particular to still provide protection for battery cells arranged in the housing.

[0009] This problem is solved by a battery housing arrangement, a battery arrangement, a motor vehicle, and a method with the features according to the respective independent patent claims. Advantageous embodiments of the invention are the subject of the dependent patent claims, the description, and the figures.

[0010] A battery housing arrangement according to the invention for a motor vehicle comprises a housing cover designed for mounting on a housing tray, including an interior space. The housing cover has a circumferential mounting area for attaching it to the housing tray, comprising an outer surface and an inner surface opposite the outer surface in a first direction. The battery housing arrangement includes a first structural body element, wherein at least one connection area of ​​the outer surface of the housing cover, distinct from the mounting area, faces the first structural body element and rests flat against it. The housing cover includes a through-opening arranged in the connection area and is attached to the structural body element by means of a fastening element passing through the through-opening.

[0011] The housing cover is thus advantageously attached to the structural frame element via a fastening element at its connection point, which differs from its circumferential mounting area. The fastening element, passing through the opening in the housing cover, is therefore partially located on the outside of a housing tray when the housing cover is arranged as intended, and partially located inside such a housing. This has the significant advantage that the fastening element can be used to transfer external loads acting on a battery housing or battery housing assembly, for example, loads directed in the first direction, through the battery housing to the structural frame element. Such loads can then advantageously be absorbed by the structural frame element and do not have to pass through the battery housing.This, in turn, allows for a significantly simpler and less robust design of such a battery housing. Simultaneously, it is possible to connect battery components inside such a housing directly to the body-in-white structural element via the mounting element, which is partially located inside the housing, in addition to the housing cover. Thus, the weight of these components does not rest on the housing, especially not on the housing cover, but is instead borne directly by the body-in-white structural element. This, too, allows for a significantly simpler and less robust design of the housing, as it does not need to be designed to support the entire weight of the battery. Instead, a large portion of the battery's weight can be borne by the body-in-white structural element itself.Connecting the housing cover to a structural element via a fastening element that passes through the through-hole in the connection area of ​​the housing cover thus advantageously enables a significantly simpler, lighter and less robust design of a battery housing as a whole.

[0012] The fastener can be, for example, a screw or a bolt. Generally, the fastener has a longitudinally extending neck and a head located at one end of the neck that widens relative to the neck.

[0013] The housing cover can have a rectangular shape or outer contour. The housing cover can, for example, lie in a plane perpendicular to the first direction or be oriented perpendicular to the first direction. The mounting area surrounding the edge can, for example, be provided by a flange area, which lies in a plane perpendicular to the first direction. The mounting area borders directly on and encompasses the edge of the housing cover. The housing cover can, for example, be divided into a mounting area and a central area of ​​the housing cover located within the mounting area and framed by the mounting area. The connection area is thus located in the central area of ​​the housing cover.In particular, the connection area with respect to the first direction is directly opposite the interior of the battery housing, which, when the housing cover is positioned on the housing tray as intended, is enclosed between the housing cover and the housing tray.

[0014] Furthermore, the housing cover can also include several connection areas, each of which may contain at least one through-opening through which a respective fastening element is passed, by which the housing cover is attached to the first or to a subsequent structural element. Multiple through-openings can also be provided in the same connection area, through which respective fastening elements are passed, by which the housing cover is attached to the structural element or to a subsequent structural element.

[0015] Furthermore, it is advantageous if the fastening element is sealed as it passes through the opening. This seal can be achieved through suitable sealing measures, which will be explained in more detail later. This ensures that the interior is hermetically sealed when the housing cover is attached to the housing tray.

[0016] The body-in-white structural element is a part of the body-in-white structure and / or body of a motor vehicle. In particular, the body-in-white structural element can be a crossmember of the vehicle. A motor vehicle typically has several crossmembers running transversely. This provides multiple attachment points through which the housing cover can be connected to such body-in-white structural elements, as well as optionally other components to be arranged inside the battery housing. This enables a particularly even distribution of forces across the body-in-white structure of the vehicle.

[0017] The terms "top" and "bottom," used in part within the scope of the present invention for the sake of simplicity, as well as directional terms derived therefrom, such as "above," "below," and / or directional or orientational terms relating to components or component parts, such as "top" and "bottom," e.g., with reference to the battery housing arrangement and the battery arrangement described later and / or its components, such as the module group, are intended, without limitation of generality, solely for better illustration and simpler description. These terms can be defined with respect to a defined coordinate system or with respect to a specific direction, which is referred to here as the first direction and which can represent one of the direction vectors spanning the defined coordinate system. This coordinate system or specific direction can be fixed with respect to the battery housing arrangement and / or the battery arrangement.This specific direction can, for example, be defined as pointing upwards. With regard to a intended or preferred installation position in a motor vehicle, this specific direction can correspond, for example, to a vehicle's vertical direction or vertical axis. Nevertheless, the battery housing arrangement and / or the battery arrangement can also be oriented differently, or be installed in a different orientation in a motor vehicle, for example, with its defined top side facing downwards with respect to a direction of gravity and / or with respect to a vehicle coordinate system.

[0018] According to a further highly advantageous embodiment of the invention, the battery housing assembly comprises a battery component which is attached to the first body-in-white structural element, in particular a cross member, by means of the fastening element, such that the housing cover is located between the battery component and the first body-in-white structural element. As already described, this is particularly advantageous because the weight of the battery component does not have to be borne by the housing cover or another housing component of a battery housing, but can be borne directly by the body-in-white structural element.

[0019] The battery component is a component that is to be arranged inside the battery housing. Specifically, the battery component can comprise one or more battery modules, each of which can contain one or more battery cells. Thus, the battery component can, for example, be a battery module assembly, as described in more detail later. In particular, all battery cells contained within a battery, especially a high-voltage battery, can be part of such a battery component. This allows the majority of the weight of such a battery to be directly supported by one or more structural body elements.

[0020] According to a further highly advantageous embodiment of the invention, the housing cover is designed as a plastic component. This allows the housing cover to be extremely lightweight. Furthermore, manufacturing such a housing cover as a plastic component is significantly simpler. Additionally, designing the housing cover from or with a plastic material offers considerably more flexibility with regard to shaping and similar aspects. Moreover, the housing cover can simultaneously provide electrical insulation. In other words, the housing cover can be electrically insulating.

[0021] A plastic component is understood to be, in particular, a component made from a material that includes a plastic. The material need not necessarily consist exclusively of such a plastic. The plastic component can also be made from a plastic that is at least partially fiber-reinforced. The material of the plastic component can also include further additives, fillers, particles, fibers, or similar materials. Such fibers can be, for example, glass fibers, aramid fibers, plastic fibers, or similar materials. The fibers can also be continuous fibers. This allows for additional reinforcement of the housing cover. Such reinforcement can also be implemented only in certain areas of the housing cover. The same applies, in particular, to the housing tray described later. For example, only the bottom of the housing tray can be reinforced.

[0022] Furthermore, the housing cover, or at least its outer surface, can be designed with a three-dimensional surface structure. The wall supporting the housing cover can itself be three-dimensionally shaped, or the housing cover can have a plate-shaped base element on which a protruding surface structure is arranged on the outside. Especially when the housing cover is made of plastic, such a three-dimensional surface structure can be produced very easily and cost-effectively, for example, using an injection molding process or similar method. Designing the outer surface with a three-dimensional surface structure offers several advantages: firstly, it provides additional stiffening to the housing cover. Secondly, it allows the housing cover to be adapted more efficiently to the spatial geometry between crossbeams.This in turn makes it possible to design the housing cover simultaneously as the central floor of the motor vehicle.

[0023] Accordingly, a further advantageous embodiment of the invention comprises a second structural element in the body shell, which is arranged at a distance from the first structural element in a second direction, such that there is a gap between the first and second structural elements in the body shell. The outer surface of this second structural element has at least one raised portion that is raised in the first direction relative to the connection area and projects into the gap. This advantageously allows the gap between structural elements in the body shell to be used efficiently to enlarge the interior space of the battery housing. The at least one raised portion can, for example, be geometrically described such that an imaginary envelope of such a raised portion has a substantially cuboid geometry.This means that the increase is geometrically well adapted to the geometry of the spaces between the structural elements of the building.

[0024] Furthermore, the housing cover can also be designed with several such raised sections. If, for example, the housing cover extends across several gaps perpendicular to the first direction, the housing cover can be designed with a number of raised sections corresponding to the number of gaps. Such a raised section can be used not only to optionally enlarge the interior of the battery housing, but, if the raised section is mounted on the base plate, also to stiffen the battery housing, especially the housing cover, and, above all, to create the flattest possible contact surface together with the structural elements of the body shell.

[0025] Accordingly, a further advantageous embodiment of the invention is achieved if the at least one raised section extends in the second direction over a large part of the width of the gap or substantially over the entire width of the gap and terminates at the same height with respect to the first direction with a first upper surface of the first structural element facing away from the connection area of ​​the housing cover and with a second upper surface of the second structural element. The raised section need not necessarily have a flat upper surface, but can, for example, also comprise several ribs projecting from the base plate. The end faces of these ribs facing in the first direction can accordingly be at the same height as the upper surfaces of the structural elements.Thus, the housing cover, together with the body-in-white structural elements, can advantageously form the vehicle floor or at least a part of this floor, for example the center floor point.

[0026] The connection area of ​​the housing cover preferably extends in the longitudinal direction of the structural element, against which the connection area rests flat. If the battery housing assembly comprises several structural elements, the housing cover can correspondingly have multiple connection areas. The housing cover can be arranged and attached to the respective structural elements via the relevant connection area, as already described with reference to the connection area and the first structural element.

[0027] According to a further advantageous embodiment of the invention, the battery housing assembly comprises the housing tray, which is sealed to the housing cover, enclosing the interior, particularly wherein the housing tray is designed as a second plastic component. The advantages and design possibilities of the housing tray as a plastic component are the same as already described for the housing cover. The housing cover and the housing tray are part of a battery housing or form such a battery housing, which seals the interior, in particular hermetically. The housing cover can be attached to the housing tray in a circumferential flange area. Both the cover and the housing tray can have such a flange area, with the flange area of ​​the cover representing the aforementioned attachment area.The at least one through-opening in the housing cover leads into the interior of the battery housing. This advantageously makes it possible to connect a battery module arrangement located inside the housing to the structural element via the mounting device.

[0028] According to a further advantageous embodiment of the invention, the housing tray comprises a receiving chamber in which the battery module arrangement is arranged, and a base having an inner side facing the receiving chamber and an outer side facing away from the receiving chamber. The housing tray includes at least one support structure arranged on the inner side of the base and projecting into the receiving chamber in a first direction.

[0029] The support structure advantageously allows external forces acting from below on the base of the housing tray to be effectively absorbed, selectively directed into specific components, and / or guided through the battery housing assembly. In conventional designs, this functionality is typically achieved only through an additional component, namely an additional underride guard mounted on the underside of the battery. By integrating the support structure into the base of the housing tray, at least part of such an underride guard, or rather its functionality, can be advantageously incorporated into the battery housing, specifically the housing tray itself. This saves installation space and weight, as well as eliminating the need for additional and complex components, such as an underride guard. This also reduces assembly effort.The support structure not only enables suitable force application and / or transmission or force reduction, but also allows a battery component to be arranged within the housing, such as battery modules and / or battery cells, to be held at a suitable distance from the bottom of the housing tray. In the event of external force being applied to the bottom from below, this distance advantageously creates a buffer zone, which is thus also advantageously integrated into the battery housing itself, namely into the housing tray. This buffer zone, including the at least one support structure, is therefore located inside the battery housing and is thus in a hermetically sealed area. This significantly improves the protection of both the buffer zone and the at least one support structure from environmental influences.This also reduces the sealing effort, as only a suitable seal between the housing cover and the housing tray is required. In contrast, with a separate underride guard and a buffer space between the underride guard and the base of the battery housing, corresponding sealing measures between the underride guard and the battery housing would also be necessary; these can now be eliminated. Such a buffer space could also house sensors, for example, to detect force applied by an external object from below and / or to detect a potential risk of damage to the battery housing.By incorporating this buffer zone inside the battery, as can now be easily achieved through the housing tray formed with the support structure, such sensors can also be located in a space that is significantly better protected from environmental influences. This reduces the overall complexity of a battery assembly, also known as a battery array, through the described design of the battery housing assembly.

[0030] The receiving space of the housing tray can be essentially cuboid in shape. The housing tray itself can also be essentially cuboid in shape. However, the housing tray can also include further components or structures arranged on its outer surface and projecting outwards, and / or arranged on its inner surface, i.e., facing the receiving space, and projecting into the receiving space. The basic shape of the housing tray can, for example, be formed by a base plate providing at least part of the bottom and four side walls of the housing tray, which define the receiving space in and against a second direction, as well as in and against a third direction, wherein the second direction is defined perpendicular to the first direction, and the third direction is perpendicular to the first and second directions.

[0031] The base of the housing tray, together with the at least one support structure, can be defined as a basic element of the housing tray. The support structure can be formed by a specific geometric shape of this basic element, for example, by a bulge towards the receiving space, or the base of the housing tray can essentially be designed as a flat plate on which the at least one support structure is arranged and projects towards the receiving space. Alternatively, the base and the at least one support structure can be manufactured as a single unit, for example, as a one-piece plastic component, or they can be provided as separate components that are joined together.

[0032] The receiving space provided by the housing tray can, when the housing tray is arranged on the lid as intended, form the entire interior of the battery housing or only a part of it.

[0033] Furthermore, it is highly advantageous if the housing tray not only has a single support structure, as would also be possible, but several support structures arranged on the inside of the base and projecting into the receiving space in the first direction. These multiple support structures can be geometrically identical or different. The following descriptions, which refer to the at least one support structure, can therefore also apply analogously to all other optional support structures.

[0034] If the housing tray is designed as a plastic component, this also advantageously allows the at least one support structure to be integrally formed with the bottom of the housing tray or the entire housing tray, for example in an injection molding process.

[0035] According to a further advantageous embodiment of the invention, the at least one support structure extends linearly in a second direction. This is particularly advantageous when the battery cells to be accommodated by the battery housing are provided in the form of cell stacks with several battery cells arranged side by side in a stacking direction. In this case, the stacking direction can then correspond to the second direction, which in turn makes it possible to position the support structures corresponding to an intermediate area between two cell stacks. This advantageously allows forces acting externally on the bottom of the housing tray to be transmitted via the support structure through this intermediate area and through the battery housing assembly, and in particular through the battery comprising the battery housing assembly, thus preventing them from acting on the battery cells.Furthermore, this allows for large-area arm support in the second direction. The support structure can, for example, extend essentially across the entire bottom of the housing tray in the second direction, or essentially across the entire recording space. If multiple support structures are provided, they can be spaced apart from each other in a third direction and run parallel to each other in the second direction.

[0036] Furthermore, it is advantageous if the at least one support structure comprises several ribs projecting from the base in the first direction. The ribs can essentially be flat, plate-shaped elements, particularly of any geometry and / or inclination relative to one another. By designing the support structure with ribs, efficient support can be achieved, while simultaneously allowing airflow through the support structure itself. This, in turn, advantageously enables the space within the receiving chamber, in which the at least one support structure is arranged, to be used as a degassing chamber for the removal of gases escaping from a battery cell in the event of thermal runaway. The individual ribs belonging to a common support structure can be interconnected or spaced apart from one another.

[0037] An imaginary envelope of the support structure can have a triangular or trapezoidal geometry perpendicular to the second direction. The width of this envelope in the third direction is preferably greater near the ground and decreases with increasing distance from the ground. This advantageously allows external forces acting on the ground to be introduced into and transmitted through a smaller area of ​​effect, which in turn enables a very narrow and space-efficient design of the aforementioned intermediate areas between the cell stacks.

[0038] According to a further advantageous embodiment of the invention, the battery housing assembly comprises a protective plate arranged on the outside of the base, in particular covering the base substantially completely. The protective plate can be made of a plastic material or a metallic material, for example, aluminum. If the protective plate is made of a plastic material, it is advantageous if it is a fiber-reinforced plastic, in particular a continuous fiber-reinforced plastic, for example, with glass fibers as continuous fibers. This allows the base area of ​​the housing tray to be additionally reinforced. Such reinforcement can also be achieved additionally or alternatively by a corresponding design of the base of the housing tray itself, which, for example, can also be designed as a fiber-reinforced plastic base, in particular with continuous fiber reinforcement, e.g.The base of the housing tray can be reinforced with fiberglass, as already described in relation to the protective plate, or other reinforcing elements can be integrated into the tray's base. This is extremely easy to achieve when manufacturing the housing tray as a plastic component, for example, using an injection molding process. This allows the base to be easily reinforced with suitable inserts. However, providing a protective plate separate from the base has the significant advantage that such a plate can be easily replaced if damaged by an external object. For example, the protective plate can be screwed to the outside of the base. This allows for particularly easy replacement of the protective plate. The screws are attached in such a way that the housing tray's seal is not compromised in the area of ​​these screw points.This can be achieved by appropriately sealing the screw points or by designing the screw points on the bottom of the housing tray, for example in the form of screw-in bosses and / or with blind holes or similar, so that no penetration of the housing tray is required in the area of ​​these screw points.

[0039] The protective plate can be positioned on the outer surface of the base in such a way that it lies flush against it. This eliminates the need for a gap between the protective plate and the outer surface of the base, resulting in a very space-saving design. As described above, a buffer zone to the battery cells housed within the casing can be provided by the housing area itself, through the placement of at least one support structure. This eliminates the need for an additional gap between the protective plate and the base of the casing.

[0040] As already mentioned, it is advantageous if the protective plate is screwed to the base. These screw points are preferably located on the side of the housing tray in the area of ​​the base where the at least one support structure is located. In the event of an external force being applied to the base from below, a point load transfer via, for example, a screw or bolt of such a screw connection to other components located inside the battery housing, in particular battery cells, can thus be avoided, since an external force in the area of ​​such a screw connection can advantageously be absorbed or suitablely guided and directed by the at least one support structure located there.In general, the protective plate can also be attached to the bottom of the housing tray in other ways, for example, in addition to or as an alternative to a screw connection, by clipping, gluing, or similar methods. A reversibly detachable connection is very advantageous for the purpose of replacement.

[0041] According to a further advantageous embodiment of the invention, the housing tray comprises a side wall surrounding the base and defining the receiving space perpendicularly to the first direction, which has four opposing side walls in pairs. A crash structure is arranged on the outside, i.e., facing away from the receiving space, of at least one of the side walls that defines the receiving space in a third direction. To increase the stiffness, crash safety, and robustness of the battery housing, particularly the housing tray, and to protect the battery cells contained therein, a crash structure can thus advantageously also be arranged on the outside of the tray. Overall, this allows a battery housing including such a crash structure to be realized much more simply, with less installation space, and above all, with less weight than if the housing components themselves had to be designed to be correspondingly robust and solid.Such a crash structure can be implemented, for example, in the form of a profile, such as an aluminum profile, and / or in the form of a plastic structure or structures. Positioning such a crash structure between a side sill of the vehicle and the battery housing tray is particularly advantageous with regard to the intended installation position of the battery housing assembly in a motor vehicle. This external crash structure allows the load transfer into the battery housing to be controlled in the event of an external force. In particular, this achieves a uniform load distribution and advantageously avoids point loads, for example, from other elements arranged externally on the tray or the battery housing, or between the battery housing and the side sill.

[0042] Such a crash structure can be screwed or clipped to the housing tub, bonded to it, or otherwise attached to the housing tub. It is also conceivable that such a crash structure could be formed as part of the side wall of the housing tub, for example, if it is also made of plastic.

[0043] Furthermore, such a crash structure can be arranged not only on one of the side walls that define the recording space in the third direction, but also, for example, on the side wall opposite with respect to the third direction.

[0044] Furthermore, the invention also relates to a battery arrangement with a battery housing arrangement according to the invention or one of its embodiments. The components of the battery arrangement, in particular with the exception of one or more structural elements, can be part of a battery, for example a high-voltage battery.

[0045] According to a further advantageous embodiment of the invention, the battery arrangement comprises a battery module arrangement for placement in an interior space of the battery housing, wherein the battery module arrangement particularly represents the aforementioned battery component. The battery module arrangement can comprise a module group arranged in a module area, wherein the module group in turn comprises at least one battery module having at least one battery cell. The module group can also comprise several battery modules, each having at least one battery cell.

[0046] The module area in which this module group, including all its battery modules, is arranged can, for example, be essentially cuboid in shape. The battery modules can be arranged side by side in a direction perpendicular to the first direction, for example, in a second and / or a third direction. Each of these battery modules can comprise one or more battery cells. The battery cells can be designed as prismatic, pouch, or cylindrical cells. The battery cells can also be lithium-ion cells. A single battery module can, for example, comprise a cell stack with several battery cells arranged side by side in a stacking direction.Without loss of generality, for the sake of simplicity, it is assumed in the following that the stacking direction corresponds to the second direction, which is perpendicular to the first direction, and that the multiple battery modules are arranged side by side in a third direction, which is again perpendicular to the first and second directions. The second direction can, for example, correspond to a longitudinal direction of the vehicle with respect to a preferred installation position in a motor vehicle, and the third direction to a transverse direction of the vehicle. Similarly, the first direction can correspond to a vertical direction of the vehicle. However, the battery modules can also be constructed differently. For example, a battery module can also comprise several cylindrical cells arranged axially parallel to each other, the axes of which can be aligned parallel to the first direction.

[0047] Furthermore, it is advantageous if the battery module arrangement has a first stiffening plate which is arranged on the module group on a side facing away from the housing cover and extends perpendicular to the first direction over the module area.

[0048] The module group can comprise a first side and a second side opposite the first side in the first direction. The first side can be defined as the side facing away from the housing cover, and the second side as the side facing the housing cover. The first side faces the bottom of the housing tray, and the second side faces away from the bottom of the housing tray. It is also possible for the first stiffening plate to be located on the second side of the module group instead of the first. In other words, the first stiffening plate can generally be located on the top or bottom of a module group. However, if it is located on the first side, it simultaneously serves as a support for the battery cells or battery modules.If the first stiffening plate is also positioned below the module group in the first direction, it provides additional protection for the battery modules against impacts from external objects below. In contrast, conventional cooling plates are typically much thinner and more flexible, and can be easily punctured by such objects, necessitating additional underride protection. The rigid, and especially torsionally rigid, design of the first stiffening plate, however, advantageously provides significantly greater protection for the battery modules against loads acting on the battery module assembly from below, without requiring a particularly robust battery housing and / or additional underride protection, although this is still possible.

[0049] Providing such a stiffening plate is particularly advantageous because it allows for additional stiffening, which in turn enables a simpler and less robust design of the battery housing, since this stiffening function is performed by the battery module arrangement located inside. In particular, the first stiffening plate can be designed to transmit an external load acting on the battery module arrangement in a direction perpendicular to the first direction through the battery module arrangement in that direction.

[0050] The first stiffening plate, which extends perpendicularly across the module area, particularly the entire module area, advantageously protects the at least one battery module or multiple battery modules arranged within the module area in the event of an external force being applied. This is because such an external load can be channeled through the battery module arrangement in the direction of impact by means of the stiffening plate. This, in turn, allows for a significantly simpler and / or less robust design of the battery housing containing the battery module arrangement, as the protection of the module group no longer needs to be provided, or at least no longer solely, by such a battery housing, but can be provided, at least partially or completely, by the battery module arrangement itself.As a result, the battery housing can, for example, be designed to be significantly lighter.

[0051] The first stiffening plate extends essentially in a plane perpendicular to the first direction. This first stiffening plate extends perpendicular to the first direction across the entire module area. In other words, the stiffening plate covers all battery modules arranged within the module area perpendicular to the first direction. It is further advantageous if the stiffening plate covers the module area not only in one direction perpendicular to the first direction, but, for example, in every direction perpendicular to the first direction. In other words, the dimensions of the stiffening plate, which may be rectangular or cuboid with a particularly small top surface in the first direction, can be at least as large as the dimensions of the module area in the second and third directions. In other words, the stiffening plate can completely cover the module area perpendicular to the first direction.The first stiffening plate can also project beyond the module area on one or both sides in the second and / or third direction. This allows for even more reliable transmission of external forces.

[0052] The stiffening plate is preferably formed in one piece, i.e., it is preferably not composed of individual plates joined together. The stiffening plate is preferably not composed of individual plates joined together, at least in the second and / or third direction. This increases the stiffness, strength, and / or robustness of the stiffening plate. Even if the module group comprises several battery modules arranged side by side in the second and / or third direction, the first stiffening plate can extend as a single component across all of these battery modules in the second and third directions.

[0053] The direction of action in which the first stiffening plate is capable of transferring the load can, for example, be the second and / or third direction. The stiffening plate can generally be rigid and / or rigid, meaning neither flexible nor elastic. Preferably, the first stiffening plate is made of a metallic material. For example, the stiffening plate can be designed as an extruded profile. This allows the stiffening plate to be equipped with particularly good stiffness properties.

[0054] Furthermore, the first stiffening plate can be adhesively bonded to the first side of the module assembly by means of an interface material, in particular a thermal interface material, and especially bonded over a surface area. The thermal interface material is preferably a thermally conductive adhesive. This allows the first stiffening plate to be advantageously bonded to the first side of the module assembly. The stiffening plate does not need to be bonded over its entire surface, but can also be bonded to the module assembly only in specific areas. These areas can, for example, correspond to individual battery modules of the module assembly. An intermediate area can be located between two adjacent battery modules. This area can be designed as a free space or other components can be arranged in this area.The stiffening plate can therefore be attached only to the battery modules of the module group, for example, directly to the respective undersides of the individual battery modules. This allows for the formation of a particularly rigid, and especially torsionally stiff, overall assembly of battery modules and the first stiffening plate. This means that the battery module assembly can be provided as a rigid, self-contained unit. This assembly can then be removed from a battery housing more easily, since it does not need to be adhesively bonded to the housing, for example, by being glued to it. This, in turn, facilitates easier replacement of the battery module assembly and / or simpler repair options.

[0055] Furthermore, it is advantageous if the battery module assembly is mounted on the housing cover and the first body-in-white structural element by means of the fastening element, which passes through the battery module assembly in the first direction. Thus, the battery module assembly can advantageously be attached to the body-in-white structural element via the fastening element, which consequently bears the weight of the battery module assembly. This weight therefore does not need to be borne by the housing cover or any other component of the battery housing.

[0056] The head of the fastener can, for example, be attached to a part of the first stiffening plate. The neck of the fastener can then extend in the first direction through the battery module assembly to the structural frame element and be screwed to or into it.

[0057] It is also conceivable that a screw or bolt, acting as a fastener, is inserted from above through the structural frame element down to the first stiffening plate. The head can then rest against a portion of the structural frame element. At the opposite end, a nut can be screwed onto the fastener, resting against a portion of the first stiffening plate. Other variations are also possible.

[0058] This generally allows the battery module arrangement to be attached to the structural element of the building shell in a particularly advantageous way.

[0059] According to a further advantageous embodiment of the invention, the battery module assembly has a second stiffening plate, wherein the module assembly is arranged between the first and second stiffening plates. In particular, this second stiffening plate can be designed in the same way as described previously and subsequently with regard to the first stiffening plate. Furthermore, the second stiffening plate can also be arranged on the module assembly, for example via a thermal interface material, as described previously and subsequently with regard to the first stiffening plate. The module assembly is thus advantageously arranged between two stiffening plates. This results in a sandwich structure with particularly high stiffness.

[0060] The first and / or second stiffening plate can also be designed as an extruded profile. This allows the stiffening plate to be equipped with particularly good stiffness properties.

[0061] The first and / or second stiffening plate can also be designed as a cooling plate with integrated cooling channels through which a coolant can flow. Generally, it is very advantageous if the first stiffening plate is designed as a cooling plate. The first and / or second stiffening plate can include at least one integrated cooling channel, which can, in principle, be of any shape.

[0062] Since the first and / or second stiffening plate is in direct contact with the module assembly, it is highly advantageous to use it simultaneously as a cooling plate. For this purpose, the first and / or second stiffening plate can be made of aluminum, for example. Such a cooling plate is then also located within the battery housing, which makes it significantly easier and better protected from external forces than, for example, if the housing base were designed as a cooling plate. Furthermore, since it also serves as a stiffening plate, such a cooling plate is considerably more robust than conventional cooling plates, which also significantly reduces the risk of damage.

[0063] According to a further advantageous embodiment of the invention, the first stiffening plate comprises a first outer wall facing the module group, a second outer wall facing away from the module group, which is arranged at a first distance from the first outer wall with respect to the first direction, and several connecting webs that connect the first and second outer walls to each other and which have a second distance from each other in a second or third direction perpendicular to the first direction. If, for example, the connecting webs have a distance from each other in the second direction, they can extend longitudinally parallel to each other in the third direction. If, on the other hand, they have a distance from each other in the third direction, they can extend longitudinally parallel to each other in the second direction, in particular in a straight line. Such a construction of the first stiffening plate offers a particularly high degree of stiffness.In particular, this allows for a very high degree of rigidity in the longitudinal direction of the connecting webs. If the connecting webs also extend in a straight line, the first stiffening plate can be easily manufactured as an extruded profile. This also enables very simple production of the stiffening plate. This design with the two outer walls and these connecting webs also makes it very easy to design the first stiffening plate as a cooling plate with integrated cooling channels through which a cooling medium can flow. The spaces between the connecting webs can accordingly be used as cooling channels.In other words, the cooling channels can be formed in the spaces between the connecting webs and the outer walls, and in particular, their direction, in which the connecting webs are arranged side by side, can be limited by the connecting webs. The longitudinal direction of the connecting webs, and especially of the cooling channels, can correspond to the stacking direction defined above.

[0064] The second stiffening plate can be designed analogously. As already described for the first stiffening plate, the stiffening plates can each also be designed with a sandwich structure, namely with the two outer walls connected to each other via the connecting webs. This results in a kind of double sandwich structure or multiple sandwich structure. It is, so to speak, a sandwich within a sandwich: the preferred double-web structure of the stiffening plate provides a micro-sandwich, while the arrangement of the stiffening plates as top and bottom ribs, together with the cells or modules as the core, provides a macro-sandwich. In particular, this arrangement of the battery modules allows for a particularly rigid composite structure.

[0065] According to a further advantageous embodiment of the invention, the fastening element is designed as part of a fastening device encompassed by the battery module assembly, which also includes a sleeve extending in the first direction. This sleeve extends at least from the first stiffening plate through the module assembly and, in particular, to the first structural element of the body shell, with at least a portion of the fastening element, especially the neck, passing through the sleeve. The sleeve acts as a spacer between the first stiffening plate and the structural element of the body shell and, when tightened, prevents the battery module assembly from being compressed in the first direction by the tightening force. The sleeve can thus be supported on the lower, i.e., the first, stiffening plate and, at the opposite end of the sleeve, for example, on the support component.This ensures that the distance between the support component and the first stiffening plate, as defined by the sleeve, cannot be reduced. The sleeve can also be used to transmit forces in the event of an external force acting on the battery module assembly from below. Such forces then do not act on the battery modules but are transferred directly into the support component via the first stiffening plate and the sleeve.

[0066] The sleeve includes a through-opening through which the fastening element can be at least partially inserted. The sleeve is preferably made of a metallic material. Furthermore, an additional sealing function can be integrated into the sleeve. For example, a sealing element can be arranged in the through-opening of the sleeve, which is pierced by the fastening element during insertion and seals the fastening element against the sleeve. The sleeve can also be arranged to seal against the corresponding components at its end face, for example, the support component, and / or seal against other components through which the sleeve can optionally be inserted, for example, against the housing cover described later.

[0067] Furthermore, it is advantageous if the module group comprises several battery modules, for example, two arranged side by side, with an intermediate section between them, and the sleeve is located in this intermediate section. This allows force transmission between the modules. With respect to the first direction, the sleeve can extend further than the battery modules or the module section. Several such sleeves can also be provided in this intermediate section as part of their respective mounting devices. These sleeves thus project beyond the module section in the first direction. In particular, the respective sleeves extend from the first stiffening plate through the battery module arrangement and also project beyond the second stiffening plate in the first direction.

[0068] If the module group comprises more than two battery modules, one or more such sleeves can be arranged in the respective intermediate areas between the battery modules. One or more such sleeves can also be arranged in an edge area adjacent to the module area with respect to the second and / or third direction. Each sleeve can be associated with a fastening element, forming a fastening device.

[0069] Furthermore, the invention also relates to a motor vehicle with a battery housing arrangement according to the invention or one of its embodiments, or with a battery arrangement according to the invention or one of its embodiments.

[0070] The motor vehicle according to the invention is preferably designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle. The motor vehicle can be designed as an electric vehicle.

[0071] Furthermore, the invention relates to a method for mounting a battery assembly on the body-in-white of a motor vehicle. The body-in-white is provided with at least one first body-in-white structural element, and a housing cover is provided comprising a circumferential mounting area, an outer surface, and an inner surface opposite the outer surface in a first direction. Additionally, a housing tray is provided, and a battery component is provided for arrangement inside the battery housing. The housing cover and the battery component are arranged on the body-in-white structural element such that a connection area of ​​the outer surface of the housing cover, distinct from the mounting area, rests flat against the body-in-white structural element, and the housing cover is located between the body-in-white structural element and the battery component.

[0072] Furthermore, the battery component and the housing cover are attached to the structural frame element by means of a fastening element, at least part of which passes through the battery component and through an opening in the housing cover located in the connection area. Subsequently, and particularly later, the housing tray is positioned and attached to the housing cover.

[0073] This allows for a particularly advantageous and simple installation of such a battery arrangement with a particularly simple and weight-saving housing on the body structure of a motor vehicle.

[0074] The second housing component is positioned next to the first housing component after the battery module assembly and the first housing component have been attached to the structural frame element. The second housing component can be screwed to the first housing component, for example, via the flange areas described above.

[0075] The invention also includes further developments of the method according to the invention, which have features already described in connection with the further developments of the battery housing arrangement and the battery arrangement according to the invention. For this reason, the corresponding further developments of the method according to the invention are not described again here.

[0076] The invention also includes further developments of the method according to the invention, which have features already described in connection with the further developments of the battery module arrangement and the battery arrangement according to the invention. For this reason, the corresponding further developments of the method according to the invention are not described again here.

[0077] The invention also includes combinations of the features of the described embodiments. The invention therefore also includes realizations that each exhibit a combination of the features of several of the described embodiments, provided that the embodiments have not been described as mutually exclusive.

[0078] The following are exemplary embodiments of the invention described. This is illustrated by: Fig. 1 a schematic cross-sectional representation of a battery arrangement according to an embodiment of the invention; Fig. 2 a schematic cross-sectional representation of a battery housing arrangement according to an embodiment of the invention; Fig. 3 a schematic cross-sectional representation of a battery arrangement during the outgassing of a battery cell according to an embodiment of the invention; Fig. 4 a schematic representation of a top view of a battery module arrangement according to an embodiment of the invention; Fig. 5 a schematic representation of an assembly step for assembling a battery module arrangement according to an embodiment of the invention; Fig. 6 a schematic cross-sectional view of the assembled battery module arrangement according to an embodiment of the invention; and Fig. 7 a schematic representation of the assembly step for mounting the battery module arrangement and a housing cover on a cross member of a body shell structure of a motor vehicle and the subsequent assembly of the housing tray according to an embodiment of the invention.

[0079] The exemplary embodiments described below are preferred embodiments of the invention. In these exemplary embodiments, the described components each represent individual features of the invention, which can be considered independently of one another and each further develops the invention independently. Therefore, the disclosure is intended to include combinations of features of the embodiments other than those shown. Furthermore, the described embodiments can also be supplemented by further features of the invention already described.

[0080] In the figures, identical reference symbols denote functionally equivalent elements.

[0081] The coordinate systems depicted in the figures are, in particular, Cartesian coordinate systems. The x-direction shown corresponds to the previously defined second direction, the y-direction to the previously defined third direction, and the z-direction to the previously defined first direction.

[0082] Fig. Figure 1 shows a schematic cross-sectional view of a battery arrangement 10 with a battery 11 according to an embodiment of the invention. This battery arrangement 10 also comprises a housing arrangement 12 and a battery module arrangement 14, which can at least partially be considered part of the battery 11. The housing arrangement 12 comprises a battery housing 16, which includes a first housing component in the form of a housing cover 18 and a second housing component in the form of a housing tray 20, which can also be referred to as a hood 20. The housing cover 18 and the housing tray enclose an interior space 22, which is in particular hermetically sealed and in which the battery module arrangement 14 is arranged. The housing arrangement 12 can also include at least one body-in-white structural element 24, which in the present example is designed as a cross member 26 of a body-in-white structure 28 of a motor vehicle.Contrary to the x-direction shown, a side sill 30 of the motor vehicle is also arranged next to the cross member 26.

[0083] The battery module arrangement 14 comprises a module group 33, which in turn comprises several battery modules 32 arranged side by side in the x-direction shown. Each of these battery modules 32 can comprise several battery cells 34, for example, prismatic battery cells 34, arranged side by side in a stacking direction, the stacking direction corresponding to the y-direction shown. An intermediate region 36 is located between the two battery modules 32 arranged adjacent to each other in the longitudinal direction. The battery modules 32 are also arranged in a continuous module region 38. This includes, in particular, the intermediate regions 36 between modules 32. Furthermore, the battery module arrangement 14 comprises two stiffening plates 40, 42.The module group 33 has a first side 33a, which in this example represents a bottom and faces the base 20a of the battery tray 20, and an opposite second side 33b, which in this example represents a top 33b and faces the housing cover 18. One of the stiffening plates 40 is arranged on the first side 33a, in particular bonded to it by means of a thermally conductive adhesive 44 as an example of a thermal interface material. The second stiffening plate 42 is arranged on the second side 33b, in particular also bonded to it by means of such a thermally conductive adhesive 44. The stiffening plates 42, 44 extend perpendicular to the Z-direction over at least the entire module group 33 or the entire module area 38 and preferably project beyond it on both sides with respect to the x-direction and / or on both sides with respect to the y-direction. The stiffening plates 42, 44 can be designed as extruded profiles.Furthermore, these can each comprise outer walls 46 that are opposite each other in the z-direction and spaced apart in the z-direction, and which are connected to each other via several connecting webs 48. The connecting webs 48 are arranged next to each other and spaced apart in the x-direction and extend with their longitudinal direction in the y-direction, in particular parallel to each other. This design of the stiffening plates 40, 42 has the advantage that these stiffening plates 40, 42 can simultaneously function as cooling plates 50. The spaces 52 between the connecting webs 48 then represent cooling channels 54, through which a coolant can flow and through which a coolant flows during operation of the battery arrangement 10. Nevertheless, these can be extremely rigid due to the described structure.

[0084] This battery module arrangement 14 provides an extremely stable and rigid overall assembly. Due to the rigidity of the stiffening plates 40, 42, the battery modules 32 are particularly well protected without requiring the battery housing 16 to be especially robust. The stiffening plates 40, 42 can, for example, transmit externally acting crash loads L in the x-direction. This significantly reduces the risk of deformation of the module group 33 in the x-direction caused by such an acting crash load L. This also makes it possible, for example, to manufacture the housing cover 18 and / or the housing base 20, and in particular the entire battery housing 16, from a plastic material K, as will be explained in more detail later.

[0085] The battery module assembly 14 also includes several fastening devices 56. These, in turn, comprise a sleeve 58, in particular a metallic sleeve 58, with a through-opening 60. The sleeve 58 is elongated in the z-direction so that it extends into the through-opening 60 in the z-direction. The sleeve 58 is supported on one side by the first stiffening plate 40, and its opposite end projects through the second stiffening plate 42, as well as through the housing cover 18, and is supported on the cross member 26. The sleeve 58 acts as a spacer and can also transmit forces in the z-direction to the cross member 26. The fastening device 56 also includes a fastening element 62, which can pass through the sleeve 58 and is, in this case, a fastening element. The fastening element 62 can be a screw, bolt, or similar component.It comprises a neck 62a elongated in the z-direction and a head 62b that is wider than the neck. The neck can be inserted from below through the through-opening 60 of the sleeve 58 and screwed into the crossbeam 26. In this way, the entire battery module assembly 14 can be attached to the crossbeam 26.

[0086] In particular, the basic structure 28 can also comprise several crossbeams 26 spaced apart from each other in the y-direction. The battery module assembly 14 can have further such fastening devices 56 to attach the battery module assembly 14 analogously to these further crossbeams 26. This enables a particularly stable attachment to the basic structure 28. In particular, the basic structure 28 thereby bears the entire weight of the battery module assembly 14, while the housing 16 does not have to bear this weight. This also advantageously makes it possible to manufacture the housing 16, or at least some of the housing components 18, 20, as a plastic component K, that is, from a plastic material.

[0087] To allow the sleeve 58 to pass through the stiffening plate 42 and the housing cover 18, both the stiffening plate 42 and the cover can be designed with a corresponding through-opening 64, 66. The sleeves 58 are also positioned in the intermediate areas 36 between the battery modules 32. The underside outer wall 46 of the lower stiffening plate 40 can also be designed with an opening opposite the sleeve 58 to allow the insertion of the fastening element 62. The head 62b can then rest against the underside of the upper outer wall 46 of the first or lower stiffening plate 40, while the neck 62a passes through an opening in this upper outer wall 46 of the first or lower stiffening plate 40.

[0088] Further details of this battery module arrangement 14 will now be discussed in connection with Fig. 3 and Fig. 4 described.

[0089] Fig. Figure 3 shows a schematic cross-sectional view of the battery arrangement 10. Fig. 1. In addition, a bulkhead 68 is shown here as part of the battery module arrangement 14, which is arranged between the two stiffening plates 40, 42, connecting them to each other. In particular, the battery module arrangement 14 can comprise several bulkheads 68 that completely surround the module group 33, as shown schematically in Fig. Figure 4 shows a top view of the battery module arrangement 14. This shows four battery modules 32 extending longitudinally in the x-direction, which are arranged on the lower stiffening plate 40, with the module area 38 being completely enclosed by the bulkheads 68.

[0090] If a thermal runaway occurs in battery cell 34, as shown schematically in Fig. As illustrated in Figure 3, a gas 35 escapes from this cell. This escaping gas 35 can, for example, be guided through an opening or predetermined breaking point in the first stiffening plate 40 below the cell 34 in question and thus discharged from the module area 38. The bulkhead 68 then advantageously prevents this gas 35 from re-entering the module area 38. Instead, the gas 35 can be discharged into the environment 70 via another designated device, for example, a suitable gas discharge path and an emergency degassing valve on the housing 16 or similar.

[0091] The following will again refer to Fig. 1. The housing 16 of the battery assembly 10 is described. The housing cover 18 has a circumferential mounting area 74, which can also be referred to as a flange area 74. The battery tray 20 has a corresponding mounting flange 76, which can be located on an end face of the side walls 20b of the tray 20 or can at least project outwards from the side walls 20b near the end face. When the two housing parts 18, 20 are arranged relative to each other as intended, the two flange areas 74, 76 are in direct contact with each other in the z-direction and, in particular, indirectly connected to each other via a seal 78. The two housing components 18, 20 are thus sealed to each other by a circumferential seal 78. One or both of the two flange areas 74, 76 can be designed with a corresponding sealing groove in which the seal 78 is partially received. A single sealing groove, i.e.Only in one of the two flange areas 74, 76 is sufficient. Furthermore, the cover 18 and the basin 20 can be screwed together or otherwise fixed to each other around the flange area 74, 76.

[0092] The cover 18 also has an outer surface 18a and an inner surface 18b. The outer surface 18a and / or its surface O comprises a connection area 80, which faces the cross member 26 and rests flat against the cross member 26. The housing cover 18 is provided in the connection area 80 with one or more through-openings 66, through which the described fastening element 62 for screwing the battery module assembly 14 and the cover 18 to the cross member 26 can be passed, and in this case has been passed.

[0093] The lid 18 can generally be designed with a three-dimensional surface O. This is shown schematically in Fig. Figure 2 illustrates this. In particular, the battery housing 16 is shown in a cross-section perpendicular to the x-direction. Several cross members 26, or more generally, body-in-white structural elements 24, are also visible in this cross-section as part of the body-in-white structure 28 of the vehicle. A gap 82 exists between the cross members 26 in the y-direction. The cover 18 has raised sections 84 between the connection areas 80. These raised sections 84 are thus higher than the connection areas 80. Specifically, these raised sections 84 extend in the z-direction into the aforementioned gaps 82. The raised sections 84 can terminate at the same level as the upper surfaces 26a of the cross members 26. The housing cover 18 can therefore simultaneously provide a portion of a vehicle floor, in particular a center floor. The raised sections 84 also provide additional stiffening of the housing 16.

[0094] The following will again refer to Fig. 1. The housing tray 20 is described. The housing tray 20 has a base 20a. The tray 20 also has a receiving space 90, which provides part of the interior space 22 or can provide the entire interior space 22. The base 20a has an inner surface 92 facing the receiving space 90 and an outer surface 94 facing away from the receiving space 90. Furthermore, the housing tray 20 includes, on the inner surface 92 of the base 20a, a support structure 96 projecting towards the receiving space 90; in this example, several such support structures 96. These can have a trapezoidal cross-section. The support structures 96, which are preferably provided in the form of several individual ribs, can also extend in the y-direction over the entire module area 38.Furthermore, the support structures 96 are located in the z-direction opposite the intermediate areas 36 or an edge space 97 directly adjacent to the module area 38 in and / or against the x-direction, which is situated between the two stiffening plates 40, 42. In particular, the support structures 96 contact the lower stiffening plate 40 and can be attached to it. Loads acting on the housing 16 from below in the z-direction can thus be directed via the support structures 96 and the stiffening plate 40 into the intermediate areas 36 and / or edge space 97, guided through the battery module arrangement 14 by means of the sleeves 58, and transferred to the support 26. The modules 32 are thereby particularly well protected.

[0095] As a further protective measure, a protective plate 98 can be arranged on the underside of the base 20a, i.e., on its outer surface 94. Additionally or alternatively, a reinforcing or stiffening structure can also be embedded in the base 20a itself. For example, the base 20a can also be made locally or completely of a plastic reinforced with continuous fibers, e.g., glass fibers. In this example, the protective plate 98 is attached to the outside of the base 20a of the housing tray 20 by means of further fastening elements 100, for example, screws, in particular by bolting. This plate 98 can be replaced in the event of minor damage instead of having to replace the entire cover 20, which offers an advantage for customer service and reduces the effort required for repairs.

[0096] All the screw connections mentioned, which may result in a penetration of part of the housing 16, are designed to be sealed. In other words, seals are preferably provided such that the interior 22 remains hermetically sealed. For example, the sleeves 58 described above can be provided with correspondingly integrated seals. In particular, the feedthrough point 66 in the housing cover 18 is sealed against the sleeve 58, as is part of the interior 60 of the sleeve itself. The screw connection using the fastening elements 100 can be made in plastic domes that are formed in or on the tray 20, especially on the inside of the cover 20. The screw connection using the fastening elements 100 can be implemented from the outside to the inside of the interior 22, especially the high-voltage (HV) compartment 22, without penetrations in the tray 20, e.g., via blind holes.The screw points for attaching the protective plate 98 to the base 20a are preferably located in the area of ​​the support structures 96. This represents a particularly safe location with regard to external loads from below, since such screw points cannot then be pressed into battery modules 32 or cells 34 or similarly sensitive parts from below.

[0097] The described hood 20 provides, in effect, an integrated underride guard within the housing 16. The support structures 96 ensure a certain distance D between the base 20a and the battery module assembly 14. Therefore, deformation of the base 20a in the direction of the battery module assembly 14 does not directly lead to damage to the battery module assembly 14. Furthermore, the resulting free space 102 can be used for the venting of harmful gases.

[0098] The tub 20 can also be equipped with further crash structures 104. In this example, such a crash structure 104, for example in the form of a profile, in particular an extruded profile, is arranged on a side wall 20b of the tub 20. Such a crash structure 104 can also be provided on the opposite side wall, which is not shown here. The fastening of the crash structure 104 to the tub 20 can also be implemented, for example, by screwing it inwards from the outside into the interior 22 without penetrations in the tub 20, e.g., via blind holes. In addition, a provision for lines for a cooling medium can be provided in a side area of ​​the receiving area 90 of the hood 20 in order to supply and discharge such a cooling medium to and from the stiffening plates 40, 42, which are designed as cooling plates 50, via these lines.

[0099] Fig. 5, Fig. 6 and Fig. Figure 7 illustrates individual assembly steps for mounting a battery assembly 10 onto a body shell 28 of a motor vehicle. First, the following steps are taken: Fig. 5. The battery module assembly 14 is assembled. The individual components of the battery module assembly 14 or the battery assembly 10 can be designed as described previously. For example, the cells 34 or the modules 32 can first be arranged or glued to one side of the first stiffening plate 40, which can also be designed as a cooling plate 50, using a thermally conductive adhesive 44. The sleeves 58 with seals can also be placed at this stage. The sandwich structure is then closed by the other stiffening plate 42 or cooling plate 50, also using thermally conductive adhesive 44. In other words, the other stiffening plate 42 is then arranged on the opposite side of the module group 33. The sleeves 58 are inserted through openings in the second stiffening plate 42.

[0100] Fig. Figure 6 shows the resulting battery module arrangement 14. This can now be arranged on the basic structure 28, as shown schematically in Figure 6. Fig.Figure 7 shows that the battery module assembly 14, together with the cover 18, is retracted against the body shell 28 and bolted to the body shell 28, particularly the crossbeams 26, via the sleeves 58 and the fastening elements 62. The hood 20 can then be retracted in the z-direction against the cover 18, ensuring a tight seal in the high-voltage compartment 22. The local protrusions, i.e., the support structures 96 of the hood 20, come into contact with the lower cooling plate 50, i.e., the first stiffening plate 40. The tray 20, or the support structures 96, can also be attached to the battery module assembly 14, although this is not explicitly shown. The protective plate 98 and the optional lateral crash reinforcements 104 are already pre-mounted on the tray 20 at the time the hood 20 is attached to the cover 18.

[0101] Overall, the examples demonstrate how the invention can provide a battery box design for electric vehicles. The battery box can comprise a lid and a housing tray. Cells can be arranged inside the battery box, which in turn are positioned on a cooling plate, namely the stiffening plate, located at least on one side of the module assembly, particularly on the top and / or bottom. The lid can simultaneously serve as the vehicle's central floor. The cells or modules are preferably bonded and / or pressed onto the cooling plates, creating a high-strength sandwich structure comprising the cooling plate on the top and / or bottom and the cells.This sandwich construction is housed within a two-part plastic structure, consisting of the housing cover and the housing tray. The plastic components ensure a tight seal for the high-voltage compartment, i.e., the interior of the battery housing. The entire assembly—housing tray, cover with internal cooling, and cells—can then be bolted securely to the crossmembers of the vehicle body. The cover can be designed as a flat mounting component, with the feature that its height or utilization fills the installation space between the metal crossmembers of the body shell. It rests against the crossmembers for connection and / or bolting of the battery box and also forms the base of the vehicle. For example, only a circumferential sealing groove can be provided, e.g., in the mounting area of ​​the cover to the hood mounted below. The sealing groove runs, for example...in a plane perpendicular to the first direction. The cover is closed on its upper surface, except for the through-holes for the fasteners and / or sleeves, and also houses, for example, the high-voltage core, which may include electronic components, controllers, a battery control unit, high-voltage contactors, switching elements, converters, fuses, etc. Optionally, an additional sealing layer can be incorporated between the high-voltage core and the cover. In other words, the high-voltage core can be located in a separate housing. The cover can be made of plastic, manufactured by injection molding and / or a pressing process. The cover also provides a recess for sleeves between the cells for body-tight bolting and ensuring the sealing of the high-voltage compartment, preferably on the cross members of the body-in-white.

[0102] The hood can be bolted to the cover in the flange area via a common sealing groove to ensure the high-voltage compartment is sealed. On the inside of the floor area, the hood can include raised plastic sections that provide local support and / or attachment of the hood to the cooling plate or modules above it, allowing for direct force transmission to the crossmember of the body shell. Additionally, the road-facing side of the hood, i.e., the floor area, can be made of a plastic material that is optionally locally reinforced with continuous fibers, such as glass fibers. Additional crash structures, such as aluminum profiles or plastic structures, can be locally attached to the sides of the hood between the sill and the battery box.Furthermore, an additional protective plate, for example made of aluminum or fiber-reinforced plastic, can be screwed to the hood from the street side using mounting points, without having to open the high-voltage compartment. This plate can be replaced in case of minor damage, instead of having to replace the entire hood. This offers an advantage for customer service and reduces the effort required for repairs. Additionally, the side area of ​​the hood can also provide space for lines carrying a cooling medium.

[0103] The cooling plates can, at least partially, make full contact with the inside of the lid, or at least one of the cooling plates can. Sleeves are provided between the cooling plates for screwing the lower cooling plate, the cells or modules, and the upper cooling plate to the lid and the structural frame, ensuring a seal for the high-voltage compartment. Sleeves with integrated seals can be provided for this purpose. The cooling plate can be designed as an extruded profile with ribs. These ribs can be used to provide cooling channels and mechanical reinforcement. Furthermore, a thermally conductive adhesive or similar material can be used to bond the cells to the cooling plates. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] CN 113889709 A

[0003] DE 10 2018 211 470 A1

[0004] DE 10 2019 214 920 A1

[0005] WO 2020 / 011680 A1

[0006]

Claims

[1] Battery housing assembly (12) for a motor vehicle, wherein the battery housing assembly (12) has a housing cover (18), - which is designed for arrangement on a housing tray (20) including an interior space (22), - which has a circumferential mounting area (74) for attaching the housing cover (18) to the housing tray (20), - one outer side (18a), and - comprises an inner side (18b) opposite the outer side (18a) with respect to a first direction (z), characterized by , that - the battery housing assembly (12) comprises a first structural element (24, 26), - at least one connection area (80) of the outside (18a) that differs from the fastening area (74) faces the first structural element (24, 26) and lies flat against the first structural element (24, 26), and - the housing cover (18) includes a through-opening (66) arranged in the connection area (80) and is attached to the body-in-white structural element (24, 26) by means of a fastening element (62) passing through the through-opening (66) to the first body-in-white structural element (24, 26). [2] Battery housing arrangement (12) according to claim 1, characterized by , that the battery housing arrangement (12) comprises a battery component (14) which is attached to the first body-in-white structural element (24, 26), in particular a cross member (26), by means of the fastening element (62), such that the housing cover (18) is located between the battery component (14) and the first body-in-white structural element (24, 26). [3] Battery housing arrangement (12) according to any one of the preceding claims, characterized by , that the housing cover (18) is designed as a plastic component (K). [4] Battery housing arrangement (12) according to any of the preceding claims, characterized by, that the battery housing assembly (12) comprises a second body-in-white structural element (24, 26) which is arranged at a distance from the first body-in-white structural element (24, 26) with respect to a second direction (y) such that there is a gap (82) between the first and second body-in-white structural elements (24, 26), wherein the outer surface (18a) has at least one raised section (84) which is raised with respect to the first direction (z) relative to the attachment area (80) and projects into the gap (82), in particular wherein the at least one raised section (84) extends in the second direction (y) over a large part of the width of the gap (82) or substantially over the entire width of the gap (82), and with respect to the first direction (z) with a first top surface (26a) of the first body-in-white structural element (24, 26) facing away from the attachment area (80) of the housing cover (18) and with a second top surface (26a) of the second structural element of the shell (24,26) ends at the same height with respect to the first direction (y). [5] Battery housing arrangement (12) according to any of the preceding claims, characterized by , that the battery housing arrangement (12) comprises the housing tray (20) which is sealedly attached to the housing cover (18) enclosing an interior space (22), in particular wherein the housing tray (20) is designed as a second plastic component (K). [6] Battery arrangement (10) with a battery housing arrangement (12) according to one of the preceding claims, characterized by , that the battery arrangement (10) comprises a battery module arrangement (14) for arrangement in an interior (22) of the battery housing (16), which in particular represents the battery component (14), - wherein the battery module arrangement (14) comprises a module group (33) arranged in a module area (38), - wherein the module group (33) comprises at least one battery module (32) having at least one battery cell (34), - wherein the battery module arrangement (14) has a first stiffening plate (40; 42) which is arranged on the module group (33) on a side (33a) facing away from the housing cover (18) and extends perpendicularly to the first direction (z) over the module area (38), - wherein the battery module assembly (14) is arranged on the housing cover (18) and the first body-in-white structural element (24, 26) by means of the fastening element (62) which passes through the battery module assembly (14) in the first direction (z). [7] Battery arrangement (10) according to claim 6, characterized by, that the battery module arrangement (14) has a second stiffening plate (42; 40), wherein the module group (33) is arranged between the first and second stiffening plate (42; 40), in particular wherein the first and / or second stiffening plate (40; 42) is designed as an extruded profile and / or as a cooling plate (50) with integrated cooling channels (54) through which a coolant can flow. [8] Battery arrangement (10) according to one of claims 6 or 7, characterized by , that the fastening element (62) is designed as part of a fastening device (56) encompassed by the battery module arrangement (14), which also includes a sleeve (58) extending in the first direction (z) through the module group (33) at least from the first stiffening plate (40; 42) and in particular to the first body-in-white structural element (24, 26), and at least part of the fastening element (62) passes through the sleeve (58). [9] Motor vehicle with a battery housing arrangement (12) according to any one of claims 1 to 5 or with a battery arrangement (10) according to any one of claims 6 to 8. [10] Method for mounting a battery arrangement (10) with a battery housing arrangement (12) according to one of claims 1 to 5 on a body shell structure (28) of a motor vehicle, characterized by the steps - Provision of the shell structure (28) with at least one first shell structure element (24, 26); - Providing the housing cover (18); - Provide a housing tray (20); - Providing a battery component (14) for arrangement in the interior (22) of the battery housing (16); - Arranging the housing cover (18) and the battery component (14) on the body-in-white structural element (24, 26) such that the first housing component (18) is located between the body-in-white structural element (24, 26) and the battery component (14), - Attaching the battery component (14) and the first housing component (18) to the body-in-white structural element (24, 26) by means of the fastening element (62), at least part of which passes through the first stiffening plate (40; 42), the module group (33) and the first housing component (18), - Arrange and attach the second housing component (20) to the first housing component (18).

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