Battery assembly with crash elements and method for manufacturing a battery assembly

Abstract

The invention relates to a battery arrangement (10) for a motor vehicle, comprising a battery housing (14), at least one battery module (22) arranged in the battery housing (14), and crash elements (12) arranged in at least a partial area (34) within the battery housing (14). The crash elements (12) each have an interior space (12b), an outer shell (12a) completely enclosing the interior space (12b), and a substance (12c, 12c') contained within the interior space (12b), wherein the crash elements (12) are each designed to be deformable upon external force (FA).

Description

[0001] The invention relates to a battery assembly for a motor vehicle with crash elements, wherein the battery assembly comprises a battery housing and at least one battery module arranged on the battery housing, wherein the crash elements are arranged in at least one partial area within the battery housing. Furthermore, the invention also relates to a method for producing a battery assembly.

[0002] In the automotive industry, vehicle structures are designed, among other things, for crash loads. To dissipate crash energy, specific formation zones are provided that are permitted to be intruded. However, due to the nesting of the vehicle, particularly the connection of many components, the energy is often not dissipated evenly, but rather abruptly. If, for example, a connection point breaks, there is again a short acceleration path before the crash object strikes the next component. Such acceleration paths are usually unavoidable due to the cavities required for assembly and providing clearance for assembly.

[0003] This is also the case with a high-voltage battery in a motor vehicle. Such a high-voltage battery can be constructed in such a way that high-voltage modules, in the form of a subassembly with the individual battery cells, are placed in a tray or frame and screwed into place, and if necessary, additionally glued. In terms of repair and warranty costs, it would also be very advantageous if the modules were designed to be replaceable. However, this would also require the connection technology and everything else to be reversible.

[0004] With previous designs, in the event of a side-to-post crash, the forces are sometimes transferred via the large sill to the module via the bolted connections, which in turn transfer the forces to the opposite side via the bolted connections. This point-based connection creates a weak point or a point of failure in the event of failure.

[0005] It would therefore be desirable to demonstrate a way in which crash energy can be dissipated more evenly and efficiently and / or guided through the vehicle in a controlled manner, which would in particular provide better protection for a high-voltage battery.

[0006] For this purpose, it is known from the prior art to use crash elements. These can take on a wide variety of forms and be arranged in a variety of positions within the vehicle.

[0007] For example, DE 10 2018 133 426 A1 describes a multifunctional battery housing for an electrically powered motor vehicle, which is made of an envelope structure filled with a porous and mechanically resilient filler. Furthermore, the housing is made of a supported vacuum insulation composite, the insulating effect of which can be adjusted by filling a vacuum-tight hollow body with a microporous filler and producing a base pan, a surrounding edge element, and a cover element from this.

[0008] DE 10 2005 055 082 A1 describes a device for protection against an impact with at least one energy absorption body arranged behind an inner body part, and with means for transmitting a force acting upon an impact from an outer body part through an opening in the inner body part to the energy absorption body. Such an energy absorption body can comprise a filling, which in turn can contain several bodies. These bodies can be arranged loosely or embedded in a matrix within the hollow body. If the bodies are spaced apart from one another by a foam matrix, they cannot touch during normal operation, thus preventing rattling noises. The bodies can be, for example, spheres made of powdered glass or plastic.

[0009] The object of the present invention is to provide a battery arrangement and a method which make it possible to reduce an external, crash-related force as efficiently as possible and / or to guide the crash load through the vehicle in a controlled manner and thereby, in particular, to protect at least one battery module comprised by the battery arrangement as well as possible.

[0010] This object is achieved by a battery arrangement and a method having the features according to the respective independent patent claims. Advantageous embodiments of the invention are the subject of the dependent patent claims, the description, and the figures.

[0011] A battery assembly according to the invention for a motor vehicle comprises a battery housing, at least one battery module arranged in the battery housing, and crash elements arranged in at least one partial area within the battery housing. The crash elements each comprise an interior space, an outer shell completely enclosing the interior space, and a respective substance accommodated in the interior space. The crash elements are each designed to be deformable upon external force.

[0012] The invention is based on several findings: Firstly, the invention takes advantage of the finding that within a high-voltage battery, for example between the battery modules and the battery housing or the frame, there are gaps and free spaces of several millimeters due to component, process, and assembly tolerances that do not contribute to energy dissipation in this area in the event of an intrusion by a crash object. These cavities can now advantageously be filled by the crash elements. The crash elements can advantageously be provided as independent, in particular non-connected, bodies, for example in the form of a bulk material. They can therefore be displaceable and movable relative to one another, even at least partially when already filled into the partial area.This means that even particularly small and geometrically arbitrarily shaped gaps and spaces can be filled particularly efficiently. A particularly advantageous feature, however, is that the crash elements are designed to be deformable when exposed to external forces and for this purpose comprise an outer shell that completely encloses an interior space and a substance contained within the interior. This allows crash energy to be dissipated particularly efficiently. In particular, some of the crash energy can be converted into deformation energy, which is required to deform the crash elements. In addition, the substance contained within the interior of the outer shell can be used to specifically set a counterforce that counteracts the external force. Because the crash elements are not firmly connected to one another, but are loose and, in particular, not fixed to one another, they can also move relative to one another.When external forces are applied, the crash elements are automatically distributed in such a way that the external crash load can be evenly distributed among the components behind them. This avoids the application of specific forces, and the more even distribution of forces effectively reduces the force acting per unit area. Furthermore, additional energy can be dissipated by shifting the individual crash elements relative to one another when external forces are applied. This means that the force or energy acting on the battery arrangement in the event of a crash can be dissipated as efficiently as possible, which simultaneously increases the protection of the battery modules or at least one battery module housed in the battery housing. If no crash occurs, the crash elements, e.g.For repair purposes of the battery assembly or the at least one battery module, or for replacing the at least one battery module, the battery assembly can be reversibly removed without damage. This also allows for easy disassembly of the battery assembly if necessary, and the individual components, e.g., the crash elements themselves, can be reused if necessary.

[0013] The battery arrangement for the motor vehicle can, for example, be a high-voltage battery. The battery housing can accommodate not only a single battery module, but also, for example, several battery modules. Each battery module comprises at least one battery cell, for example a lithium-ion cell. Preferably, each battery module comprises several battery cells. The crash elements are preferably, as already mentioned, designed as separate bodies. The external geometry of the bodies of the respective crash elements is basically arbitrary. For example, the crash elements can each be spherical. In principle, the crash elements can also differ in terms of their geometric design. The crash elements can also differ from one another in terms of their material composition.

[0014] The interior of the crash elements can be filled only partially or completely with the absorbed substance. Preferably, a large part of the interior, based on its volume in the undeformed state, for example under defined standard conditions or normal conditions, is filled with the absorbed substance. The substance is preferably incompressible or almost incompressible and therefore preferably not a gas. The substance can, for example, be in the form of a fluid, in particular a liquid. However, it can also be a solid, for example a powdered solid. It can also be a mixture of different substances. The different substances can each comprise a gas and / or a liquid and / or a solid.

[0015] The outer shell can also be referred to as a membrane, for example. The outer shell is made of a different material than the substance contained in the interior. The outer shell is also impermeable to the substance contained in the interior. This means that the substance contained in the interior cannot escape through the outer shell and out of the crash element, provided the outer shell is intact. The wall thickness of the outer shell is preferably between 0.1 millimeters and 3 millimeters.

[0016] The crash elements can also be designed so that they are not only deformable when subjected to external forces, but also elastically deformable, for example. This elasticity can provide an additional counterforce to the applied force.

[0017] The outer shell can, in principle, be made of any material, for example, a plastic and / or a metal and / or a fiber-reinforced plastic. Preferably, the outer shell is made of a plastic or a material that includes a plastic.

[0018] In a further very advantageous embodiment of the invention, the respective crash elements are designed such that, when a predetermined high force is applied to the respective crash element, their respective outer shell is damaged, in particular tears and / or bursts, to such an extent that the respective outer shell no longer completely encloses the respective interior. In this case, that the outer shell is damaged by the predetermined high force, the substance located in the interior can escape from the outer shell. This has the great advantage that a multi-stage energy dissipation process can be implemented by the crash elements in the event of an external force. According to a first stage of energy dissipation, the crash elements initially shift relative to one another and / or deform. In this case, the acting energy is first converted into deformation and / or displacement energy.The crash elements can, for example, be deformed until their respective outer shells burst or tear. This bursting or tearing, or generally the damage to the outer shell, dissipates energy in a second stage. As already described, the substance located in the interior is preferably incompressible or nearly incompressible, i.e., a solid, such as solid powder, and / or a liquid. Bursting initially slightly reduces the force opposing the applied force.However, with further deformation, for example of the battery casing and the resulting reduction in the internal volume of the battery casing, there is again an increase in the force opposing the acting force, namely due to the incompressible substance, which now progressively and ultimately completely fills the interior of the battery casing as the outer casings increasingly burst. The outer casings of the crash elements do not all have to burst or open at the same time, but can also do so sequentially. As a result, the described energy dissipation stages are repeated until all outer casings have opened, at least locally, and / or the remaining space within the casing is completely filled with the substance that has leaked out or been released from the corresponding interior spaces of the burst crash elements.If all outer shells of the crash elements have burst and / or the interior of the housing is completely filled with the incompressible substance, the incompressible substance exerts a very high counterforce within the system, namely within the battery assembly, particularly within the battery housing. This protects the battery assembly from further intrusion by the crash object that caused the external force. This consequently enables even more efficient energy dissipation of the impacting crash energy.

[0019] The volume of the sub-area is filled with crash elements, e.g., at least 50 percent, preferably at least 75 percent to a maximum of 100 percent, and in particular up to a maximum of 90 percent, based on a crash-free condition or the condition of the crash elements prior to a crash. This ensures that, even if the volume of the sub-area is reduced slightly due to a crash, the reduced volume of the sub-area can be quickly and completely filled by the substance escaping from the crash elements.

[0020] In particular, a respective crash element can be designed such that when subjected to an external force with a magnitude in a first value range, it is only deformed and its outer shell continues to enclose the interior completely and tightly with respect to a possible escape of the substance located in the interior, and that an outer shell is damaged, in particular tears and / or bursts, when subjected to a force with a magnitude in a second value range, in such a way that it no longer encloses the interior completely and tightly.

[0021] The values ​​in the second range are correspondingly larger than the values ​​in the first range. For example, with small applied forces, the crash elements are merely deformed. With larger applied forces that cannot be completely dissipated by such deformation, the outer shells open, e.g., tear or burst. The respective limit values ​​of the respective outer shells of the individual crash elements do not necessarily have to be the same, but can also differ from one another.The crash elements can, for example, be designed differently, in particular with regard to the limit value above which the outer shell tears or bursts, in order to ensure, for example, that in the event of an external force, not all outer shells of all crash elements burst or tear at the same time or almost simultaneously, but such tearing or opening of the crash elements occurs successively and / or at different times.

[0022] In a further advantageous embodiment of the invention, it is provided that the respective substance is electrically non-conductive, in particular wherein the substance is a fluid, in particular a liquid. If the substance is a solid or comprises a solid, for example a powder, it is preferably also non-conductive. This makes it possible to prevent short circuits within the battery or the battery module or its cells. If the substance is a fluid, in particular a liquid, it is therefore preferable to use an electrically non-conductive liquid, for example an electrically insulating oil or the like.

[0023] The use of a liquid as a substance for at least partially or completely filling the interior of a respective crash element is particularly advantageous, as it allows for the deformability of the crash elements to be implemented in a simple manner. Furthermore, it allows for simple and cost-effective filling of the outer shells.

[0024] In a further advantageous embodiment of the invention, the crash elements comprise first crash elements and second crash elements. In other words, the crash elements can be divided into two different groups, for example. It can be provided that the first crash elements have a first substance accommodated in their respective interior, and the second crash elements have a second substance, different from the first substance, accommodated in their respective interior. The crash elements can therefore be designed differently not only with regard to their geometry, but additionally or alternatively also with regard to their material properties, in particular with regard to their filling. This allows energy dissipation in the event of a crash to be implemented in an even more targeted and defined manner.For example, this can be used to implement different deformation properties and counterforces caused by the crash elements in the event of such a deformation. However, it is particularly advantageous to use the two different substances to induce a specific reaction, particularly a chemical reaction, by mixing them.

[0025] Therefore, it represents a further very advantageous embodiment of the invention if the first and the second substance are designed such that they form a foam when mixed, in particular a curable foam. For example, the substances can represent two components of a 2K (component) PU (polyurethane) foam or of a silicone foam, which react when mixed and thereby produce such a foam. The formation of such a foam during mixing has numerous advantages: Firstly, a particularly large volume can be filled, which in turn makes it possible to very quickly achieve a particularly even distribution of the still acting external force and a particularly even force reduction. The force opposing the acting force can therefore also be distributed particularly evenly.Such a foam can be used to fill any remaining gaps within the battery casing, thereby eliminating empty spaces and gaps that cannot resist an intrusion. The counterforce generated when the respective substances are released can be generated particularly quickly by forming a foam.

[0026] The ratio of the components—that is, the two different substances comprised by the respective crash element types—can also adjust the reaction time. This allows the formation of a foam that multiplies its original volume within milliseconds.

[0027] In a further advantageous embodiment of the invention, the first and second substances are designed such that, when mixed, their total volume increases compared to the total initial volume before mixing, in particular at least doubles it, preferably at least triples it. When forming a foam, it is particularly possible for the volume to be at least fivefold higher than the initial total volume of the individual substances. This extreme increase in volume counteracts the external force with a particularly strong counterforce. Furthermore, the substances can be designed such that they form a foam that hardens, in particular within a very short time, for example within one second. This leads to stiffening, which further impedes further intrusion of the crash object.The formation of a foam, especially a curable foam, also has the positive side effect that individual battery cells of the battery module are separated from one another by the foam expanding into every conceivable gap, particularly in several respects. For example, this promotes thermal decoupling of the cells. If a crash results in thermal runaway of a battery cell and the associated gas leakage from such a battery cell, the foam additionally prevents the escaping gas from coming into contact with neighboring cells.

[0028] In a further advantageous embodiment of the invention, the crash elements are spherical. This allows for particularly simple design and manufacture of the crash elements. Furthermore, it enables isotropic force distribution. Existing installation spaces can be filled particularly efficiently with spherical crash elements.

[0029] In a further advantageous embodiment of the invention, a maximum outer diameter of a respective crash element is between one millimeter and 20 millimeters inclusive, preferably between one millimeter and ten millimeters inclusive. This allows particularly small spaces and gaps, which are usually always present in the battery housing of a high-voltage battery, to be filled particularly efficiently with such crash elements, for example in the form of bulk material. The crash elements do not necessarily all have to have the same outer diameter. They can also differ from one another in terms of their outer diameter. For example, small, large, or medium-sized spheres, or even a wider range of sizes, can be provided as crash elements. This provides particularly good adaptations.This allows gaps to be filled particularly efficiently. However, the crash elements can also all have the same outer diameter. For example, the crash elements can also be designed with the same outer geometry but different outer diameters, or vice versa.

[0030] In a further advantageous embodiment of the invention, the battery housing has a fluid-tight receiving area in which the at least one battery module is arranged, wherein the partial area filled with the crash elements is part of the receiving area and in particular directly adjoins the battery module. In other words, the partial area should not only be located within, for example, a hollow profile of a frame of the battery housing, but in a receiving area within the battery housing itself, in which the battery module is also arranged. In particular, the described crash elements can be used to fill any remaining gap or space within a battery housing, be it within the frame parts of the battery housing itself or additionally or alternatively within the receiving area of ​​the battery housing, in which the battery modules are also located.For this purpose, for example, at least one battery module or multiple battery modules can first be inserted into the battery housing in a setting process, for example, into a battery tray that provides the receiving area. The modules can be interconnected, and the corresponding cabling can also be housed within the battery housing. The remaining gaps can be filled with the crash elements as bulk material. The crash elements are poured into the battery tray with the modules, for example, as bulk material, until the battery tray overflows with the crash elements. The battery housing cover can then be put on.

[0031] Furthermore, the invention also relates to a method for producing a battery assembly, wherein a battery housing is provided, at least one battery module is arranged in the battery housing, and crash elements are arranged in at least one partial area within the battery housing. In this case, each crash element is provided with an outer shell completely enclosing an interior space and containing a substance contained in the respective interior space. Each crash element is designed to be deformable upon external force, and the crash elements are filled into the partial area as bulk material.

[0032] The advantages described for the battery arrangement according to the invention or its embodiments apply equally to the method according to the invention.

[0033] The invention also includes further developments of the method according to the invention that have features already described in connection with the further developments of the battery arrangement according to the invention. For this reason, the corresponding further developments of the method according to the invention are not described again here.

[0034] Furthermore, the invention also includes a motor vehicle with a battery arrangement according to the invention or one of its embodiments.

[0035] The motor vehicle according to the invention is preferably designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle.

[0036] The invention also encompasses combinations of the features of the described embodiments. The invention therefore also encompasses implementations that each comprise a combination of the features of several of the described embodiments, unless the embodiments are described as mutually exclusive.

[0037] Exemplary embodiments of the invention are described below. Shown are: Fig. 1 a schematic perspective view of a battery arrangement with crash elements not shown for better illustration according to an embodiment of the invention; Fig. 2 a schematic representation of a part of the battery arrangement of Fig. 1 in a side view with crash elements now shown in an initial situation according to an embodiment of the invention; Fig. 3 a schematic representation of the battery arrangement from Fig. 2 during the action of an external crash load in a first stage according to an embodiment of the invention; Fig. 4 a schematic representation of the battery arrangement from Fig. 2 and Fig. 3 upon further application of the crash load according to a second stage according to an embodiment of the invention; Fig. 5 a schematic representation of the battery arrangement from Fig. 2 to Fig. 4 upon further impact of the crash load in a third stage according to an embodiment of the invention; and Fig. 6 a schematic representation of the battery arrangement from Fig. 2 to Fig. 5 upon further application of the crash load in a fifth stage according to an embodiment of the invention.

[0038] The exemplary embodiments explained below are preferred embodiments of the invention. In the exemplary embodiments, the described components of the embodiments each represent individual features of the invention that can be considered independently of one another, each of which also develops the invention independently of one another. Therefore, the disclosure is intended to encompass combinations of the features of the embodiments other than those shown. Furthermore, the described embodiments can also be supplemented by further features of the invention already described.

[0039] In the figures, the same reference symbols designate elements with the same function.

[0040] Fig. 1 shows a schematic and perspective view of a battery arrangement 10 or a part thereof, with crash elements 12 not explicitly shown for better illustration (compare for example Fig. 2) according to an exemplary embodiment of the invention. The battery arrangement 10 comprises a battery housing 14. This can, for example, have a base 16 and a surrounding frame 18. This allows a tray to be formed which provides a receiving area 20 for receiving a battery module 22, which is also part of the battery arrangement 10 and, in the present illustration, is also arranged in the battery housing 14, in particular in the receiving area 20. Furthermore, the battery housing 14 can be designed to receive a plurality of battery modules 22, of which only one is shown by way of example. Accordingly, the housing 14 can also provide a plurality of receiving areas 20 in the interior 24 of the housing 14. These can be spatially separated from one another by partition walls 26, which can also be regarded as part of the housing 14.In addition, the housing 14 can also have a cover, which is not shown here for reasons of clarity. The battery module 22 comprises a plurality of battery cells, which are not explicitly shown here. Optionally, the battery module 22 can also be attached to the housing 14 via fastening elements 28, for example screw connections. Alternatively or additionally, the battery module 22 can also be adhesively bonded to the housing 14. For this purpose, for example, a thermal interface material 30 (cf. Fig. 2) can be used, which is designed as a thermally conductive adhesive. This thermal interface material 30 can simultaneously bond the battery module 22 to the base 16 of the housing 14 with good thermal conductivity. The base 16 can also be designed as a cooling device 32 and, for example, can have cooling channels through which a coolant can flow. However, the thermal interface material 30 does not necessarily have to have adhesive properties, but can, for example, merely serve to thermally connect the module 22 to the cooling device, while the aforementioned fastening elements 28 can be used for fastening purposes.

[0041] As especially in Fig. As can be clearly seen in Figure 1, gaps 34, for example in the form of gaps or the like, arise between such a battery module 22 and the tray or the housing 14 and its components, such as the frame 18 and the partition walls 26. These gaps are dependent on component, process, and assembly tolerances. For example, during the manufacture of such a battery arrangement 10, which may in particular represent a high-voltage battery, the battery module 22 is inserted into the housing 14 using a gripping device. This gripping device is removed again after the module 22 has been inserted. At the point where the gripping device was located on the module 22, such a gap 34 ultimately remains.There may also be additional gaps 34 or gaps or similar elsewhere within the battery housing 14, particularly in the receiving areas 20, for example, directly adjacent to the corresponding battery modules 22, which, despite maximum utilization of the installation space by other components such as cables or the like, remain unused, at least in conventional batteries. In the present case, these free spaces 34 are now used to fill them with the aforementioned crash elements 12.

[0042] Fig. 2 shows a schematic representation of the battery arrangement 10 from Fig. 1, in particular of a part thereof, in a schematic side view. The intermediate space 34 between a side wall 18a of the housing 14 as part of the frame 18 and the battery module 22 is now filled with a plurality of crash elements 12. For reasons of clarity, only some of these crash elements 12 are provided with a reference numeral. The crash elements 12 are designed as independent, individual, and separable bodies, in particular spherical bodies. A respective crash element 12 has an outer shell 12a that completely encloses an interior space 12b of the respective crash element 12. Furthermore, a substance 12c is arranged in this interior space 12b. This substance can be, for example, a liquid, in particular an electrically insulating or electrically non-conductive liquid.

[0043] In a further embodiment, it is conceivable that not all of the crash elements 12 are filled with the same substance 12c. It is also conceivable that the crash elements 12 can be divided into at least two groups. The crash elements 12 can, for example, have first crash elements 36a filled with a first substance 12c, and second crash elements 36b filled with a second substance 12c' that is different from the first substance 12c. These second crash elements 36b also comprise an outer shell 12a that completely encloses a corresponding interior space 12b of the respective crash element 12, namely in this case the second crash element 36b. In particular, the crash elements 12, in particular the first and second crash elements 36a, 36b, can otherwise be of identical design.However, it is also conceivable that the crash elements 12 differ from one another in further properties, for example, their size, which can be measured based on a maximum diameter d assigned to the respective crash elements 12, and / or their geometry and / or the material properties of their outer shell 12a, or similar. With regard to these further properties, not only the first and second crash elements 36a, 36b can differ from one another, but also, for example, the first crash elements 36a from one another and / or the second crash elements 36b from one another.

[0044] Furthermore, the crash elements 12 are designed such that they are deformable upon application of an external force FA, for example, elastically and also inelastically deformable. Furthermore, the crash elements 12 are designed such that, upon application of a predetermined high force, they burst or tear, or their outer shell 12a is otherwise damaged, allowing the substance 12c, 12c' contained within the interior 12b to escape. This advantageously enables a stepwise, sequential energy dissipation process, which will now be described in more detail below.

[0045] Fig. Figure 2 shows a first stage of such a crash scenario, in which a force FA acts on the side wall 18a of the frame 18 of the battery housing 14 as a result of such a crash, for example, via a side sill (not shown) of the motor vehicle in which the battery assembly 10 is arranged. The side sill can, for example, extend in or opposite to the x-direction shown. In this example, the force FA acts on the side wall 18a from the outside, opposite to the y-direction shown. Furthermore, in Fig. 2 schematically shows another coordinate system, which illustrates the force distribution of the counterforce FG depending on the path S of the external force FA. Before the force FA acts on the side wall 18a, the force FG opposing this external force FA by the battery arrangement 10 is zero or approximately zero. This case is shown in Fig. 2. This counterforce FG, which is Fig. 2 and is essentially zero, is illustrated by the arrow FG 0.

[0046] The crash elements 12, which can also be referred to as crash balls or simply as balls 12, are loosely filled into the free space 34. In this state, the balls 12 are not yet subjected to any deformation and are not squeezed together or similar. This has the advantage that the mechanical stress on the balls 12 can be kept low under normal conditions, i.e., in normal operating situations of the battery arrangement 10, which prevents unwanted damage or bursting of the balls 12 or reduces the risk of this to a minimum. If the external force FA now acts on the side wall 18a and pushes it against the illustrated y-direction, the balls 12 are displaced, possibly with deformation, and exert a counterforce, as shown schematically in Fig. 3 is shown.

[0047] Fig. 3 shows the same battery arrangement 10 as already shown in Fig. 2 and in particular to Fig. 1, whereby the side wall 18a has now been moved slightly towards the battery module 22 by the external force FA. As a result, the crash elements 12 have deformed. As a result, the counterforce FG, which opposes the external force FA, increases slightly, as also shown in Fig. 3, in particular by the now rising force arrow FG1.

[0048] Upon further intrusion, individual spheres 12 burst open, and the substance 12c, 12c` contained within, for example the liquid contained within, flows in the direction of gravity. This is Fig. 4 is illustrated only for the substance labelled 12c, which in the following examples represents a liquid 12c. Due to the bursting of these spheres 12, the counterforce FG is reduced somewhat, which is indicated by the arrow section FG2 in Fig. 4. However, the remaining balls 12 continue to exert a force which increases further upon further intrusion of the external force FA or the side wall 18a caused by the external force FA, which is indicated by the arrow FG3 in Fig. 4. As a result of this increase in force, further balls 12 burst, as shown in Fig. 5. This in turn leads to a slight reduction in the counterforce FG, illustrated by the counterforce section FG4, and subsequently to a further increase in force, illustrated by the force arrow FG5. The remaining gap 34, meanwhile, continues to fill with the liquid 12c or another substance 12c, 12c' held in the balls 12. If all balls 12 or a sufficient number of balls 12 have burst to completely fill the holding area 20 with the substance 12c, 12c', such as the held liquid 12c, the liquid 12c causes a very high counterforce FG in the system. This is shown in Fig. 5 by the additional force curve component FG6. The fluid 12c has no or very low compressibility, which enables this very large counterforce FG in this stage. The fluid 12c is electrically non-conductive. Accidental bursting of individual balls in normal operating situations does not lead to a short circuit within the battery assembly 10. Furthermore, contamination of the battery modules 22 in the event of a crash is also insignificant, since such a high-voltage battery 10 must subsequently be replaced, and no further customer service applications for the high-voltage battery 10 are to be expected.

[0049] As already mentioned, it is also possible to fill the spheres 12 not only with the same liquid 12c or in general substance 12c, but with two different substances 12c, 12c', which can also react with each other, for example, and form a foam 12c'' as a result of such a reaction. This is shown schematically in Fig.6. The battery assembly 10 can otherwise be designed as previously described. In this case, two different fillers 12c, 12c' are used to fill the spheres 12. These fillers react with each other and reduce or prevent thermal propagation in the event of a crash. Thermal propagation is understood to mean that one of the battery cells of the battery module 22 thermally breaks through, and then this igniting, thermally broken cell infects the next, for example, neighboring, battery cell, which in turn infects a neighboring cell, and so on. As a result, the ignition of the module 22 infects the next module 22, and so on, until, in the worst case, all cells of the battery 10 have broken through. The foam 12c'' forms a thermal barrier and also a physical barrier between the cells and / or modules, whereby such thermal propagation can be prevented or at least slowed down.

[0050] For example, to produce such a foam 12c'', a reactive 2K silicone system can be used, which reacts within one or a few seconds and forms the foam 12c'', increasing the volume many times over, for example, by a factor of 5. The filling 12c, 12c' of the spheres 12 can be carried out in such a way that, taking into account the statistical distribution, a suitable ratio of components A and B of the reactive 2K system is achieved, wherein these components A and B are provided by the respective substances 12c, 12c' of the respective spheres 12a, 12b.

[0051] Overall, the examples demonstrate how the invention can be used to provide reversible block formers in cavities in the event of a crash. For this purpose, the cavities can be filled with a material after the module has been installed. This material exerts a counterforce upon compression and can be removed without causing damage, for example, during customer service. The counterforce of the filling material, namely the crash elements, allows the crash load to be dissipated more homogeneously in the event of an intrusion. In the event of an intrusion, this counterforce arises in the cavity between the tub or frame and the module. Furthermore, the force is transmitted across the entire surface from the sill to the module, reducing stress peaks and thus critical component failure. QUOTES CONTAINED IN THE DESCRIPTION

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

[0000] DE 10 2018 133 426 A1

[0007] DE 10 2005 055 082 A1

[0008]

Claims

[1] Battery arrangement (10) for a motor vehicle, comprising a battery housing (14), at least one battery module (22) arranged in the battery housing (14), and crash elements (12) arranged in at least one partial area (34) within the battery housing (14), characterized by , that - the crash elements (12) each have an interior space (12b), an outer shell (12a) completely enclosing the interior space (12b) and a respective substance (12c, 12c') accommodated in the interior space (12b), - wherein the crash elements (12) are each designed to be deformable upon external force application (FA). [2] Battery arrangement (10) according to claim 1, characterized bythat the respective crash elements (12) are designed in such a way that their respective outer shell (12a) is damaged, in particular tears and / or bursts, when a predetermined large force (FA) is applied to the respective crash element (12) in such a way that the respective outer shell (12a) no longer completely encloses the respective interior space (12b). [3] Battery arrangement (10) according to one of the preceding claims, characterized by that the respective substance (12c, 12c') is not electrically conductive, in particular wherein the substance (12c, 12c') represents a fluid, in particular a liquid. [4] Battery arrangement (10) according to one of the preceding claims, characterized bythat the crash elements (12) comprise first crash elements (12, 36a) and second crash elements (12, 36b), wherein the first crash elements (12, 36a) have a first substance (12c) accommodated in their respective interior space (12b) and the second crash elements (12, 36b) have a second substance (12c') different from the first substance (12c) accommodated in their respective interior space (12b). [5] Battery arrangement (10) according to one of the preceding claims, characterized by that the first and the second substance (12c, 12c') are designed such that when mixed they form a foam (12c''), in particular a curable foam, e.g. a 2K PU foam or a silicone foam. [6] Battery arrangement (10) according to one of the preceding claims, characterized bythat the first and the second substance (12c, 12c') are designed such that when mixed they increase their total volume compared to a total initial volume before mixing and in particular at least double it, preferably at least triple it. [7] Battery arrangement (10) according to one of the preceding claims, characterized by that the crash elements (12) are spherical. [8] Battery arrangement (10) according to one of the preceding claims, characterized by that a maximum outer diameter (d) of a respective crash element (12) is between 1 mm and 20 mm inclusive, preferably between 1 mm and 10 mm inclusive. [9] Battery arrangement (10) according to one of the preceding claims, characterized byin that the battery housing (14) has a fluid-tight receiving area (20) in which the at least one battery module (22) is arranged, wherein the partial area (34) filled with the crash elements (12) is part of the receiving area (20) and in particular directly adjoins the battery module (22). [10] Method for producing a battery assembly (10), - providing a battery housing (14); - arranging at least one battery module (22) in the battery housing (14); - arranging crash elements (12) in at least one partial area (34) in the battery housing (14); characterized bythat an outer shell (12a) completely enclosing an interior space (12b) with a substance (12c, 12c') accommodated in the respective interior space (12b) is provided as the crash elements (12), wherein a respective crash element (12) is designed to be deformable upon external force application (FA), and wherein the crash elements (12) are filled into the partial area (34) as bulk material.

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