Battery tray for accommodating a battery

Abstract

The utility model provides a kind of battery tray for containing battery, the battery tray includes: tray shell (190;290);Wherein on or above the continuous first layer (110;210) on the concave side of tray shell (190;290) is arranged with conductive track layer (130), and wherein at least in the conductive track layer (130) on the flat portion of tray shell (190;290) is formed multiple electrically readable deformation measurement structures (140).

Description

Technical Field

[0001] This utility model relates to a battery tray, and more particularly to a battery tray for accommodating vehicle batteries in a vehicle. Background Technology

[0002] Rechargeable batteries (such as vehicle batteries used in battery electric or hybrid vehicles) are typically stored in battery trays, which allow them to be transported and protected from external influences.

[0003] In particular, vehicle batteries are typically positioned as low as possible within the vehicle to maintain a low center of gravity and thus improve the vehicle's grip. The corresponding battery trays in which the vehicle batteries are housed are usually made of robust materials and, for example, help to mitigate or completely eliminate external impacts that could otherwise damage or even destroy the vehicle batteries.

[0004] Since damage to a vehicle battery can negatively impact other components or the vehicle's driving characteristics, it is advantageous to be able to identify whether the battery tray is damaged and the extent of the damage.

[0005] For example, DE102020119287A1 describes a protection plate with integrated conductor rails acting as deformation sensors, positioned on the outer side of the convex surface of a battery tray. Thus, the protection plate can, to some extent, keep various external influences away from the battery tray. If the protection plate performs this function, the integrated deformation sensor will typically report damage because the protection plate itself has been damaged, leaving it unclear whether the battery tray to be protected (or even the vehicle battery itself) has actually been damaged. Utility Model Content

[0006] Therefore, the objective of this invention is to provide an improved battery tray, which is particularly capable of improving the detection of any damage.

[0007] These tasks are addressed by the subject matter of the independent claims and the aspects of the present invention described.

[0008] Therefore, a battery tray for holding batteries (particularly vehicle batteries) is provided, comprising:

[0009] Pallet shell;

[0010] A conductive track layer is arranged on (i.e., directly on) or above (i.e., also indirectly on) a continuous first layer on the concave side of the tray housing, and

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

[0012] Therefore, the basic idea of ​​this invention is that the deformation measuring structures are arranged on the inner side of the battery tray housing, i.e., on the concave side. This increases the likelihood that these deformation measuring structures will detect deformations that not only affect the upstream protection plate or the tray housing itself but also potentially damage the internal battery. Therefore, in the assembled state, the conductive track layer with the deformation measuring structures is specifically located between the battery (e.g., a vehicle battery) and the tray housing.

[0013] The conductive track layer can be disposed directly on or above the continuous first layer, i.e., there can be other layers in between, such as at least one electrically insulating layer and / or varnish layer.

[0014] According to some preferred embodiments, variations, or improvements of the embodiments, the first layer of the tray housing is formed of metal, particularly steel or aluminum, or a steel or aluminum alloy. Preferably, at least (or exactly) an electrical insulating layer (e.g., electrical insulating varnish) is arranged between the first layer and the conductive track layer. An advantage of making the first layer of metal is that metal is inelastic, meaning that deformation, for example, caused by impact, remains physically visible and can be permanently measured by a deformation measuring structure. This deformation can also be evaluated optically (e.g., visually) for plausibility checks.

[0015] According to some preferred embodiments, variations or improvements of the embodiments, the conductive track layer is embedded in a (particularly additional continuous) second layer of the tray housing, for example on the side or on all sides, and thus particularly also from above, i.e. on the side of the conductive track layer opposite to the continuous first layer. The second layer may be an insulating layer and / or a protective layer.

[0016] According to some preferred embodiments, variations or improvements of the embodiments, the second layer is a paint coating, which may be specifically applied over the conductive track layer and the gaps in the layer. This paint coating, as the second layer, may be applied directly to the conductive track layer (if present) and additionally directly to the layer to which the conductive track layer is attached.

[0017] According to some preferred embodiments, variations or improvements of the embodiments, the pallet housing includes a first metal component formed as a pallet-shaped part and a flat (i.e., planar) second metal component, such as a metal plate. Specifically, the second metal component may be directly attached to the pallet bottom of the pallet-shaped part of the first component on its concave side. A continuous first layer of the pallet housing may be formed from the second component.

[0018] Both the first and second metal components can be made of steel, aluminum, steel alloys, or aluminum alloys.

[0019] In this way, the advantages of metallic materials can be combined: the first metal part can be formed using simple forming techniques (such as deep drawing) without conductive tracks being arranged on it, which significantly simplifies the forming process. On the other hand, the conductive track layer can be arranged on a flat second metal part, which simplifies the formation of the conductive tracks, since the conductive tracks can be printed on it, for example.

[0020] The first part of a metal typically retains its shape after damage, so the damage remains physically visible, and more importantly, it can still be detected by subsequent measurements.

[0021] The second component is advantageously designed as a metal sheet with a thickness of less than 1 mm, particularly less than 0.5 mm. In this way, the total weight of the pallet housing increases only slightly.

[0022] The second component can, for example, be designed as so-called “special functional steel” (i.e., TFS) and thus produced in a corresponding advanced manufacturing process.

[0023] Another advantage of the variant with two metal components is that the battery tray can be easily adapted to customer requirements. For example, for large quantities of products, the first metal component (i.e., the tray-shaped part) can be manufactured with the same shape, which also provides advantages in storage and warehouse logistics. Then, by selecting and attaching different second metal components in each case, different interconnection or cable arrangements of the battery tray can be provided in a simple manner.

[0024] For example, depending on the metal plates arranged therein, different functions can be provided in the same geometric tray shape, such as for different battery types, vehicle types, or for basic and advanced functions. Therefore, the geometry of the battery tray can be optimally adapted to a specific vehicle type, body, vehicle platform, etc., while electrical functions and, for example, the location of connection contact points, can be individually adapted to the battery tray.

[0025] Furthermore, the cable arrangement of the existing battery tray can be easily altered by simply replacing the second metal component (i.e., the metal plate). Therefore, upgrading or recycling is possible without any issues.

[0026] According to some preferred embodiments, variations or improvements of the embodiments, the deformation measurement structure is at least partially (or entirely) formed as a capacitive sensor structure, for example, at least partially (or entirely) formed as interdigital electrodes. Deformation of the tray housing alters the capacitive coupling between the individual electrodes of the interdigital electrodes in the affected sensor structure, which can be detected by the corresponding evaluation equipment.

[0027] According to some preferred embodiments, variations or improvements of the embodiments, the deformation measurement structure is at least partially designed as a resistive sensor structure. Due to the deformation of the tray housing, the affected deformation measurement structure is stretched, compressed or interrupted, which changes its resistance (especially ohmic resistance), which can be detected by the corresponding evaluation equipment.

[0028] Temperature compensation can be provided, based on which the temperature of the battery tray, tray housing, or even individual deformation measurement structures is recorded, and thermally induced changes in the resistance of the deformation measurement structures are ignored during the evaluation of the evaluation equipment. 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 equipment.

[0029] According to some preferred embodiments, variations or improvements of the embodiments, (especially capacitive or resistive) the sensor structure is covered with plastic foam, particularly polyurethane foam or polystyrene foam, on the side opposite to the tray housing. The plastic foam may be directly arranged on a second layer of the sensor structure and / or the tray housing, or there may be an intermediate space.

[0030] According to some preferred embodiments, variations or improvements of the embodiments, the battery tray also includes an evaluation device suitable for:

[0031] Electrical excitation signals are applied to at least some (and preferably all) of the deformation measurement structure.

[0032] And read out the corresponding signal response of the deformation measurement structure to the corresponding excitation signal, so as to determine the normal state or deformation state of the corresponding deformation measurement structure based on the signal response.

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

[0034] The evaluation device may 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 may include at least one processing unit, such as a central processing unit (CPU) and / or a graphics processing unit (GPU) and / or a field-programmable logic array (FPGA) and / or an application-specific integrated circuit (ASIC) and / or a combination thereof. The computing device may also include working memory operatively coupled to at least one processor unit, and non-volatile memory operatively coupled to at least one processor unit and working memory. The computing device may be implemented entirely or entirely in a local device and / or entirely or entirely in a remote system such as a remote server and / or a cloud computing platform.

[0035] The evaluation equipment can also be arranged in the cavity of the battery tray, for example, directly or indirectly attached to the bottom of the battery tray, particularly to the conductive tracks of the conductive track layer. This means that the signal lines for excitation signals and signal responses can be advantageously arranged within the conductive track layer.

[0036] The evaluation equipment can also be located outside the battery tray. Electrical inlet and outlet conduits between the deformation measurement structure and the evaluation equipment can extend along the inner wall of the battery tray housing.

[0037] In some variations where the first layer of the tray housing is formed of metal, the inlet and outlet conduits may be placed on or above the first layer during the manufacture of the battery tray and then formed together with portions of the tray housing intended to form the walls of the tray housing, for example in a deep drawing process.

[0038] According to some preferred embodiments, variations, or improvements of the embodiments, the evaluation equipment can be calibrated during the calibration process such that the corresponding current signal response during the calibration process indicates a normal state and the deviation from the current signal response indicates the deformation state of the corresponding deformation measurement structure. This means that the calibration process can be performed not only as an initial calibration after the battery tray is completed or immediately after its installation (e.g., in a vehicle), but also as a periodic or event-based calibration process as a recalibration. Possible recalibrations involve, for example, the current temperature in the battery tray, and can be performed periodically or based on events (e.g., when a temperature threshold is exceeded and / or not reached).

[0039] Recalibration can also be performed after deformation has been detected, for example, if deformation of the battery tray that does not impair its function (or is only within predetermined tolerances) has been detected. The current state can then be redefined as the normal state in the calibration process, so that only additional deformation beyond this is detected.

[0040] According to another aspect, a method for manufacturing a battery tray (particularly a battery tray according to the present invention) is also provided, wherein the method includes at least the following steps:

[0041] Multiple electrically readable deformation measurement structures (e.g., during printing) are applied to or above a portion of a flat metal blank (e.g., a sheet of metal); and

[0042] A flat metal blank with a deformation measurement structure is formed into a tray shell (or, in other words, a tray-shaped part formed into a tray shell).

[0043] Deformation measurement structures can be embedded in insulating layers, especially before forming the blank.

[0044] An insulating layer (e.g., a varnish layer) can be arranged on a flat metal blank, thereby applying multiple deformation measurement structures directly to the insulating layer.

[0045] In this way, the deformation measuring structure can be easily arranged on a flat blank, which is then formed simply into a tray-shaped part. For example, this can be achieved by deep drawing. The formed surface (e.g., the wall of the tray-shaped part of the tray housing) may include an inlet and / or outlet leading to the deformation measuring structure, or advantageously, there may be no conductive track.

[0046] According to some preferred embodiments, variations, or improvements of the embodiments, the portion of the blank containing the deformation measuring structure remains undeformed. In other words, the blank is not altered by forming in the area of ​​the deformation measuring structure, and in particular, the deformation measuring structure remains undeformed. Thus, damage to the deformation measuring structure and undesirable deformation can be avoided during the manufacturing of the battery tray.

[0047] In the case of a blank in which the deformation measurement structure is partially or completely deformed, at least the affected deformation measurement structure can be calibrated by means of the aforementioned evaluation equipment.

[0048] According to some preferred embodiments, variations or improvements of the embodiments, the method further includes the following steps:

[0049] An electrical excitation signal is applied to at least a portion of the deformation measurement structure (especially after forming if forming occurs);

[0050] The electrical readout deformation measurement structure responds to the corresponding applied excitation signal; and

[0051] The calibration and evaluation equipment is such that the signal response read out in each case indicates the undeformed normal state of the corresponding deformation measurement structure, and the deviation in the signal response indicates the deformation state of the corresponding deformation measurement structure.

[0052] As described above with reference to the evaluation equipment, the functions of one or more battery trays can be optimally adjusted in this manner, particularly after the battery trays have been manufactured and / or immediately after the battery trays have been installed at their intended destination (such as a vehicle).

[0053] 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.

[0054] According to another method, a method for manufacturing a battery tray is also provided, which includes at least the following steps:

[0055] Multiple electrically readable deformation measurement structures are applied to a metal plate (i.e., directly on the metal plate) or above it (i.e., also indirectly on the metal plate, for example); and

[0056] Secure the metal plate to the inside of the bottom of the metal pallet-shaped component.

[0057] Specifically, the metal tray-shaped part can be made of steel or aluminum or a steel or aluminum alloy. Optionally, the method also includes manufacturing the metal tray-shaped part, for example, by deep drawing from a sheet metal.

[0058] Therefore, the forming of the pallet structure is completely separated from the application of the deformation measuring structure to its carrier. This means that, regardless of other components, the most suitable process can be used both for applying the deformation measuring structure and for producing pallet-shaped parts.

[0059] The individual production of components also allows for the combination of the same tray-shaped part with metal plates of different designs (particularly in terms of deformation measurement structures and / or their interconnections). For battery trays with different electrical deformities, only the production of the parts using metal plates needs to be changed, resulting in positive economies of scale. Furthermore, even with deformation measurement structures attached, metal plates are easier to store than finished battery trays, which also simplifies production logistics.

[0060] 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

[0061] The present invention will now be explained in more detail with reference to examples of embodiments shown in the accompanying drawings.

[0062] Figure 1 A schematic cross-sectional view of a battery tray according to one embodiment of the present invention is shown;

[0063] Figure 2AShowing from Figure 1 A schematic isometric representation of the battery tray;

[0064] Figure 2B A schematic top view of a modified battery tray is shown;

[0065] Figure 3 An exemplary portion of a modified battery tray according to the present invention is shown;

[0066] Figure 4 An exemplary portion of a battery tray according to another variation of the present invention is shown;

[0067] Figure 5 A schematic cross-sectional view illustrating another embodiment of the present invention is shown;

[0068] Figure 6 A schematic flowchart illustrating a method for manufacturing a battery tray according to one embodiment of the present invention is shown; and

[0069] Figure 7 A schematic flowchart illustrating a method for manufacturing a battery tray according to another embodiment of the present invention is shown.

[0070] 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.

[0071] List of reference numerals

[0072] 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-Metal tray-shaped part; 210-Metal plate; 215-Coating; 290-Tray housing; S01~S13-Method steps. Detailed Implementation

[0073] Figure 1 A schematic cross-sectional view is shown to explain a battery tray 100 according to one embodiment of the present invention.

[0074] Figure 1The battery tray 100 includes a tray housing 190, which is formed in the shape of a tray having tray walls 192 and a tray bottom 191 made substantially of metal. The metal may include, for example, steel, steel alloys, aluminum and / or aluminum alloys, or be composed of the like. The metal forms a continuous first layer 110 of the tray housing 190. In the example shown, the metal is coated with an electrically insulating coating 115, such as a varnish, at least on its inner side (i.e., on one side of the cavity 195 arranged within the tray shape).

[0075] 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.

[0076] 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.

[0077] The conductive track layer 130 is disposed above the inner side of the first layer 110, for example, directly on the electrically insulating coating 115. A plurality of 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.

[0078] The conductive track layer 130 is advantageously embedded in a continuous second layer 120, which may, for example, be designed 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.

[0079] 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.

[0080] 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.

[0081] like Figure 1As 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).

[0082] 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.

[0083] 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.

[0084] For manufacturing purposes, the first layer 110, the second layer 120, and the conductive track layer 130 can be provided initially in a flat state and then assembled together by forming (e.g., deep drawing) into a tray-shaped part.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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 deformed 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 in... 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.

[0089] 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.

[0090] 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.

[0091] In order to produce Figure 2B The battery tray 100 can be produced by stamping or cutting a metal plate before or after applying the deformation measuring structure 140. Figure 2B The metal plate, with the deformation measuring structure 140 attached, can be deformed (especially by deep drawing) to achieve the three-dimensional shape shown.

[0092] 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.

[0093] Figure 3 The deformation measurement structure 140 shows that the substrate on which it rests has been removed from the outside ( Figure 3The 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] Figure 4 An 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.

[0098] Figure 5 A schematic cross-sectional view is shown to explain another embodiment of the present invention, specifically a battery tray 200.

[0099] 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 metal components. The first component consists of, or includes, a metal tray-shaped piece 205 having a tray bottom.

[0100] A metal plate 210 with an electrically insulating coating 215 is attached to the bottom of the tray or above the bottom of the tray as a second component of the tray housing 290, and a conductive track layer 130 and a second layer 120 are disposed on or above this second component. According to... Figure 5 In this embodiment, the metal tray shape 205 and the metal plate 210 and its coating 215 can therefore be considered as achieving the first layer.

[0101] In this variant, the flat metal plate 210 with the deformation measuring structure 140 attached can be advantageously inserted into and fixed there, for example, by gluing, inside the flat tray bottom 191 of the metal tray shape 205 after its manufacture. The metal plate 210 can be formed to have a thickness of less than 1 mm, particularly less than 0.5 mm, which makes it particularly lightweight.

[0102] Therefore, the structural stability of the tray housing 290 is basically provided by the first component (i.e., the metal tray shape 205), while the electrical functions (especially the deformation sensor) are provided by the metal plate 210 on which the deformation measurement structure 140 is arranged.

[0103] In the following sections, various methods for manufacturing the battery trays 100 and 200 according to this invention will be described. To explain their 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.

[0104] Figure 6 A schematic flowchart illustrating a method for manufacturing a battery tray is shown. The produced battery tray may be the aforementioned battery tray 100, 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 100 according to this invention, and vice versa.

[0105] In step S01, a plurality of electrically readable deformation measurement structures 140 are applied onto or over a portion of a flat metal blank, wherein any technique known in the art may be used for this purpose. Since the metal blank 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 contemplated, such as robotic spraying methods using masks. The deformation measurement structures 140 may be as specifically referred to above. Figure 1 It forms as described.

[0106] A flat metal blank may include a first layer 110 of metal and at least one coating 115 applied thereon, in which case the deformation measuring structure 140 is advantageously arranged on one of the coatings 115. The metal may be steel, a steel alloy, aluminum, or an aluminum alloy.

[0107] In an optional step S02, the deformation measuring structure 140 is embedded in an insulating layer 120, wherein the insulating layer 120 may be, for example, an electrically insulating varnish layer that surrounds the deformation measuring structure 140 on the sides (roughly equivalent to the conductive track layer 130) and—preferably—also covers them on top.

[0108] In optional step S03, a protective film is applied to the deformation measurement structure 140 and the insulating layer 120.

[0109] In step S04, a flat metal blank with the deformation measuring structure 140 (and, if applicable, an insulating layer 120 and / or a protective film) is formed into a tray housing 190, for example, by deep drawing. Here, preferably only those portions without the deformation measuring structure 140 are formed, for example, only the (rear) tray wall 192 of the tray housing 190 is formed, without forming the (rear) tray bottom 191. In other words, the portions of the metal blank with the deformation measuring structure 140 remain undeformed.

[0110] According to a specific implementation, the portion of a metal blank with an inlet and / or outlet conduit may be formed or unformed.

[0111] In an optional step S05, the protective film is removed after forming S04. However, the protective film may also remain in place after forming, for example, as an (possibly additional) insulating layer 120.

[0112] 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 after step S04 or step S05 and / or immediately after the battery tray 100 has been installed at its intended future destination (such as a vehicle).

[0113] Specifically, calibration procedures S06-S08 may be performed after one, several, or all of the following sub-steps, which may be performed in this order or in a different order:

[0114] Make the evaluation device 30 electrically connected / in contact with the conductive track of the conductive track layer 130;

[0115] Apply plastic foam 160 onto conductive track layer 130;

[0116] The evaluation device 30 is connected to the vehicle's electronic components;

[0117] Install battery 20 in battery tray 100; and / or

[0118] Install the battery tray 100 in the vehicle.

[0119] 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.).

[0120] In step S06, particularly after forming S04, an electrical excitation signal 71 is applied to at least some (preferably all) of the deformation measurement structure 140.

[0121] 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.

[0122] 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.

[0123] In an alternative step, for example, the evaluation device 30 may output an output signal indicating the normal and / or deformed state of one or more deformation measurement structures 140, and optionally include additional information such as the degree of deformation.

[0124] 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 200, its variations or improvements, or different battery trays. Therefore, the method can be adapted according to all the options, variations, implementations, and improvements described with respect to all battery trays according to this invention, and in particular the battery tray 200 according to this invention, and vice versa.

[0125] In optional step S09, the metal tray shape 205 can first be formed, for example, by forming (e.g., deep drawing) a sheet of metal (particularly steel, aluminum, steel alloys, or aluminum alloys). This may include first cutting the metal part intended for forming into a certain shape, particularly a non-rectangular shape, by stamping or cutting. In this way, the external contour of the metal tray shape 205 can be achieved, such as... Figure 2B Those shown. However, the metal tray-shaped piece 205 can also be provided as a ready-made alternative.

[0126] In an optional step S10, an insulating coating 215 may be applied to the metal layer of a metal blank (such as a metal sheet) to produce a metal plate 210. The insulating coating 215 may be, for example, a varnish-based coating, such as a primer coating system. In step S10, the primer coating system may be applied to the metal plate, for example, to a steel plate, by roll coating, and the primer coating system may be 6 micrometers to 100 micrometers (μm) thick, particularly 60 micrometers to 90 micrometers, for example, 80 micrometers thick.

[0127] In step S11, a plurality of electrically readable deformation measurement structures 140 are applied to or over the metal plate 210, for example, as previously referred to Figures 1 to 4 And especially refer 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 using masks.

[0128] The metal plate 210 may have a metal layer on which an electrically insulating coating 215 is directly applied, and this can be done for this purpose in optional step S10. If optional step S10 is omitted, the metal plate 210 already coated with the insulating coating 215 can be used. In step S11, the deformation measuring structure 140 is applied to or over the insulating coating 215 of the metal plate 210, preferably directly to the insulating coating 215 of the metal plate 210.

[0129] In an optional step S12, an insulating layer 120 is applied to the metal plate 210 (particularly directly to the insulating coating 215), wherein the deformation measuring structure 140 is embedded in the insulating layer. 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, an electrically insulating plastic foam 160 may also be applied in this step.

[0130] In step S13, a metal plate 210 (optionally with an insulating layer 120 attached thereto) is attached (e.g., glued) to the interior of the tray bottom 191 of the metal tray shape 205. Electrically insulating plastic foam 160 may then be applied to the tray bottom 191 to which the metal plate 210 is glued.

[0131] Already referred to Figure 6 The calibration procedures S06-S08 described can also be performed in this method, particularly after one or more of the following sub-steps, which can be performed in this order or in a different order:

[0132] Make the evaluation device 30 electrically connected / in contact with the conductive track of the conductive track layer 130;

[0133] Apply plastic foam 160 onto conductive track layer 130;

[0134] The evaluation device 30 is connected to the vehicle's electronic components;

[0135] Install the battery 20 in the battery tray 200; and / or

[0136] Install the battery tray 200 in the vehicle.

Claims

1. A battery tray for holding batteries, characterized in that, include: Pallet shell; A conductive track layer is arranged on or above a continuous first layer on the concave side of the tray housing, and A plurality of electrically readable deformation measurement structures are formed in the conductive track layer, at least on the flat portion of the tray housing.

2. The battery tray according to claim 1, characterized in that, The first layer of the tray housing is formed of metal.

3. The battery tray according to claim 2, characterized in that, The first layer of the tray housing is formed of steel or aluminum or a steel or aluminum alloy.

4. The battery tray according to claim 2, characterized in that, The conductive track layer is embedded in the second layer of the tray housing.

5. The battery tray according to claim 4, characterized in that, The second layer is a paint coating.

6. The battery tray according to claim 1, characterized in that, The pallet housing includes a first metal component formed in the shape of a pallet and a second metal component that is flat, the second component being attached to the bottom of the pallet of the first component on its concave side, and wherein the continuous first layer of the pallet housing is formed by the second component.

7. The battery tray according to claim 6, characterized in that, The second component, made of flat metal, is directly attached to the bottom of the tray.

8. The battery tray according to claim 6, characterized in that, The second component is formed as a metal plate with a thickness of less than 1 mm.

9. The battery tray according to claim 1, characterized in that, The deformation measurement structure is designed, at least in part, as a capacitive sensor structure.

10. The battery tray according to claim 9, characterized in that, The capacitive sensor structure is at least partially designed as interdigitated electrodes.

11. The battery tray according to claim 1, characterized in that, The deformation measurement structure is designed at least in part as a resistive sensor structure.

12. The battery tray according to claim 9 or 11, characterized in that, The sensor structure is covered with plastic foam on the side opposite to the tray housing.

13. The battery tray according to claim 12, characterized in that, The plastic foam is either polyurethane foam or polystyrene.

14. The battery tray according to claim 1, characterized in that, It also includes an evaluation device, which is configured to: An electrical excitation signal is applied to at least a portion of the deformation measurement structure. Furthermore, the corresponding signal response of the deformation measurement structure to the corresponding electrical excitation signal is read out, so as to determine the normal state or deformation state of the corresponding deformation measurement structure based on the signal response.

15. The battery tray according to claim 14, characterized in that, The evaluation device can be calibrated during the calibration process such that the corresponding current signal response during the calibration process indicates the normal state and the deviation from the current signal response indicates the deformation state of the corresponding deformation measurement structure.

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