Method and apparatus for joining a battery module and a compartment

Abstract

A method for joining at least one battery module (11) and a compartment (12), comprising the steps of: providing the compartment (12) and the at least one battery module (11), which are designed and configured to be connected to each other at a common contact surface (13) via a thermal conducting medium; applying a layer of the thermal conducting medium to a compartment-side and / or battery module-side area (14, 15) of the contact surface (13); arranging the compartment (12) and the battery module (11) in a hermetically sealable assembly chamber (20) such that the battery module (11) and the compartment (12) are spaced apart from each other on the contact surface side; closing the assembly chamber (20) and subsequently evacuating the assembly chamber (20) to a predetermined negative pressure;Joining the compartment (12) and the battery module (11) by reducing the contact surface distance between the compartment (12) and the battery module (11) until the compartment (12) and the battery module (11) are connected to each other at the common contact surface (13) via the thermal conducting medium, and removing the compartment (12) joined with the battery module (11) from the assembly chamber (20); furthermore, a device (10) for joining at least one battery module (11) and a compartment (12).

Description

[0001] The invention relates to a method for joining a battery module and a compartment and a related device.

[0002] When joining components using an adhesive and / or sealant under normal atmosphere, it is common for air pockets to form, at least partially, between the joining components. This problem is particularly significant in battery assembly. In this process, a thermally conductive paste (also known as a gap filler) is applied to an existing battery tray consisting of several individual compartments. The battery modules (composite of several battery cells) are then placed in the compartments on top of the gap filler.

[0003] During the installation and pressing of the modules, unwanted air pockets regularly occur. The required bonding or wetting between the compartment floor and the module underside of at least 90% of the surface cannot be guaranteed. Subsequent testing can currently only be performed destructively.

[0004] As an improvement, for example, DE 10 2021 131 798 A1 proposes a method for filling a cavity in a battery tray with a battery accommodated in the battery tray, in which the cavity formed between the battery and the battery tray is filled with a viscous material, wherein the cavity is evacuated before the viscous material is introduced.

[0005] DE 10 2021 206 824 A1 also discloses an energy storage device comprising a battery module and a battery tray, with a thermal interface material (TIM) filling the space between the battery module and the battery tray. The TIM can be inserted into the battery tray using a vacuum gripping technique. The battery module is then placed onto the TIM.

[0006] Furthermore, DE 10 2018 208 070 A1 describes a method for producing a battery module device, in which a battery module is mounted in a battery tray. A heat-conducting medium is introduced into a space between the battery module and the battery tray, wherein a negative pressure is generated in the space before or during the introduction of the heat-conducting medium in order to draw the heat-conducting medium into the space.

[0007] Against this background, the invention is based on the object of providing improved methods and devices for joining a battery module and a compartment, in which gas inclusions in a space between the battery module and the compartment for receiving a heat-conducting medium can be prevented with little effort.

[0008] This object is achieved by a method having the features of claim 1 and by a device having the features of claim 6. Further, particularly advantageous embodiments of the invention are disclosed in the respective subclaims.

[0009] It should be noted that the features listed individually in the claims can be combined with one another in any technically reasonable manner (even across category boundaries, for example, between methods and devices) and demonstrate further embodiments of the invention. The description further characterizes and specifies the invention, particularly in conjunction with the figures.

[0010] It should also be noted that a conjunction "and / or" used herein between two features and linking them together is always to be interpreted in such a way that in a first embodiment of the subject matter according to the invention only the first feature can be present, in a second embodiment only the second feature can be present and in a third embodiment both the first and the second feature can be present.

[0011] The invention relates to a method for joining at least one battery module and a compartment (hereinafter also referred to as joining method), which comprises the steps: - Providing the compartment and the at least one battery module, which are designed and configured to be connected to one another at a common contact surface via a heat-conducting medium, - Applying a layer of the heat-conducting medium to a compartment and / or battery module-side area of ​​the contact surface, - Arranging the compartment and the battery module in a hermetically sealable assembly chamber such that the battery module and the compartment are spaced apart from each other on the contact surface side, - Closing the assembly chamber and - subsequent evacuation of the assembly chamber to a predetermined negative pressure, - Joining the compartment and the battery module by reducing the contact surface spacing between the compartment and the battery module until the compartment and the battery module are connected to each other at the common contact surface via the heat transfer medium and - Removing the compartment joined to the battery module from the assembly chamber.

[0012] By joining and setting the at least one battery module and the compartment in the evacuated assembly chamber, in which the lower negative pressure prevails compared to atmospheric pressure outside the assembly chamber, air inclusions can no longer occur in the heat-conducting medium, since the air is extracted from the assembly chamber before joining.

[0013] The thermally conductive medium, e.g. a thermally conductive paste or a gap filler, represents a thermally conductive connection between the at least one battery module and the compartment. The thermally conductive medium is applied to one or both surfaces of the battery module or compartment that are to be thermally connected, which are referred to herein as the common contact surface, before joining. During the setting and joining process of the battery module to the compartment, the thermally conductive medium is pressed by the assembly forces that occur (e.g. clamping forces) in such a way that a required minimum wetting surface area of ​​the (active) surfaces to be thermally connected is sufficiently wetted with the thermally conductive medium for heat transfer, and thus sufficient heat transfer by thermal conduction between the battery module and the compartment is achieved. Since gas inclusions in the thermally conductive medium are avoided by the joining process according to the invention, a connection orWetting with the heat-conducting medium between the compartment and the battery module, in particular between a compartment base and a module underside, of at least 90% of the common contact area can be reliably achieved.

[0014] Preferred embodiments provide that the at least one battery module is gripped by a gripper (e.g., on the top side of the module) before being arranged in the assembly chamber and is arranged in the assembly chamber. In other words, the at least one battery module is held by the gripper in the assembly chamber in preparation for the joining process and during the joining process.

[0015] In further advantageous embodiments, the gripper is provided as a vacuum gripper, wherein a negative pressure is generated at the vacuum gripper for gripping the at least one battery module, which negative pressure is greater than the predetermined negative pressure in the evacuated assembly chamber.

[0016] In further preferred embodiments, several battery modules are arranged relative to one another in a predetermined manner before being arranged in the assembly chamber and then joined together as a group with the compartment. In other words, the pre-positioned battery modules to be joined are picked up simultaneously and completely by the gripper and arranged in the assembly chamber. A pre-positioning aid or pre-positioning device can be provided for the geometrically precise arrangement of the individual battery modules relative to one another.

[0017] In the event that the gripper is designed as a vacuum gripper, the suction of the multiple battery modules onto the vacuum gripper ensures that the individual battery modules have exactly the same height level in relation to the compartment to be joined or a compartment base.

[0018] Particularly preferably, the compartment is provided as a battery tray for accommodating the at least one battery module. If multiple battery modules are joined to a battery tray, the battery tray can have multiple compartments, each of which accommodates a battery module after joining.

[0019] Furthermore, the invention relates to a device for joining at least one battery module and a compartment (hereinafter also referred to as joining device), which are designed and configured to be connected to one another at a common contact surface via a heat-conducting medium. The device has a gripper for gripping the at least one battery module, a hermetically sealable assembly chamber with an upper part and a lower part, wherein the lower part is designed and configured to hold the compartment, and the upper part can be placed onto the lower part to produce the hermetic seal. Furthermore, the device has an evacuation means (e.g.a vacuum pump) for generating a predetermined negative pressure in the hermetically sealed assembly chamber and means for the controlled movement of the gripper within the hermetically sealed, evacuated assembly chamber between a first assembly position in which the battery module gripped by the gripper and the compartment, including a heat-conducting medium applied to a compartment- and / or battery module-side region of the contact surface, are spaced apart from one another on the contact surface side, and a second assembly position in which the contact surface-side spacing between the compartment and the battery module is reduced such that the compartment and the battery module are connected to one another at the common contact surface via the heat-conducting medium.

[0020] It should be understood that with regard to device-related definitions of terms as well as the effects and advantages of device-related features, the disclosure of corresponding definitions, effects, and advantages of the joining method according to the invention can be fully relied upon, and vice versa. Repetition of explanations of similar features, their effects, and advantages can thus be omitted in favor of a more concise description, without such omissions being interpreted as a limitation of any of the disclosed subject matter of the invention.

[0021] In preferred embodiments, the gripper and the upper part of the assembly chamber are connected to each other. For example, the gripper can be attached to the upper part, or the upper part can be attached to the gripper. The gripper and the upper part can be designed as an integrated structural unit, so that the gripper simultaneously forms the upper part of the assembly chamber.

[0022] In further preferred embodiments, the gripper is designed as a vacuum gripper.

[0023] In yet further advantageous embodiments, the device further comprises a pre-positioning device for arranging a plurality of battery modules relative to one another in a predetermined manner, wherein the gripper is designed and configured to grip the plurality of pre-positioned battery modules together as a group. The gripper holds and positions the plurality of gripped battery modules simultaneously and completely in the assembly chamber.

[0024] According to other advantageous embodiments, the means for moving the gripper are designed as at least one (eccentric) control cam arranged on a drive shaft rotatably mounted on the upper part of the mounting housing, which, depending on a rotation angle of the drive shaft, pushes the gripper toward the lower part (herein also referred to as the vertical direction). The drive shaft and control cam can be collectively understood as a camshaft. The movement of the gripper relative to the lower part or to the compartment held by the lower part presses the at least one battery module into the compartment.

[0025] In other preferred embodiments, the pressing of the at least one battery module and thus the movement of the gripper toward the lower part is carried out by a plurality of (eccentric) control cams. The control cams are preferably arranged at a distance from one another so that they act on the gripper over a larger effective area and thus achieve a uniform movement of the gripper, which is particularly advantageous when joining several battery modules simultaneously, since in this case, exactly the same height level of all battery modules relative to the compartment can be ensured during joining.

[0026] Camshaft drives can be arranged outside the assembly chamber on linear units.

[0027] The drive and camshaft are preferably connected by a conical polygon. After the drives are "docking" to the camshaft, the drives' incremental encoders can be zeroed. This ensures precise vertical feed of the gripper.

[0028] Further features and advantages of the invention will become apparent from the following description of non-limiting embodiments of the invention, which are explained in more detail below with reference to the drawings. In this drawing, schematically show: Fig. 1 a sectional view of a joining device according to an embodiment of the invention in a first assembly state; and Fig. 2 the joining device Fig. 1 in a second assembly state.

[0029] In the different figures, parts that are equivalent in terms of their function are always provided with the same reference symbols, so that they are usually only described once.

[0030] Fig. Fig. 1 schematically shows a sectional view of a joining device 10 according to an embodiment of the invention in a first assembly state. The device 10 serves to join at least one battery module 11 and a compartment 12, which can be designed as a battery tray without any mandatory limitation thereto. The at least one battery module 11 and the compartment 12 are designed and configured to be joined at a common contact surface 13, of which Fig. 1 both the battery module-side area 14 of the contact surface 13 and the compartment-side area 15 can be seen to be connected to one another via a heat-conducting medium (not shown).

[0031] In Fig. 1, the device 10 can be seen with a gripper 16 for gripping the at least one battery module 11. The gripper 16 is a vacuum gripper in the present case, without necessarily being limited to this. The vacuum gripper 16 can generate a negative pressure on the battery module 11 via evacuation connections (also not shown) connected to a means for generating a negative pressure - for example, a vacuum pump (not shown) - in order to grip the battery module 11, for example, at its top side, as is shown by way of example in the present exemplary embodiment of the joining device 10. The gripper 16 can be moved and controlled via one or more manipulation arms 17. For example, the gripper 16 can be moved between a position for gripping the battery module 11 and a position in which the gripper 16 aligns the gripped battery module 11 relative to the compartment 12 for the subsequent joining process.In addition, the evacuation connection can be provided in the manipulation arm 17 so that, if necessary, the gripping and releasing of the battery module 11 can be controlled via the manipulation arms 17.

[0032] Furthermore, the Fig. The joining device 10 shown in Figure 1 has a hermetically sealable assembly chamber 20 with an upper part 21 and a lower part 22. The lower part 22 is designed and configured to hold the compartment 12. The upper part 21 can be placed onto the lower part 22 to create the hermetic seal. Fig. 1 shows the assembly chamber 20 in the first assembly state in which the assembly chamber 20 is open, ie the upper part 21 is removed from the lower part 22.

[0033] The joining device 10 further comprises evacuation means such as a vacuum pump (not shown) in order to maintain a predetermined negative pressure in the hermetically sealed assembly chamber 20 (cf. Fig. 2). For this purpose, at least one evacuation port 23 is provided on the assembly chamber 20, to which the evacuation means can be fluidly connected in order to extract air from the assembly chamber 20.

[0034] Furthermore, the joining device 10 has means 25 for the controlled movement of the gripper 16 within the hermetically sealed, evacuated assembly chamber 20 between a first assembly position, in which the battery module 11 gripped by the gripper 16 and the compartment 12, including a heat-conducting medium applied to a compartment- and / or battery module-side region of the contact surface 13, are spaced apart from one another on the contact surface side, and a second assembly position, in which the contact surface-side spacing between the compartment 12 and the battery module 11 is reduced such that the compartment 12 and the battery module 11 are connected to one another at the common contact surface 13 via the heat-conducting medium (cf. Fig. 2).

[0035] Preferably, the means 25 for moving the gripper 16 are designed as at least one switching cam arranged on a drive shaft 25 rotatably mounted on the upper part 21 of the assembly housing 20. In the present case, the joining device 10 has three switching cams 24. The switching cam 24 presses the gripper 16 in the hermetically closed state of the assembly chamber 20 in the direction of the lower part 22 depending on the angle of rotation of the drive shaft 25 (see FIG. Fig. 2).

[0036] The exact positioning of the upper part 21 relative to the lower part 22 for hermetically closing the assembly chamber 20 can be achieved via conical polygons 26. These are formed, for example, on the lower part 22 to interact with corresponding polygonal recesses 27 formed on the upper part 21 to precisely align the upper part 21 with the lower part 22 during closing. The conical polygons 26 can alternatively or additionally be provided on the upper part 21, in which case corresponding polygonal recesses 27 are provided on the lower part 22. The polygons 26 and 27 can additionally serve as a locking mechanism to firmly connect the upper part 21 to the lower part 22 for the hermetic closure of the assembly chamber 20.

[0037] Particularly advantageously, the gripper 16 is connected to the upper part 21, as is the case with the joining device 10 in Fig. 1 is shown as an example. In this way, the upper part 21 can be moved simultaneously with the gripper 16 via its manipulation arms 17.

[0038] Fig. 2 represents the joining device 10 Fig. 1 in a second assembly state, in which the upper part 21 is placed on the lower part 22. The assembly chamber 20 is hermetically sealed in the illustrated state, but the battery module 11 and the compartment 12 are not yet joined. Rather, the battery module 11 and the compartment 12 are in Fig.2 are still spaced apart from each other on the contact surface side. Only by rotating the drive shafts 25 do the (eccentric) switching cams 24 press the gripper 16 within the hermetically sealed assembly chamber 20 toward the lower part 22 or the compartment 12 accommodated in the lower part 22 in order to reduce the contact surface spacing between the compartment 12 and the battery module 11 until the compartment 12 and the battery module 11 are connected to each other at the common contact surface 13 via the heat-conducting medium.

[0039] In the joining method of at least one battery module 11 and the compartment 12, the compartment 12 and the battery module 11 are provided, wherein the at least one battery module 11 and the compartment 12 are designed and configured to be connected to one another at the common contact surface 13 via a heat-conducting medium not shown in the figures. Furthermore, a layer of the heat-conducting medium is applied to a compartment- and / or battery module-side region 14 or 15 of the contact surface 13. In the hermetically sealable assembly chamber 20, the compartment 12 and the battery module 11 are arranged such that the battery module 11 and the compartment 12 are spaced apart from one another on the contact surface side. The assembly chamber 20 is closed and then evacuated to a predetermined negative pressure.The compartment 12 and the battery module 11 are joined by reducing the contact surface spacing between the compartment 12 and the battery module 11 until the compartment 12 and the battery module 11 are connected to each other at the common contact surface 13 via the heat-conducting medium. Subsequently, the compartment 12 joined to the battery module 11 is removed from the assembly chamber 20.

[0040] If several battery modules 11 (not shown) are to be joined to the compartment 12 simultaneously, the individual battery modules 11 can be precisely arranged and aligned relative to one another beforehand, for example, with the aid of a pre-positioning device, and then joined together as a group to the compartment 12. The gripper 16, which can be designed as a vacuum gripper, grips the battery modules 16 together, preferably at their module tops. The gripper 16 preferably simultaneously forms the upper part 21 of the assembly chamber 20 or is connected to the upper part 21.

[0041] After the compartment 12, e.g., a battery tray, is inserted into the lower part 22 of the assembly chamber 20, the upper part 21 and the lower part 22 are positioned relative to each other and brought together. The positioning of the upper part 21 and the lower part 22 relative to each other can be achieved using the conical polygons 26, 27.

[0042] After the assembly chamber 20 has been evacuated and a desired negative pressure has been generated in the assembly chamber 20, wherein the negative pressure in the chamber 20 is not greater than a negative pressure generated by a vacuum gripper 16, the vacuum gripper 16, which is preferably integrated in the upper part 21 of the chamber 20, places the individual battery modules 11 simultaneously into the compartment 12.

[0043] The pressing of the battery modules 11 into the compartment 12, i.e., the movement of the gripper 16 toward the compartment 12, is preferably carried out by several (eccentric) switching cams 24. These are positioned on the drive shaft 25 (e.g., camshaft). Drives of the drive shafts 25 can be located outside the assembly chamber 20 on linear units (not shown).

[0044] The drive and drive shaft 25 are preferably connected by a conical polygon (not shown). After the drives are "docking" to the drive shafts 25, the incremental encoders of the drives are zeroed. This ensures precise feed of the gripper 16 in the vertical direction, i.e., in the direction of the lower part 22 or compartment 12. LIST OF REFERENCE SYMBOLS: 10 Joining device 11 Battery module 12 compartments 13 Contact surface 14 Battery module side area 15 Compartment-side area 16 grippers 17 Manipulation arm 20 assembly chamber 21 Top 22 Lower part 23 Evacuation connection 24 switching cam 25 Drive shaft 26 Conical polygon 27 Polygonal recess

Claims

[1] Method for joining at least one battery module (11) and a compartment (12), comprising the steps: - providing the compartment (12) and the at least one battery module (11), which are designed and configured to be connected to one another at a common contact surface (13) via a heat-conducting medium, - applying a layer of the heat-conducting medium to a compartment and / or battery module-side area (14, 15) of the contact surface (13), - arranging the compartment (12) and the battery module (11) in a hermetically sealable assembly chamber (20) such that the battery module (11) and the compartment (12) are spaced apart from each other on the contact surface side, - Closing the assembly chamber (20) and - subsequent evacuation of the assembly chamber (20) to a predetermined negative pressure, - joining the compartment (12) and the battery module (11) by reducing the contact surface spacing between the compartment (12) and the battery module (11) until the compartment (12) and the battery module (11) are connected to one another at the common contact surface (13) via the heat-conducting medium, and - Removing the compartment (12) joined to the battery module (11) from the assembly chamber (20). [2] Method according to claim 1, wherein the at least one battery module (11) is gripped by means of a gripper (16) before being arranged in the assembly chamber (20) and is arranged in the assembly chamber (20). [3] Method according to the preceding claim, wherein the gripper (16) is provided as a vacuum gripper and a negative pressure is generated at the vacuum gripper (16) for gripping the at least one battery module (11), which negative pressure is greater than the predetermined negative pressure in the evacuated assembly chamber (20). [4] Method according to one of the preceding claims, in which a plurality of battery modules (11) are arranged relative to one another in a predetermined manner before being arranged in the assembly chamber (20) and are then joined together as a group to the compartment (12). [5] Method according to one of the preceding claims, in which the compartment (12) is provided as a battery tray. [6] Device (10) for joining at least one battery module (11) and one compartment (12), which are designed and arranged to be connected to one another at a common contact surface (13) via a heat-conducting medium, comprising - a gripper (16) for gripping the at least one battery module (11), - a hermetically sealable assembly chamber (20) having an upper part (21) and a lower part (22), wherein the lower part (22) is designed and configured to hold the compartment (12), and the upper part (21) can be placed on the lower part (22) to produce the hermetic seal, - evacuation means for generating a predetermined negative pressure in the hermetically sealed assembly chamber (20) and - Means (24) for the controlled movement of the gripper (16) within the hermetically sealed, evacuated assembly chamber (20) between a first assembly position, in which the battery module (11) gripped by the gripper (16) and the compartment (12), including a heat-conducting medium applied to a compartment- and / or battery-module-side region (14, 15) of the contact surface (13), are spaced apart from one another on the contact surface side, and a second assembly position, in which the contact surface-side spacing between the compartment (12) and the battery module (11) is reduced such that the compartment (12) and the battery module (11) are connected to one another at the common contact surface (13) via the heat-conducting medium. [7] Device according to claim 6, wherein the gripper (16) and the upper part (21) of the assembly chamber (20) are connected to one another. [8] Device according to claim 6 or 7, wherein the gripper (16) is designed as a vacuum gripper. [9] Device according to one of claims 6 to 8, further comprising a pre-positioning device for arranging a plurality of battery modules (11) relative to one another in a predetermined manner, wherein the gripper (16) is designed and arranged to grip the plurality of pre-positioned battery modules (11) together as a group. [10] Device according to one of claims 6 to 9, in which the means (24) for moving the gripper (16) are designed as at least one switching cam arranged on a drive shaft (25) rotatably mounted on the upper part (21) of the mounting housing (20), which presses the gripper (16) in the direction of the lower part (22) depending on an angle of rotation of the drive shaft (25).

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