Battery holder part, in particular battery holder, and method for producing battery holder part

Abstract

The invention relates to a battery carrier component (2), in particular a battery carrier, having a component element (4) with a receiving region (6) for receiving at least one battery for use as a drive energy storage device of an electric vehicle, having a foam structure (12) and at least one component element (4), the component element (4) has at least one receiving region (6) for contacting and / or receiving the at least one battery (14, 22), the foam structure (12) being arranged at least partially in the receiving region (6). The invention also relates to a method for producing a battery carrier part (2).

Description

Technical Field

[0001] This invention relates to a battery holder component for accommodating at least one battery, particularly a battery holder used as a drive energy storage device for an electric vehicle. The invention also relates to a battery holder component, and particularly a method for manufacturing the aforementioned battery holder component. Background Technology

[0002] Electric vehicles of the type described herein are typically equipped with multiple battery modules, each containing battery cells. These battery modules serve as energy storage devices and provide the electrical energy required for vehicle operation. Specifically, electric vehicles of the type described herein are electric vehicles, whose power is essentially provided entirely by an electric motor. Alternatively, the aforementioned battery rack can also be used in hybrid vehicles, which are equipped with an internal combustion engine in addition to an electric motor.

[0003] Since battery modules are typically heavy, their placement in a vehicle not only places high demands on the vehicle's support structure from a static perspective, but also affects the dynamic forces generated during driving.

[0004] In terms of driving performance, it has been proven advantageous to arrange individual battery modules or individual batteries (also known as battery cells) in the vehicle floor area. To achieve this layout, a battery tray that is essentially a flat plate has been proposed. Such a battery tray can be installed in the vehicle floor area and connected to the vehicle chassis.

[0005] Therefore, the static and dynamic load-bearing capacity of the aforementioned battery bracket must meet considerably high requirements. The battery bracket should not only be able to support a single battery module but also absorb the dynamic loads generated during vehicle operation. Furthermore, the battery bracket must provide the best possible protection for the highly flammable battery modules it supports, especially in the event of an accident.

[0006] Furthermore, it is advantageous to make the battery tray as lightweight as possible, which avoids excessively increasing the vehicle's overall weight and saves energy while the vehicle is in motion. Manufacturing the battery tray as cost-effectively as possible is also beneficial. This presents a further challenge, as the aforementioned static and dynamic load-bearing capacity requirements for the battery tray must still be met even with weight reduction and cost savings.

[0007] Therefore, battery trays are critical components for a vehicle's safety, functionality, and cost-effectiveness. The manufacturing requirements of these battery trays and their components sometimes lead to complex battery tray geometries. Due to the complex geometry of the battery tray, multiple components often need to be joined together during the manufacturing process, particularly by welding. However, the resulting joints can lead to leaks, meaning that the battery module carried by the battery tray cannot effectively prevent liquids (especially water) from seeping in.

[0008] Against this backdrop, the frame structure of battery trays manufactured using at least one deep-drawn component (particularly at least one deep-drawn metal sheet) has proven to have significant advantages. The deep-drawing process enables battery trays with very few joints, thereby improving the sealing performance of the battery trays.

[0009] However, the aforementioned method has drawbacks. Deep drawing processes are essentially unable to create vertical wall components, meaning that battery modules or individual cells cannot be mounted in the edge areas of the battery tray due to limited installation space. Furthermore, this results in unutilized gaps in the edge areas of the battery tray. Due to limited installation space, structural optimization of the corresponding edge areas quickly reaches its limits.

[0010] Furthermore, existing technology provides a frame structure as a component of a battery tray, which encloses a battery module or individual battery, and is arranged in the edge region of the battery tray. This frame structure is typically a multi-part structure, for example, bonded to other components of the battery tray, and may be made of plastic and / or metal. The frame structure also functions as an energy absorber and can buffer forces acting on the battery module or individual battery, especially during sudden acceleration or deceleration of the vehicle. A disadvantage of multi-part frame structures is that, for example, the individual components may expand differently when subjected to temperature changes. This can lead to gaps between the components and increase the forces acting on each component of the frame structure. Additionally, the manufacturing process required for multi-part frame structures can be complex. Summary of the Invention

[0011] Against this backdrop, the objective of this invention is to provide a battery tray component, particularly a battery tray. This design allows for advantageous utilization of the edge areas of the battery tray component and offers advantageous characteristics in terms of static and dynamic loads, as well as weight and cost-effectiveness. Furthermore, a method for manufacturing the battery tray component should be provided, which enables cost-effective production of a lightweight battery tray component with advantageous static and dynamic characteristics.

[0012] According to a first teaching of the present invention, this task is accomplished by a battery holder component, in particular a battery holder, for accommodating at least one battery, which serves as a drive energy storage device for an electric vehicle. The battery holder component has: at least one foam structure and at least one component element, the at least one component element having at least one receiving area for contacting and / or accommodating the at least one battery, wherein the foam structure is at least partially disposed in the receiving area.

[0013] Advantageously, the foam structure can buffer impact loads by acting as an energy absorber, particularly in the event of vehicle vibration and / or sudden acceleration or deceleration, and provides protection for the at least one battery. Furthermore, in the event of a collision with other vehicles or objects, the foam structure can (partially) absorb energy and advantageously distribute it across multiple batteries, thereby reducing mechanical stress on individual batteries. Simultaneously, the foam structure has a relatively low weight compared to corresponding metal and / or plastic structures. Thus, a battery tray component can be provided that is lightweight and reliably compensates for dynamic and static loads on the vehicle, particularly on the battery tray, and especially protects the battery from these loads. The foam structure can also be designed with flexible geometry, allowing it to fill or effectively utilize gaps, for example, created by the non-vertical walls of the battery tray. The foam structure also compensates for the thermal expansion of other materials in the battery tray.

[0014] The battery tray component is specifically designed as a battery tray, including at least one battery tray frame. In particular, the foam structure is securely and / or substantially inseparable from the component elements, for example by form-fitting and / or material bonding.

[0015] Preferably, a binder, such as an adhesive, potting compound, or the like, is provided between the foam structure and the component element. This allows the foam structure to be advantageously connected to the at least one component element. For example, it is also preferred that the foam structure itself adheres to the at least one component element, for example, through a chemical reaction that occurs during the expansion of the foam structure. In particular, the foam structure is connected to the at least one component element in a form-fitting manner. For example, for this purpose, the at least one component element has at least one shaped element, particularly in the form of at least one protrusion, whereby the foam is form-fitted to the at least one shaped element during expansion.

[0016] The receiving area preferably adjoins the at least one battery and / or at least partially covers the battery. Preferably, the receiving area is designed to receive one or more batteries or battery modules, and in particular, the shape of the receiving area is adapted accordingly.

[0017] The component element can be designed, for example, as a single element of the battery tray frame, such as as a side wall of the frame, or as multiple (particularly connected) sub-elements of the battery tray component, particularly the battery tray frame.

[0018] The accommodating area can accommodate one or more batteries, as well as one or more battery modules having multiple batteries (also known as individual battery cells), and / or provide abutment for them. In particular, the at least one battery serves as a drive energy storage device for an electric vehicle.

[0019] The foam structure may partially or substantially completely encapsulate one or more batteries or one or more battery modules, thereby enabling the at least one battery to be reliably protected from stress.

[0020] Preferably, the foam structure is at least partially disposed between the at least one battery and the component element, so that it can advantageously function as an energy absorber and protect the at least one battery from forces applied from the direction of the component element (e.g., forces caused by vibration of the component element). Further, the foam structure may be configured to substantially completely surround the at least one battery to ensure a particularly high level of protection.

[0021] Preferably, in the installed state, the foam structure substantially completely surrounds the receiving area at least in the horizontal plane; in particular, the entire receiving area is covered by the foam structure, so that the foam structure can not only absorb mechanical loads but also improve the sealing of the battery relative to the battery tray component environment.

[0022] Furthermore, recesses can be provided in the battery tray components, for example in the component elements and / or foam structures, for example for (cooling) channels and / or for electrical connections. More preferably, fixing receiving slots (e.g., threaded sockets) and / or receiving slots for electronic components are provided in the battery tray components, particularly in the foam structures.

[0023] The foam structure can, for example, consist substantially of expanded polypropylene (EPP), polyurethane (PU), and / or expanded polyethylene (EPE, cross-linked or non-cross-linked), particularly expanded polypropylene (EPP), polyurethane (PU), and / or expanded polyethylene (EPE, cross-linked or non-cross-linked). For example, the foam structure can also be a metal foam, particularly aluminum foam. This allows the foam structure to be lightweight while also possessing high thermal conductivity and excellent mechanical properties.

[0024] The battery bracket component can be specifically connected to the vehicle chassis and can be specifically used to accommodate multiple batteries, wherein multiple batteries or battery cells can be arranged in one or more battery modules.

[0025] According to a second teaching of the invention, the above-mentioned task is also accomplished by a method for manufacturing a battery tray component, particularly a battery tray, especially the aforementioned battery tray component, in which a component element having a receiving area for accommodating and / or contacting at least one battery is provided, wherein the component element and / or foam structure are optionally surface-treated, and wherein the foam structure is at least partially disposed in the receiving area. Preferably, for this purpose, foam is first injected or sprayed, particularly injected into or sprayed onto the component element, particularly into the receiving area, and cured to form a foam structure, particularly the foam structure formed inside or outside the battery tray component, in the latter case, for example, by means of another component element for forming the foam structure.

[0026] This provides a simple and cost-effective method for manufacturing battery tray components. In particular, the foam structure can be flexibly designed and attached to the receiving area, allowing the geometry of the battery tray component to be adapted in a particularly advantageous manner to the number and shape of batteries or battery modules. Furthermore, it preferably eliminates the need for steps that might require gluing or other joining or assembling of multiple components (especially multiple components including auxiliary component elements) assembled into a frame structure.

[0027] For example, a surface treatment, such as a so-called corona treatment, can improve the adhesion of the at least one foam structure or foam to the at least one component element. Specifically, the corona treatment is an electrochemical surface treatment that can particularly increase surface tension. For example, the adhesion of the at least one foam structure or foam to the at least one component element can also be improved by means of an adhesive applied to the at least one component element and / or the at least one foam structure.

[0028] Specifically, the foam structure is manufactured using foams made of expanded polypropylene (EPP), polyurethane (PU), and / or expanded polyethylene (EPE, cross-linked or uncross-linked). In particular, the foam structure is manufactured by introducing, in particular injecting, the foam into the battery tray component.

[0029] The following describes various other preferred embodiments of battery tray components, particularly battery trays, and methods for manufacturing battery tray components, wherein the various embodiments can be combined with each other and are accordingly adapted to embodiments of battery tray components and embodiments of the methods.

[0030] According to one embodiment of the battery tray component, the at least one component element is designed as a tray, particularly a battery tray having a bottom and walls arranged at an angle thereto, wherein the upper side of the bottom and the inner side of the walls at least partially define a receiving area.

[0031] This forms a receiving slot for at least one battery, which surrounds the battery on at least three sides, thereby reliably protecting the battery. In particular, a cover can be provided to close the top of the tray, so that the battery is protected on virtually all sides.

[0032] For example, the battery bracket component extends in length ranging from 1500 to 2500 mm and in width ranging from 800 to 1600 mm. These dimensions enable the battery to provide sufficient power for propulsion.

[0033] For example, the weight of the battery tray component is in the range of 3 to 6 kg, particularly in the range of 4 to 5 kg. Further, preferably, the weight of the foam structure is in the range of 1 to 3 kg, particularly in the range of 1.25 to 2.25 kg. Therefore, the use of a foam structure can provide a particularly lightweight battery tray component, and especially a particularly lightweight battery tray, which can still absorb the required mechanical load.

[0034] Further, preferably, a battery tray component with substantially the same structure is connected to the battery tray component as a cover in a mirror-reversed manner (particularly by welding, screwing, especially screwing and then sealing and / or gluing), thereby providing an externally enclosed battery tray. In particular, in this case, both battery tray components include a deeply drawn, one-piece component element designed as a tray.

[0035] According to another embodiment of the battery tray component, the foam structure is at least partially disposed on the inner side of the tray wall. In this way, the foam structure can be particularly advantageously used as an energy absorber between the tray and the at least one battery. Preferably, the foam structure is disposed substantially inside the tray, particularly at the inner edge of the tray. In particular, the foam structure is disposed on all the inner sides of the wall. The foam structure can also be disposed (particularly additionally) on the upper side of the bottom, i.e., on the side of the tray whose bottom faces the at least one battery. Preferably, the foam structure forms an internal frame for the at least one battery within the battery tray component, particularly within the battery tray frame, especially a laterally disposed internal frame.

[0036] According to another embodiment of the battery bracket component, at least one force distribution element is disposed on at least one outer side of the wall, wherein the force distribution element is designed to distribute the force acting on the at least one outer side of the wall to the respective wall.

[0037] In this way, forces are prevented from being applied only at specific points on the walls of the component element, and thus to the foam structure (particularly behind these points), thereby preventing damage to the component element, the foam structure, and / or the battery. Instead, the at least one force distribution element is used to distribute the forces to be absorbed at specific points onto at least a portion of the force distribution element, so that these forces can also be introduced over a large area into the at least one component element and the foam structure. Preferably, the force distribution element is substantially form-fitted against the outer side of the wall of the component element. Preferably, the force distribution element is designed to increase the stiffness of the battery tray component. Preferably, the at least one component element is also designed to at least partially increase the stiffness of the battery tray component, thereby distributing the forces present at specific points.

[0038] For example, the at least one force distribution element comprises an aluminum alloy, particularly EN AW 6060, and is specifically composed of therefrom. This provides a material for the at least one force distribution element that, despite its light weight, enables effective distribution of the present forces. Alternatively, the at least one force distribution element may comprise a steel alloy, particularly composed of therefrom, and / or may comprise fiber-reinforced plastics, particularly composed of therefrom.

[0039] Preferably, at least two opposing force distribution elements are provided on the outer sides of the opposing walls of the at least one component element. This further improves the introduction of force into the at least one battery tray component. In this context, it is particularly preferred that at least one force distribution element be provided on the outer side of each wall of the component element designed as a tray.

[0040] Another preferred embodiment is characterized in that the at least one force distribution element is designed as a substantially elongated profile, particularly an extruded profile. For example, the at least one force distribution element extends substantially over the entire outer side of at least one wall. This design has proven advantageous, particularly in terms of good force distribution. For example, the profile structure of a substantially elongated profile can have multiple cavities, thereby reducing the overall weight of the force distribution element.

[0041] According to another embodiment of the battery tray component, the component element is designed as a sheet metal component manufactured by forming, particularly by deep drawing, and specifically as a thin-walled sheet metal component. This has been found to provide a particularly durable and cost-effective battery tray component, which also offers advantages in terms of sealing. In particular, the component element is designed as a deep-drawn sheet metal component, especially a lightweight sheet metal component, such as an aluminum sheet metal component. Alternatively, the sheet metal component can be configured to be substantially composed of a composite material (e.g., a composite of metal and plastic, particularly a composite material with a fiber composite structure). In this way, both weight reduction and increased rigidity of the battery tray component are achieved. It is also preferable that the component element is one-piece or two-piece.

[0042] According to another embodiment of the battery tray component, the foam structure is arranged and constructed in such a way that it forms at least one receiving slot for at least one battery, particularly for at least one battery cell. In this way, at least one battery can be securely fixed and protected without attaching other components to the battery tray component. The provision of such a receiving slot has proven particularly advantageous in so-called "cell-to-pack technology," in which individual battery cells are directly disposed in the battery tray without being assembled into a single battery module. For example, the at least one receiving slot can be used to securely fix battery cells, such as pouch cells, circular cells, and / or prismatic cells, without requiring additional components for storing the battery cells. Furthermore, the at least one receiving slot disposed in the foam structure can provide improved protection for the at least one battery cell. In particular, the foam structure can form multiple receiving slots. Particularly preferably, a battery or battery module can be accommodated and securely held in two opposing receiving slots.

[0043] According to another embodiment of the battery holder component, the at least one receiving slot corresponds to the outer contour of the at least one battery, wherein the at least one receiving slot is designed to be substantially curved, particularly preferably semi-cylindrical. This allows the battery cell to be reliably secured in the battery holder component. "Substantially semi-cylindrical" is understood to mean that the shape deviates slightly from an ideal semi-cylindrical shape (e.g., due to design and manufacturing deviations). Such a shape is particularly advantageous for accommodating a single battery. Furthermore, other shapes of the at least one receiving slot are also feasible depending on other possible battery shapes, such as rectangular or triangular, especially those with rounded corners.

[0044] According to one embodiment of the method, the foam structure is disposed in the receiving area by introducing (particularly injecting) foam into a component element and allowing it to foam (particularly by expansion or curing) to form a foam structure. This achieves a particularly simple and flexible manufacturing method. For example, foam can be introduced, particularly injected, into one or more pre-formed recesses in a component element, particularly in the battery holder, such as one or more recesses for one or more batteries or battery modules. It is also possible to form recesses or receiving slots for batteries in the foam structure simply by inserting foam and allowing it to foam.

[0045] According to another embodiment of the method, the foam structure is disposed in the receiving area by: detachably disposing the molding tool in the receiving area in such a way that at least one gap is formed between the inside of the component element and the molding tool, foam is introduced, in particular injected into the gap, and foamed, in particular cured, to form the foam structure.

[0046] In this way, a large number of battery tray components with substantially identical foam structures can be manufactured cost-effectively using molding tools. Specifically, the molding tool is configured to form multiple, preferably multi-sided, closed gaps. Specifically, the molding tool is removed again after the foam has cured to form the foam structure. Specifically, the cured foam remains in the at least one intermediate gap as the foam structure. For example, a mold positioned outside the battery tray component or an external mold into which the component element is inserted can be used as the molding tool. Specifically, the molding tool can be closed and then reopened. For example, the molding tool is first closed around the component element, forming at least one gap between the inside of the component element and the molding tool, foam is injected into this gap, and after curing, the molding tool is reopened to remove the component element with the foam structure.

[0047] According to another embodiment of the method, the foam structure is disposed in the receiving area by: disposing at least one boundary element in the receiving area, particularly by bonding it to the inside of the component element; forming at least one gap between the inside of the component element and the boundary element; introducing, particularly injecting, foam into the gap; and foaming, particularly curing, to form the foam structure. Specifically, after the foam has cured, The boundary element is retained in the receiving area, particularly on the inside of the component element, and especially preferably on the inside of the bottom of the component element (particularly the tray). Preferably, the at least one gap formed by the boundary element is open on at least one side so that foam material can be advantageously introduced (particularly injected) from that side.

[0048] According to another embodiment of the method, the foam structure is disposed in the receiving area by: introducing, in particular injecting, foam at least partially into at least one mold element and causing it to foam (in particular cure) to form a foam structure, wherein the mold element at least partially restricts the foaming of the foam, and the foam structure, in particular together with the mold element, is disposed in the receiving area. Specifically, the foam structure may be bonded to the mold element in the receiving area, particularly on the inner side of the component element. Preferably, the foam structure is formed by expanding the foam until the expanded plastic reaches the inner contour of the at least one mold element. The foam introduced into the mold element may, for example, be pre-foamed foam, in particular pre-foamed foam beads. Preferably, it is formed at least partially by means of the inner contour of the at least one mold element. For example, the foam is foamed, in particular expanded, by means of steam and / or radio wave radiation, whereby the foam is preferably welded together.

[0049] In this way, the desired shape of the foam structure can be flexibly selected outside the battery tray component and before the foam structure is attached. The at least one mold element can be, for example, an element surrounding the foam, such as a metal (especially aluminum) guide rail.

[0050] According to another preferred embodiment, the foam structure can be formed by applying force using at least one forming element or by means of a forming element. Preferred force application is achieved, in particular, by means of a forming element, for example, by pressing the forming element into the expanded foam, causing the foam to take shape according to the shape of the forming element (particularly a negative shape), particularly by foaming into a foam structure. Specifically, the forming element (particularly at least one side of the element pressed into the foam) forms a negative shape of the desired shape of the foam structure. For example, at least one side of the forming element pressed into the foam is convex, thereby producing a concave shape of the foam structure. For example, during curing, force is applied to the foam by means of the at least one forming element, thereby forming the desired foam structure.

[0051] Other preferred exemplary embodiments of the invention will be embodied in the following detailed description of certain embodiments of the invention, particularly in conjunction with the accompanying drawings. However, the accompanying drawings are for illustrative purposes only and are not intended to define the scope of the invention. The drawings are not necessarily drawn to scale and are intended only to illustrate the general concept of the invention through example. In particular, the features shown in the drawings should not be considered as essential components of the invention. Attached Figure Description

[0052] The present invention will now be described with reference to the accompanying drawings and examples. The drawings show: Figures 1a to 1c A first embodiment of the battery tray component is shown. Figure 2a and Figure 2b Another embodiment of the battery tray component is shown. Figures 3a to 3c A first embodiment of a method for manufacturing a battery tray component is shown. Figure 4a and Figure 4b A second embodiment of a method for manufacturing a battery tray component is shown, and Figure 5a and Figure 5b A third embodiment of a method for manufacturing a battery tray component is shown. Detailed Implementation

[0053] In the following description of various embodiments of the present invention, even though the size or shape may differ in different embodiments, the same reference numerals are used for parts and elements having the same function and the same mode of operation.

[0054] Figure 1a A schematic perspective view of a first embodiment of a battery tray component 2 (presented herein as a battery tray) is shown. In this example, the battery tray 2 has a component element 4 in the form of a tray. However, it is also conceivable that the component element 4 has the shape of only one side of the tray, or has a completely different shape (not shown). The component element 4 also has a receiving area 6, which is defined by the upper side of the bottom 8 of the tray and the inner sides of the tray walls 10a to 10d. A foam structure 12 is disposed in the receiving area 6, in this case inside the tray, and is substantially inseparable from the component element 4. The foam structure 12 surrounds a plurality of battery modules 14, which are received within the tray by the receiving area 6. In addition to receiving battery modules 14, the receiving area 6 can also receive one or more individual batteries, also referred to as battery cells. The foam structure 12 is disposed between the battery modules 14 and the component element 4 (present herein as a tray) and acts as an energy absorber between these components. The shapes of the battery modules or batteries shown in this and other figures should be considered as exemplary only.

[0055] In addition to the components of the battery tray shown, other components may be present, such as a cover for covering the battery module 14 from above and a base plate disposed below the tray. Furthermore, the battery module can be encapsulated with encapsulating compound 16, for example, in such a manner that the top and bottom sides of the battery module are covered by encapsulating compound 16. The battery module is encapsulated in… Figure 1b As shown in the figure, this schematically illustrates the process along... Figure 1a A lateral sectional view of the central axis Ib. Figure 1a and Figure 1c For clarity, encapsulated compound 16 is not shown.

[0056] Figure 1b It is also shown that, for component element 4 designed as a tray, the edge region formed by its non-vertical wall 10 is effectively filled and utilized by the foam structure 12. Furthermore, a force distribution element 18 is provided on the outer side of the wall 10a of component element 4. This force distribution element 18 is designed to distribute the force acting on the side of wall 10a to the entire surface of that side, so that no point force acts on the side of the tray, and therefore not on the foam structure 12. For this purpose, the force distribution element 18 is shaped such that it fits snugly against the side of wall 10a, increasing the rigidity of the battery tray component 4 structure. For clarity, the force distribution element 18 is only provided on the outer side of wall 10a. However, preferably, at least one force distribution element 18 is provided on the outer side of each of the opposite walls 10a to 10d, particularly on the outer side of all walls 10a to 10d.

[0057] at last, Figure 1c It shows along Figure 1b A cross-sectional view of the battery tray component 2 (in this case, the battery tray) taken along the central axis Ic. It can be seen that the foam structure 12 acts as the internal frame of the tray and thus provides protection for the battery module 14 housed therein.

[0058] Figure 2a and Figure 2b Another embodiment of the battery holder component 2 is schematically shown. In this embodiment, the foam structure 12 is arranged and constructed, in particular shaped, in such a way that it forms a plurality of receiving slots 20 for a single battery 22 (including battery cells such as pouch cell cells). Figure 2a A schematic top view of component element 4 of battery holder assembly 2 is shown. The three generally semi-cylindrical receiving slots 20 shown are for accommodating three individual batteries 22, as... Figure 2b The schematic perspective view is shown in the figure. The number of three batteries shown here is merely exemplary. Multiple individual batteries 22 can be configured to be held and securely fixed by corresponding receiving slots 20 of the foam structure 12, or by holding and securely fixing one or more battery modules 14 by semi-cylindrical or differently shaped receiving slots 20.

[0059] Finally, Figures 3 to 5 show examples of embodiments of the method for manufacturing the battery bracket component 2.

[0060] exist Figures 3a to 3c In the first method embodiment shown, the foam structure 12 is attached to the receiving area 6 of the component element 4 in the form of a tray in such a way that the molding tool 24 is first detachably disposed in the receiving area 6 of the battery tray component 2 in such a way that a gap 26 is formed between the inner side of the walls 10a to 10d and the molding tool 24. Figure 3a and Figure 3bThen, with the molding tool 24 closed, foam is injected into these gaps 26. Figure 3b ), and allow it to solidify to form a foam structure 12. Then, reopen the molding tool 24, remove the component element 4 with the foam structure 12, and the molding tool 24 can be reused. Figure 3c ).

[0061] exist Figure 4a and Figure 4b In the second method embodiment shown, the foam structure 12 is arranged in the receiving area 6 in the following manner: First, the boundary element 28 is arranged in the receiving area 6, particularly in a manner facing inward toward the component element 4, such that a top-open gap 26 is formed between the inner side of the outer wall 10a to 10d and the boundary element 28. Figure 4a Then, the foam is injected into the gap 26 and allowed to cure to form the foam structure 12. Figure 4b After the foam has cured, for example, boundary element 28 remains in the receiving area 6.

[0062] exist Figure 5a and Figure 5b In the third method embodiment shown, the foam structure 12 is attached to the receiving region 6 by introducing foam into the mold element 30 and then allowing it to foam. During the foaming process, the foam preferably expands. For example, the foam is pre-foamed into small beads, and then the foam is introduced into the at least one mold element 30 in the form of small beads. The inserted foam is then foamed, for example by means of water vapor or radio wave radiation, particularly by at least partially expanding and / or fusing the foam. Preferably, the expansion of the foam is limited by the inner contour of the at least one mold element, thereby producing a predetermined foam structure.

[0063] exist Figure 5b In the method shown, different shapes of foam structure 12 are provided due to the different inner contours of mold element 30.

[0064] The exemplary embodiments / examples of the invention described in this specification should be understood as being disclosed both individually and in combination with each other. In particular, unless explicitly stated otherwise, the description of a feature included in a particular embodiment should not be construed as meaning that the feature is indispensable or essential to the functionality of that embodiment. The order of the process steps shown in the flowcharts of this specification is not mandatory; alternative orders of process steps are conceivable. Process steps can be implemented in various ways, for example, software (via program instructions), hardware, or a combination of both.

[0065] Terms such as “comprising,” “having,” “including,” and “containing” used in the patent claims do not exclude other elements or steps. The phrase “at least partially” covers both “partially” and “completely.” The phrase “and / or” should be understood to disclose both alternatives and combinations; that is, “A and / or B” means “(A) or (B) or (A and B).” In the context of this specification, multiple units, persons, etc., refer to multiple units, persons, etc. The use of indefinite articles does not exclude plural forms. A single device can perform the functions of multiple units or devices mentioned in the patent claims. Reference numerals specified in the patent claims should not be considered as limitations on the methods and steps used.

Claims

1. A battery bracket component (2), particularly a battery bracket for accommodating at least one battery used as a drive energy storage device for an electric vehicle, -Having at least one component element (4), said component element (4) having at least one receiving area (6) for contacting and / or accommodating said at least one battery (14, 22), and -Having at least one foam structure (12), wherein, The foam structure (12) is at least partially disposed in the containment area (6).

2. The battery bracket component (2) according to claim 1. Its features are, - The at least one component element (4) is designed as a tray having a bottom (8) and walls (10a-d) arranged at an angle thereto, wherein the upper side of the bottom (8) and the inner side of the walls (10a-d) at least partially define the receiving area (6).

3. The battery bracket component (2) according to claim 2. Its features are, - The foam structure (12) is at least partially disposed on the inside of the wall (10a-d) of the tray.

4. The battery bracket component (2) according to claim 2 or 3. Its features are, - At least one force distribution element (18) is disposed on at least one outer side of the wall (10a-d), wherein the force distribution element (18) is designed to distribute the force acting on the at least one outer side of the wall (10a-d) to the respective wall (10a-d).

5. The battery bracket component (2) according to claim 4. Its features are, - The at least one force distribution element (18) is designed as a substantially elongated profile, particularly an extruded profile.

6. The battery bracket component (2) according to any one of claims 1 to 5. Its features are, - The component element (4) is designed as a sheet metal component manufactured by forming, particularly by deep drawing, especially as a thin-walled sheet metal component, wherein the component element (4) is preferably one-piece or two-piece.

7. The battery bracket component (2) according to any one of claims 1 to 5. Its features are, - The foam structure (12) is arranged and designed in such a way that it forms at least one receiving groove (20) for at least one battery (14, 22), particularly for at least one battery cell (22), and - The foam structure (12), in particular the plurality of receiving grooves (20) of the foam structure, preferably extends substantially along the entire inner side of the wall (10a-d).

8. The battery bracket component (2) according to claim 7. Its features are, - The at least one receiving groove (20) corresponds to the outer contour of the at least one battery (14, 22), and is particularly substantially curved, and particularly preferably semi-cylindrical.

9. A method for manufacturing a battery tray component (2), particularly a battery tray, preferably a method for manufacturing a battery tray component according to any one of claims 1 to 8. - In the method, a component element (4) is provided having a receiving area (6) for receiving and / or contacting at least one battery (14, 22). -In the method, the component element (4) may optionally undergo surface treatment, and - In the method, the foam structure (12) is at least disposed in the receiving area (6).

10. The method according to claim 9, Its features are, - The foam structure (12) is provided in the receiving area (6) by introducing foam into the component element (4), particularly by injecting it into the component element (4), and foaming it, particularly by curing it to form the foam structure (12).

11. The method according to claim 9 or 10, Its features are, - The foam structure (12) is disposed in the receiving area (6) by means of a molding tool (24) being detachably disposed in the receiving area (6) such that at least one intermediate gap (26) is formed between the inner side of the component element (4) and the molding tool (24), the foam is introduced, in particular injected into the intermediate gap (26), and foamed, in particular cured to form the foam structure (12).

12. The method according to claim 9 or 10, Its features are, - The foam structure (12) is disposed in the receiving area (6) by disposing of at least one boundary element (28) in the receiving area (6), particularly by bonding it to the inside of the component element (4), such that at least one intermediate gap (26) is formed between the inside of the component element (4) and the boundary element (28), the foam is introduced, particularly injected into the intermediate gap (26), and foamed, particularly cured to form the foam structure (12).

13. The method according to claim 9, Its features are, The foam structure (12) is disposed in the receiving area (6) by introducing the foam into the mold element (30), particularly by injecting it into the mold element (30), and foaming it, particularly by curing it to form the foam structure, wherein the mold element (30) at least partially restricts the foaming of the foam, and - The foam structure (12), in particular together with the mold element (30), is placed in the receiving area (6).

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