Battery tray for holding battery

Abstract

The utility model provides a battery tray for accommodating a battery. The battery tray (100; 200) comprises at least: a tray housing (190; 290) in the housing; wherein in a tray housing (190; 190 ') made of a composite material; 290) on the concave side thereof, an electrically conductive track layer (130) is arranged on or above a continuous first layer of the tray housing (190; a plurality of electrically readable deformation measurement structures (140) are formed in the conductive track layer (130) on the flat portion of the substrate (290, 290).

Description

TECHNICAL FIELD

[0001] The utility model relates to a battery tray, in particular for accommodating a vehicle battery in a vehicle. BACKGROUND

[0002] Rechargeable batteries, such as vehicle batteries for battery electric or hybrid vehicles, are usually stored in a battery tray, in which they can be transported and protected from external influences.

[0003] In particular, vehicle batteries are usually positioned as low as possible in the vehicle in order to maintain a low center of gravity and thus to improve the grip of the vehicle. The respective battery tray in which the vehicle battery is arranged is usually made of a robust material and, for example, helps to cushion or completely eliminate external impacts that could otherwise damage or even destroy the vehicle battery.

[0004] Since damage to the vehicle battery can have a negative effect on other components or the driving characteristics of the vehicle, it is advantageous to be able to identify whether the battery tray is damaged and to what extent.

[0005] For example, DE 102020119287 A1 describes a protective plate, the integrated conductor track of which serves as a deformation sensor, which is arranged on the convex outer side of the battery tray. The protective plate can thus to some extent shield the battery tray from various external influences. If the protective plate fulfills this function, it is usually the case that the integrated deformation sensor reports damage since the protective plate has already been damaged, whereby it is still unclear whether the battery tray (or even the vehicle battery itself) to be protected has actually been damaged. SUMMARY

[0006] It is therefore the task of the utility model to provide an improved battery tray, which in particular enables improved detection of any damage.

[0007] These tasks are solved by the subject matter of the independent claims and the aspects of the utility model described.

[0008] According to a first aspect, therefore, a battery tray for holding a battery, in particular a vehicle battery, is provided, comprising:

[0009] a tray housing;

[0010] wherein a layer of an electrically conductive track is arranged on (i.e. directly on) or above (i.e. for example also indirectly on) a continuous first layer on the concave side of the tray housing made of a composite material, and

[0011] wherein a plurality of electrically readable deformation measurement structures are formed in the layer of the electrically conductive track at least on the flat portion of the tray housing.

[0012] Thus, the basic idea of the utility model is that the deformation measuring structures are arranged on the inner side of the battery tray housing, i.e. on the concave side. In this way, the likelihood that these deformation measuring structures detect a deformation not only affecting the upstream protection plate or the tray housing itself but also actually damaging the internal battery is increased. Thus, in the assembled state, the electrically conductive track layer with the deformation measuring structures is particularly located between the battery, e.g. a vehicle battery, and the tray housing.

[0013] The electrically conductive track layer can be arranged directly on the continuous first layer or above it, i.e. there can be further layers, such as at least one electrically insulating layer and / or a lacquer layer, etc., therebetween.

[0014] According to some preferred embodiments, variants or improvements of the embodiments, the electrically conductive track layer is embedded in a (particularly further continuous) second layer of the tray housing, e.g. on the side or on all sides, thus particularly also from above, i.e. on the side of the electrically conductive track layer facing away from the continuous first layer. The continuous second layer can be an insulating layer and / or a protective layer.

[0015] According to some preferred embodiments, variants or improvements of the embodiments, the second layer is a lacquer coating, which can particularly be applied above the electrically conductive track layer and the gap in this layer. This lacquer coating as the second layer can be applied directly on the electrically conductive track layer, if present, and additionally directly on the layer to which the electrically conductive track layer is attached.

[0016] According to some preferred embodiments, variants or improvements of the embodiments, the tray housing is formed from a fiber composite material hardened into the corresponding shape, which particularly comprises glass fibers and / or carbon fiber inserts. Thus, the tray housing can e.g. be formed from carbon fiber reinforced plastic, i.e. CFRP. Such a tray housing offers a particularly good balance between low weight and robustness.

[0017] According to some preferred embodiments, variants or improvements of the embodiments, the tray housing comprises a first component made of a composite material formed into a tray shape and a second component of a flat, i.e. planar, metal, e.g. a metal sheet. In particular, the second component of the metal can be directly attached to the tray bottom of the tray shape of the first component on the concave side thereof. The continuous first layer of the tray housing can be formed by the first component.

[0018] In this way, the advantages of metal materials and composite materials can be combined: composite materials are strong and light, but can sometimes act elastically, so that damage to the composite material is sometimes not visible. In particular, in adverse situations, the composite material can deform and then elastically return to its original shape between two measurements in the deformed state, in particular if measurements in the deformed state are planned to be taken regularly. Thus, a deformation that has occurred and that can have caused damage to the internal battery can not be visible to the measurement.

[0019] In contrast, metal materials generally retain their shape after damage, so that the damage remains physically visible and, more importantly, can still be detected by subsequent measurements. Furthermore, the electrically conductive track layer can be easily attached to a second component of metal, which in turn can be easily attached to the composite material.

[0020] The second component is advantageously designed as a metal plate with a thickness of 1 millimeter or less, in particular 0.5 millimeters or less. In this way, the overall weight of the tray housing is only slightly increased.

[0021] The second component can be designed, for example, as so-called "tailor-made functional steel" (i.e., TFS) and thus produced in a corresponding advanced manufacturing process.

[0022] The first component can be formed from a fiber composite material hardened into a corresponding shape, which in particular comprises glass fibers and / or carbon fiber inserts. Thus, the tray housing can be formed, for example, from carbon fiber reinforced plastic, i.e., CFRP.

[0023] Another advantage of the variant with two different components is that the battery tray can be easily adapted to customer requirements. For example, for a large number of products, the first component, i.e., the tray shape made of composite material, can be produced with the same shape, which also offers advantages in terms of storage and warehouse logistics. Then, by selecting and attaching a different second metal component in each case, different interconnections or cable arrangements of the battery tray can be provided in a simple manner.

[0024] For example, depending on the metal plate arranged therein, different functions can also be provided in the same geometric tray shape, for example for different battery types, vehicle types or for basic and advanced functions. Thus, the geometry of the battery tray can be optimally adapted to a specific vehicle type, vehicle body, vehicle platform, etc., while the electrical functions and, for example, the position of the connection contacts can also be individually adapted to the battery tray.

[0025] Furthermore, the cable arrangement of an existing battery tray can be easily changed by simply exchanging the second component of metal, i.e., the metal plate. Thus, an upgrade or recycling is possible without any problems.

[0026] According to some preferred embodiments, variants or improvements of the embodiments, the deformation measurement structures are at least partially (or entirely) formed as capacitive sensor structures, for example at least partially (or entirely) as interdigital electrodes. The deformation of the tray housing changes the capacitive coupling between the individual electrodes of the affected sensor structures, which can be detected by a corresponding evaluation device.

[0027] According to some preferred embodiments, variants or improvements of the embodiments, the deformation measurement structures are at least partially designed as resistive sensor structures. Due to the deformation of the tray housing, the affected deformation measurement structures are stretched, compressed or interrupted, which changes their electrical resistance (in particular ohmic resistance), which can be detected by a corresponding evaluation device.

[0028] Temperature compensation can be provided, according to which the temperature of the battery tray, the tray housing or even of the individual deformation measurement structures is recorded and the thermally induced changes in the electrical resistance of the deformation measurement structures are ignored during the evaluation by the evaluation device. For this purpose, one or more temperature sensors can be arranged in or on the tray housing, which can also be evaluated by the evaluation device.

[0029] According to some preferred embodiments, variants or improvements of the embodiments, the (in particular capacitive or resistive) sensor structures are covered on the side facing away from the tray housing with a plastic foam, in particular a polyurethane foam or a polystyrene. The plastic foam can be arranged directly on the sensor structures and / or on the second layer of the tray housing, or an intermediate space is present.

[0030] According to some preferred embodiments, variants or improvements of the embodiments, the battery tray further comprises an evaluation device, which is adapted to:

[0031] applying an electrical excitation signal to at least some (and preferably all) of the deformation measurement structures,

[0032] and reading out a respective signal response of the deformation measurement structures to the respective excitation signal in order to determine a normal state or a deformed state of the respective deformation measurement structure on the basis of the signal response.

[0033] The nature of the excitation signal and the signal response depends in particular on the selected design of the deformation measurement structures: In the case of resistive sensor structures as deformation measurement structures, the excitation signal can for example be an applied voltage with a predetermined voltage value, and the signal response correspondingly is a measured current, which thus indicates the current electrical resistance. In the case of capacitive sensor structures, the excitation signal can for example be an alternating current signal, and the signal response can be a reactive current which depends on the current capacitance.

[0034] The evaluation device can have a digital computing device. Such a digital computing device can be or can be implemented as any device capable of computing and in particular capable of executing software, applications or algorithms. For example, the computing device can comprise at least one processing unit, such as a central processing unit (CPU) and / or a graphics processing unit (GPU) and / or a field-programmable gate array (FPGA) and / or an application-specific integrated circuit (ASIC) and / or a combination thereof. The computing device can further comprise a working memory operably coupled to the at least one processor unit, and a non-volatile memory operably coupled to the at least one processor unit and the working memory. The computing device can be implemented completely or entirely in a local device and / or completely or entirely in a remote system, such as a remote server and / or a cloud computing platform.

[0035] The evaluation device can also be arranged in a recess of the battery tray, for example directly or indirectly attached to the bottom of the battery tray, in particular to the electrically conductive tracks of the electrically conductive track layer. This means that the signal lines for the excitation signal and the signal response can advantageously be arranged within the electrically conductive track layer.

[0036] The evaluation device can also be arranged outside the battery tray. The electrical inlet and outlet conduits between the deformation measurement structure and the evaluation device can extend along the inner walls of the battery tray housing.

[0037] According to some preferred embodiments, variants or improvements of the embodiments, the evaluation device can be calibrated in a calibration process, such that a respective current signal response during the calibration process is indicative of a normal state and a deviation from this current signal response is indicative of a deformation state of the respective deformation measurement structure. This means that the calibration process can not only be performed as an initial calibration after completion of the battery tray or immediately after its installation, for example in a vehicle, but also that a periodic or event-based calibration process can be performed as a recalibration. Possible recalibrations relate, for example, to the current temperature in the battery tray and can be performed periodically or based on events, for example when a temperature threshold is exceeded and / or not reached.

[0038] A recalibration can also be performed after a deformation condition has been detected, for example if a deformation of the battery tray has been detected which does not impair the functionality of the battery tray (or only within a predetermined tolerance range). The current state can then be redefined as a normal state in the calibration process, such that only additional deformations beyond this are detected.

[0039] According to another aspect, a method of manufacturing a battery tray is also provided, the method comprising at least the following steps:

[0040] manufacturing a tray-shaped piece from a composite material; and

[0041] applying a plurality of electrically readable deformation measurement structures to or above the tray shape, in particular by means of a jet printing process.

[0042] According to yet another aspect, there is also provided a further method of manufacturing a battery tray, comprising at least the following steps:

[0043] applying a plurality of electrically readable deformation measurement structures to or above the metal plate (i.e. directly on the metal plate) and

[0044] fixing the metal plate internally to the tray bottom of the tray-shaped composite material.

[0045] Optionally, the method further comprises manufacturing the composite material in the form of a tray.

[0046] The shaping of the tray structure is thus completely separated from the application of the deformation measurement structures on their carrier. This means that, without taking into account other components, the most suitable process can be used for applying the deformation measurement structures and for manufacturing the tray shape.

[0047] The separate production of the components also makes it possible to combine the same tray form with metal plates of different design (in particular in terms of deformation measurement structures and / or their wiring). Thus, for battery trays with different electrical variants, only the production of the component using the metal plate needs to be changed, which leads to positive economies of scale. Furthermore, the metal plate can be stored more easily than the finished battery tray, even with the deformation measurement structures attached, which also simplifies the production logistics.

[0048] In all variants and aspects, the tray shape can be made of a composite material by hardening (in the tray shape) a fiber composite material, in particular comprising glass fibers and / or carbon fiber inserts.

[0049] The tray housing can thus be made of, for example, carbon fiber reinforced plastic, i.e. CFRP.

[0050] According to some preferred embodiments, variants or improvements of the embodiments, the method further comprises the following steps:

[0051] applying an electric excitation signal to at least one portion of the deformation measurement structures;

[0052] electrically reading out a respective signal response of the deformation measurement structures to the respective applied excitation signal; and

[0053] calibrating the evaluation device such that in each case the read-out signal response is indicative of an undeformed normal state of the respective deformation measurement structure and a deviation in the signal response is indicative of a deformed state of the respective deformation measurement structure.

[0054] As described above with reference to the evaluation equipment, the battery tray can be optimally adjusted in this manner, especially after the battery tray has been manufactured and / or immediately after the battery tray has been installed at its intended destination (such as a vehicle).

[0055] Applying an excitation signal, reading out the signal response, and / or calibrating the evaluation device (in particular all three steps) can advantageously be performed once or multiple times periodically or on an event-based basis during battery operation in the battery tray, especially for recalibration.

[0056] Further advantageous embodiments, variations and improvements of the embodiments are shown in the following detailed description with reference to the accompanying drawings. Attached Figure Description

[0057] The present invention will now be explained in more detail with reference to examples of embodiments shown in the accompanying drawings.

[0058] Figure 1 A schematic cross-sectional view of a battery tray according to one embodiment of the present invention is shown;

[0059] Figure 2A Showing from Figure 1 A schematic isometric representation of the battery tray;

[0060] Figure 2B A schematic top view of a modified battery tray is shown;

[0061] Figure 3 An exemplary portion of a modified battery tray according to the present invention is shown;

[0062] Figure 4 An exemplary portion of a battery tray according to another variation of the present invention is shown;

[0063] Figure 5 A schematic cross-sectional view illustrating another embodiment of the present invention is shown;

[0064] Figure 6 A schematic flowchart illustrating a method for manufacturing a battery tray according to one embodiment of the present invention is shown; and

[0065] Figure 7 A schematic flowchart illustrating a method for manufacturing a battery tray according to another embodiment of the present invention is shown.

[0066] In all the accompanying drawings, unless otherwise specified, identical or functionally identical elements and devices are given the same reference numerals. The naming and numbering of process steps do not necessarily imply sequence, but are used for better distinction; however, in some variations, the sequence may correspond to the order of the numbers.

[0067] List of reference numerals

[0068] 20-Battery; 30-Evaluation equipment; 71-Electrical excitation signal; 79-Signal response; 100-Battery tray; 110-First layer; 115-Coating; 120-Second layer; 130-Conductive track layer; 140-Deformation measurement structure; 141-Capacitive sensor structure; 142-Resistive sensor structure; 160-Plastic foam; 190-Tray housing; 191-Tray bottom; 192-Tray wall; 195-Cavity of tray-shaped part of tray housing; 200-Battery tray; 205-Tray-shaped part; 210-Metal plate; 215-Coating; 290-Tray housing; S01~S08-Method steps. Detailed Implementation

[0069] Figure 1 A schematic cross-sectional view is shown to explain a battery tray 100 according to one embodiment of the present invention.

[0070] Figure 1 The battery tray 100 includes a tray housing 190, which is formed in the shape of a tray (having a tray bottom 191 and tray walls 192) made of a composite material. The composite material can be formed from a fiber composite material hardened to the corresponding shape, particularly including glass, fiber, and / or carbon fiber inserts. The tray housing 190 can therefore be formed, for example, from carbon fiber reinforced plastic, i.e., CFRP. The composite material forms a continuous first layer 110 of the tray housing 190.

[0071] In this context and hereinafter, terms such as “inner” or “middle” always refer to the cavity 195 formed by the pallet-shaped part, while “outer” or “outer” always refer to the space outside the pallet-shaped part, particularly on its convex side.

[0072] The battery tray 100 is configured to receive the battery 20 in a recess 195. In some variations, the battery tray 100 includes the battery 20 disposed in the recess 195, particularly a vehicle battery.

[0073] The conductive track layer 130 is disposed above the inner side of the first layer 110, for example, directly thereon. Multiple electrically readable deformation measurement structures 140 are formed in the conductive track layer 130 on the flat portion of the tray housing 190 at the tray bottom 191, as described below. Figures 2A to 4 To explain in more detail.

[0074] The conductive track layer 130 may optionally be embedded in a continuous second layer 120, which may be designed, for example, as an electrically insulating varnish coating. The second layer 120 may extend adjacent to and above the conductive track layer 130 to protect its interior from damage. For this purpose, the second layer 120 may be applied, for example, after the deformation measuring structure 140 has been applied over the first layer 110.

[0075] The battery tray 100 may also include an evaluation device 30, which is configured to apply an electrical excitation signal 71 to at least some (preferably all) of the deformation measurement structure 140 and read out the corresponding (particularly electrical) signal response 79 of the deformation measurement structure 140 to the corresponding electrical excitation signal 71 in order to determine the normal or deformed state of the corresponding deformation measurement structure 140 based on the signal response.

[0076] The determination of the deformation state may include only information that deformation has occurred in the corresponding deformation measurement structure 140, or it may additionally include other information, such as the degree of deformation, deformation time, and / or other parameters. The relevant information can be indicated by the output signal of the evaluation device 30.

[0077] like Figure 1 As schematically shown, the evaluation device 30 can be inserted together with the battery 20 into the recess 195 of the tray housing 190. For this purpose, the dimensions of the battery 20, the evaluation device 30, and the tray housing 190 can be configured such that the evaluation device 30 and the battery 20 are mounted adjacent to each other on or above the top layer of the tray bottom 191 (here: on the conductive track layer 130 and the second layer 120).

[0078] The evaluation device 30 can be directly or indirectly connected to the conductive path of the conductive track layer 130 so as to apply an electrical excitation signal 71 to the deformation measurement structure 140 and receive a signal response 79 from the deformation measurement structure 140. For this purpose, wires, cables, flexible conductors, etc. can be used.

[0079] Alternatively, the evaluation device 30 may also be arranged outside the tray housing 190. In this case, inlet and outlet conduits or signal lines may be arranged between the deformation measurement structure 140 and the evaluation device 30 on the tray wall 192. For this purpose, the conductive track layer 130 may also extend entirely or partially above the tray wall 192 and include inlet and outlet conduits.

[0080] For manufacturing purposes, the conductive track layer 130 can be applied to the composite material of the first layer 110 of the tray-shaped part, for example, by a printing process.

[0081] If the evaluation device 30 is arranged within the tray housing 190, inlet and outlet conduits can be provided from the evaluation device 30 to external devices such as vehicle computers and / or battery control units. Signals indicating the state (in each case, normal or deformed state) of the deformation measurement structure 140 as determined by the evaluation device 30 can be output by the evaluation device 30 via the outlet conduit. For example, a trigger can be received via the inlet conduit, in response to which the evaluation device 30 transmits one or more electrical excitation signals 71 and / or performs a calibration process.

[0082] Figure 2A An exemplary isometric representation of the battery tray 100 according to the present invention is shown. Individual deformation measurement structures 140 are provided substantially throughout the flat bottom 191 of the tray, preferably in a regular grid. The deformation measurement structures 140 may each be individually electrically readable, or may be connected in series or parallel, wholly or partially, so that they can be read at least partially as a group by the evaluation device 30.

[0083] Individual deformation measurement structures 140 can be capacitive or resistive, thus all deformation measurement structures 140 can be resistive, or all deformation measurement structures 140 can be capacitive, or some deformation measurement structures 140 can be resistive while others can be capacitive.

[0084] Figure 2B A schematic top view of a modified battery tray 100 is shown. Figure 2B In the battery tray, individual deformation measurement structures 140 also extend above the tray wall 192; therefore, deformation of the tray wall 192 can also be detected. As an example, three individual resistive deformation measurement structures 140 are present. Figure 2B The circuits are shown as separate circuits, each of which can be used to monitor deformation of a corresponding area of ​​the battery tray 100.

[0085] These individual resistive deformation measurement structures 140 may have the same or different designs and shapes, be symmetrical or asymmetrical, and have the same or different dimensions. In this way, for example, individual areas of the battery tray 100, certain portions of the battery 20, or other components arranged in the battery tray 100 can be monitored individually.

[0086] The corresponding evaluation device 30 or common evaluation device 30 can be electrically connected via the connection contacts of the corresponding deformation measurement structure 140 (these connection contacts are in Figure 2B (shown as disconnected) so as to exchange the electrical excitation signal 71 and the signal response 79.

[0087] Manufacturing made of composite materials Figure 2BThe process of shaping the battery tray 100 allows for a great deal of freedom in its geometry design, while the application of the deformation measurement structure 140 can be adapted to its geometry, for example, by using a printing process, in order to achieve optimal results.

[0088] Figure 3 An exemplary isometric representation of a portion of a battery tray 100 is shown, which includes a single deformation measurement structure 140 implemented as a capacitive sensor structure 141. The deformation measurement structure 140 shown includes interdigitated electrodes, to which an evaluation device can apply an alternating current signal as an electrical excitation signal 71 to determine current capacity.

[0089] Figure 3 The deformation measurement structure 140 shows that the substrate on which it rests has been removed from the outside ( Figure 3 The bottom of the structure is deformed in the shape of a spherical cross section. Therefore, the current capacitance of the interdigitated electrodes is different from the capacitance determined during the calibration of the deformation measurement structure 140 (preferably in an undeformed state), so that the evaluation device 30 can determine the deformation state of the deformation measurement structure 140 based on this.

[0090] To improve measurement, plastic foam 160 (e.g., polyurethane foam, polystyrene, etc.) can be applied to or above the conductive track layer 130. This plastic foam not only acts as an additional protective layer ( Figure 3 An additional protective layer for the battery, arranged at the top, resists external influences, as does an additional protective layer for the conductive track layer 130, resisting internal influences, and also acts as an additional dielectric between the interdigital electrodes. When the tray housing 190 deforms from the outside, the plastic foam 160 also deforms (compresses or stretches), which also causes the capacitance of the capacitive sensor structure 141 to change in a measurable manner.

[0091] Figure 4 An exemplary isometric representation of a portion of a battery tray 100 is shown, which includes a single deformation measurement structure 140 implemented as a resistive sensor structure 142.

[0092] exist Figure 4 As can be seen, individual wires within the conductive track layer 130 can be folded forward and backward several times along themselves to form a resistive sensor structure 142 (in each case, there is an insulating distance between the parallel strands), such that the flat portion densely covered by the wires is formed as a rectangle, or more specifically a square.

[0093] Figure 4An example of existing deformation of the substrate of the deformation measurement structure 140 is also shown, whereby portions of the wires of the deformation measurement structure 140 are compressed or (most importantly) stretched. Short circuits or complete interruptions due to cutting may also occur. In each of these cases, the resistance of the resistive sensor structure 142 changes, which can then be detected by the evaluation device 30.

[0094] Figure 5 A schematic cross-sectional view is shown to explain another embodiment of the present invention, specifically a battery tray 200.

[0095] Figure 5 The battery tray 200 is Figure 1 A variation of the battery tray 100, and differing from the latter in that the tray housing 290 of the battery tray 200 includes two parts. The first part consists of or includes a tray-shaped member 205, which is made of a composite material and has a tray bottom 191.

[0096] A metal plate 210 with an electrically insulating coating 215 is attached as a second component of the tray housing 290 to the tray bottom 191 or above the tray bottom 191, and a conductive track layer 130 and a second layer 120 are disposed on or above this second component. Figure 5 In this embodiment, composite material 305 can therefore be considered as realizing the first layer.

[0097] In this variant, the flat metal plate 210, to which the deformation measuring structure 140 is attached, can be advantageously inserted into and secured there, for example, by gluing, inside the flat tray bottom 191 of the tray-shaped part 205 made of composite material after its manufacture. The metal plate 210 can be formed to have a thickness of 1 mm or less, particularly 0.5 mm or less, which makes it particularly lightweight.

[0098] Therefore, the structural stability of the pallet housing 290 is essentially provided by the first component (i.e., the pallet-shaped part 205 made of composite material), while the electrical functions (especially the deformation sensor) are provided by the metal plate 210 on which the deformation measurement structure 140 is arranged.

[0099] The following describes a method for manufacturing the battery tray 100; 200 according to the present invention. To explain the process steps, in some cases, methods from the foregoing will be used. Figures 1 to 5 The reference numerals in the accompanying drawings should be understood to be unrelated to the intended use and are not intended to be limiting. To avoid repetition, the characteristics of each element are not always described in detail; for this purpose, reference is made to the foregoing general description of the present invention. Figures 1 to 5 A detailed description.

[0100] Figure 6A schematic flowchart illustrating a method for manufacturing a battery tray is shown. The produced battery tray may be the aforementioned battery tray 200, its variations or improvements, or different battery trays. Therefore, the method can be adapted according to all options, variations, implementations, and improvements described with respect to all battery trays according to this invention, and particularly to battery tray 200 according to this invention, and vice versa.

[0101] In step S02, a plurality of electrically readable deformation measurement structures 140 are applied to or above the metal plate 210, for example as previously referred to Figure 5 As explained, since the metal plate 210 is flat, the conductive tracks of the conductive track layer 130 can be applied, for example, by a printing process. However, other methods are also conceivable, such as robotic spraying methods (or robotic inkjet printing processes) using masks. The metal plate 210 may be a metal layer having an electrically insulating coating 215 directly attached thereto.

[0102] In optional step S03, an insulating layer 120 is applied to the metal plate 210 (particularly directly to the electrically insulating coating 215), wherein the deformation measuring structure 140 is embedded in the insulating layer 120. In this case, the insulating layer at least on the sides (i.e., within the conductive track layer 130 in which the deformation measuring structure is formed) and preferably additionally on all sides surround the deformation measuring structure 140. Alternatively or additionally, electrically insulating plastic foam 160 may also be applied in this step.

[0103] In step S04, for example, a metal plate 210 (optionally, with an insulating layer 120 attached thereto) is fastened to the interior of the bottom 191 of the composite material formed into a tray shape 205 by gluing.

[0104] In optional step S01, the composite material can first be formed into a tray-shaped part 205, for example by injection molding or compression molding. The composite material can be, for example, a fiber composite material hardened into the shape of the tray-shaped part 205, particularly including glass fiber and / or carbon fiber inserts.

[0105] In step S05, additional sub-steps may be performed to produce the battery tray 200, for example (in this order or in a different order):

[0106] Make the evaluation device 30 electrically connected / in contact with the conductive track of the conductive track layer 130;

[0107] Apply plastic foam 160 onto conductive track layer 130;

[0108] The evaluation device 30 is connected to the vehicle's electronic components;

[0109] Install the battery 20 in the battery tray 200; and / or

[0110] Install the battery tray 200 in the vehicle.

[0111] In alternative steps S06-S08, a calibration process for the evaluation device 30 of the battery tray 100 may also be performed. This calibration process S06-S08 may be performed immediately after step S04 or step S05 (including one, more, or all of the sub-steps), particularly after the battery tray 200 has been installed in its intended future location (such as a vehicle).

[0112] The calibration process S06-S08 can also be performed several times, especially periodically or based on events (whenever a service is performed, whenever a shock is detected, etc.).

[0113] In step S06, an electrical excitation signal 71 is applied to at least some (preferably all) of the deformation measurement structure 140.

[0114] In step S07, for example, the evaluation device 30 electrically reads out the corresponding signal response 79 of the deformation measurement structure 140 to the corresponding applied electrical excitation signal 71, as explained above.

[0115] In step S08, the calibration evaluation device 30 (i.e., in particular, its decision algorithm is adjusted) so that the corresponding readout signal response 79 indicates the undeformed normal state of the corresponding deformation measurement structure 140, and the deviation in the signal response 79 indicates the deformation state of the corresponding deformation measurement structure 140.

[0116] In another optional step, for example, an output signal may be output indicating the normal state and / or deformation state of one or more deformation measurement structures 140, and optionally with additional information such as the degree of deformation.

[0117] Figure 7 A schematic flowchart illustrating another method for manufacturing a battery tray is shown. The battery tray produced can be the aforementioned battery tray 100, its variants or improvements (such as...). Figure 2A or Figure 2B ( ), or a different battery tray. Therefore, the method can be adapted according to all options, variations, implementations and improvements described with respect to all battery trays according to the present invention and in particular battery tray 100 according to the present invention, and vice versa.

[0118] In step S01, the composite material is formed into a tray-shaped part 205, for example, by injection molding or compression molding. The composite material may be, for example, a fiber composite material cured into the shape of the tray-shaped part 205, particularly comprising glass fiber and / or carbon fiber reinforcement.

[0119] In step S09, multiple electrically readable deformation measurement structures 140 are applied to or above the tray-shaped part 205 generated in step S01 using a printing process. Specifically, the deformation measurement structures 140 are applied directly to the tray-shaped part 205. For example, the printing process can be performed by a robot.

[0120] Optionally, each of steps S05-S08 described above can then be performed subsequently.

Claims

1. A battery tray for housing a battery, characterized by, Comprising: a tray housing; wherein on or above a continuous first layer on the concave side of the tray housing made of a composite material a conductive track layer is arranged, and wherein a plurality of electrically readable deformation measurement structures are formed in the conductive track layer at least on a flat portion of the tray housing.

2. The battery tray of claim 1, wherein, The conductive track layer is embedded in a second layer of the tray housing.

3. The battery tray of claim 2, wherein, The second layer is a lacquer coating.

4. The battery tray of claim 1, wherein, The first layer of the tray housing is formed from a fiber composite material hardened into a corresponding shape.

5. The battery tray of claim 4, wherein, The fiber composite material comprises glass fibers and / or carbon fiber inserts.

6. The battery tray of claim 1, wherein, The tray housing comprises a first component formed as a tray shape made of a composite material and a second component of flat metal, which is attached to a tray bottom on the concave side of the tray shape of the first component.

7. The battery tray of claim 6, wherein, The second component of flat metal is directly attached to the tray bottom.

8. The battery tray of claim 6, wherein, The second component is formed as a metal plate having a thickness of 1 millimeter or less.

9. The battery tray of claim 1, wherein, The deformation measurement structures are at least partially designed as capacitive sensor structures.

10. The battery tray of claim 9, wherein, The capacitive sensor structures are at least partially designed as interdigital electrodes.

11. The battery tray of claim 1, wherein, The deformation measurement structures are at least partially designed as resistive sensor structures.

12. The battery tray of claim 9 or 11, wherein, The sensor structures are covered on a side facing away from the tray housing with a plastic foam.

13. The battery tray of claim 12, wherein, The plastic foam is a polyurethane foam or a polystyrene.

14. The battery tray of claim 1, wherein, Further comprising an evaluation device configured to: apply electrical excitation signals to at least a portion of the deformation measurement structures, and to read out respective signal responses of the deformation measurement structures to the respective electrical excitation signals in order to determine a normal state or a deformed state of the respective deformation measurement structures based on the signal responses.

15. The battery tray of claim 14, wherein, The evaluation device can be calibrated in a calibration process such that a respective electrical current signal response during the calibration process is indicative of the normal state and a deviation from the electrical current signal response is indicative of a deformed state of the respective deformation measurement structures.

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