Battery system and method for manufacturing a battery system

Abstract

The presented invention relates to a battery system (100) for storing electrical energy, wherein the battery system (100) comprises: - a number of battery cells (103), - a cell housing (101) in which the number of battery cells (103) are arranged, - a battery housing (107) for receiving the cell housing (101), wherein the battery housing (107) includes at least one receptacle (115), wherein the cell housing (101) comprises a number of first spring elements (111) and a number of second spring elements (113), wherein the number of first spring elements (111) is configured to engage in the at least one receptacle (115) and to secure the cell housing (101) against movement in a vertical direction relative to the battery housing (107), and wherein the number of second spring elements (113) is configured to press the cell housing (107) against a side wall of the battery housing (107) in order to secure the cell housing (101) against movement in a horizontal direction relative to the battery housing (107).

Description

[0001] The presented invention relates to a battery system and a method for manufacturing a battery system according to the attached claims. State of the art

[0002] To manufacture battery systems, battery cells are bundled into cell stacks and placed in a housing. Wedges are used to set an angle between the housing and the cell stack. These wedges are inserted into the housing with a predetermined force and bonded between the cell stack and the housing.

[0003] Such manufacturing processes are time-consuming, prone to errors, and therefore expensive. Disclosure of the invention

[0004] Within the scope of the presented invention, a battery system and a method for manufacturing the battery system are introduced. Further features and details of the invention will become apparent from the respective dependent claims, the description, and the drawings. Features and details described in connection with the method according to the invention naturally also apply in connection with the battery system according to the invention, and vice versa, so that the disclosure regarding the individual aspects of the invention always refers, or can refer, to each other.

[0005] The presented invention serves in particular to provide a cost-optimized and stable battery system.

[0006] Thus, according to a first aspect of the presented invention, a battery system for storing electrical energy is presented.

[0007] The presented battery system comprises a number of battery cells, a cell housing in which the number of battery cells are arranged, and a battery case to accommodate the cell housing.

[0008] The battery housing includes at least one receptacle. The cell housing includes a number of first spring elements and a number of second spring elements, wherein the number of first spring elements is configured to engage in the at least one receptacle and secure the cell housing against movement in a vertical direction relative to the battery housing, and wherein the number of second spring elements is configured to press the cell housing against a side wall of the battery housing to secure the cell housing against movement in a horizontal direction relative to the battery housing.

[0009] In the context of the presented invention, a spring element is understood to be a deformable element that provides a spring force which moves the spring element into a basic position.

[0010] The presented battery system is based in particular on two elements, namely a battery housing and a cell stack, i.e., a cell housing with battery cells arranged inside it for storing electrical energy.

[0011] In order to secure the cell stack firmly in the battery housing despite manufacturing-related length tolerances, first and second spring elements are provided on the cell housing, which, when installed, press the cell stack to a predetermined position in the battery housing.

[0012] According to the invention, the first spring elements are configured to engage in a receptacle formed in the battery housing and to secure the cell housing against movement in a vertical direction relative to the battery housing. This means that the first spring elements prevent or block upward movement of the cell stack, i.e., towards an opening of the battery housing. For this purpose, the first spring elements can push the cell stack away from the receptacle towards the bottom or be vertically rigid.

[0013] Furthermore, the second set of spring elements is configured to press the cell casing against a side wall of the battery housing, securing the cell casing against horizontal movement relative to the battery housing. This means that, through a combination of the first and second set of spring elements, the cell stack is secured within the battery housing in both horizontal and vertical directions.

[0014] Due to the spring action of the first and second spring elements, these are movable and can adapt to a specific dimension of a respective cell stack or cell housing, for example to compensate for manufacturing tolerances.

[0015] Due to the first and second spring elements, the cell housing automatically aligns itself within the battery casing. This means that the first and second spring elements automatically force or press the cell housing into a predetermined position within the battery casing. Accordingly, the cell housing can be inserted into the battery casing easily and quickly in one step without additional work, such as applying adhesive.

[0016] It may be provided that the number of first spring elements is configured to engage in an undercut into at least one receptacle, in particular to latch onto the undercut.

[0017] Due to an undercutting engagement of the first spring elements in the receptacle, each first spring element is superimposed by an overhang in the vertical direction, so that the first spring element abuts the overhang when it moves in the vertical direction and, as a result, blocks a movement of the cell stack in the vertical direction relative to the battery housing.

[0018] It may also be provided that the number of first spring elements is configured to engage in at least one receptacle.

[0019] Due to the spring action of a respective first spring element, this can be compressed by an overhang when the cell stack moves into the battery housing and then snap into place or spring into position.

[0020] It may also be provided that the number of first spring elements and the number of second spring elements are formed in one piece from the cell casing.

[0021] Spring elements that are formed in one piece from the cell housing can, for example, be punched or cut out from an end plate of the cell housing.

[0022] A one-piece design of cell housing and spring elements necessitates a cost-effective, captive and precisely positioned arrangement of the spring elements on the cell housing.

[0023] It may also be provided that the number of first spring elements and the number of second spring elements are formed on only one side of the cell housing.

[0024] By arranging or shaping the spring elements on only one side of the cell housing, only a special end plate is needed to shape the cell housing provided according to the invention, so that it can be provided simply and cost-effectively.

[0025] Furthermore, shaping the spring elements on only one side of the cell housing allows the side opposite the battery housing that forms the receptacle to be shaped independently of the spring elements, for example to provide a space for movement for a gripper to engage.

[0026] It may also be provided that the at least one recess of the battery housing includes an overhang that overlaps the at least one recess and limits it upwards.

[0027] An overhang that limits the recess upwards, i.e., in a direction opposite a base of the battery housing, can, for example, be flush with a side wall of the battery housing, so that the recess forms a notch in the side wall and the overhang continues the course of the side wall.

[0028] It may also be provided that the battery housing includes an inclined plane on a side forming at least one recess, which continuously tapers to create a space for receiving the cell housing.

[0029] An inclined plane guides the cell stack or cell housing to a predetermined position within the battery housing during insertion. There, the cell stack is fixed or secured by its spring elements, particularly by the second set of spring elements.

[0030] It may also be provided that at least one mounting is arranged above the inclined plane, and that the number of first spring elements is arranged above the number of second spring elements.

[0031] By arranging the first spring elements above the second spring elements, the inclined plane can run along the lower end of the battery housing and, for example, taper continuously to the bottom of the battery housing, so that the smallest area is formed at the bottom of the battery housing.

[0032] It may also be provided that the battery housing has a recess on a second side, opposite a second side forming at least one receptacle. A recess, such as an inclined plane extending from an upper end of the battery housing towards a base of the battery housing, continuously tapering to create a space for receiving the cell housing and extending, for example, only over a portion of the side wall of the battery housing, allows, for instance, a gripper to engage for the automatic insertion of the cell stack into the battery housing, so that the gripper can enter the battery housing together with the cell stack.

[0033] It may also be provided that the number of first spring elements and the number of second spring elements are horizontally elastic and vertically stiff.

[0034] Vertically rigid first spring elements block movement of the cell stack in a vertical direction relative to the battery housing.

[0035] Horizontally spring-loaded first spring elements allow these to spring into a respective receptacle and be arranged there with an undercut.

[0036] Horizontally spring-loaded second spring elements press the cell stack against the battery housing and thereby secure it in its position within the battery housing.

[0037] According to a second aspect, the presented invention relates to a method for manufacturing a battery system.

[0038] The presented method comprises providing a cell housing and a battery housing according to a possible embodiment of the presented battery system, gripping the cell housing by means of a gripper which engages on a first side in a gap between a housing wall of the cell housing and the number of first spring elements and clamps the cell housing on a second side opposite the first side, and inserting the cell housing into the battery housing by means of the gripper, wherein the gripper is shaped such that the number of first spring elements initially deform in the direction of battery cells arranged in the cell housing when inserted into the cell housing and then move away from the gripper into the at least one receptacle due to their spring force.

[0039] The advantages described in detail for the battery system for storing electrical energy according to the first aspect of the invention apply equally to the method for manufacturing a battery system according to the second aspect of the invention.

[0040] Further advantages, features, and details of the invention will become apparent from the following description, in which exemplary embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description can each be essential to the invention individually or in any combination.

[0041] They show: Fig. 1 a schematic representation of a possible design of the presented battery system, Fig. 2. A possible design of the presented procedure.

[0042] In Fig. Figure 1 shows a battery system 100. The battery system 100 comprises a cell housing 101, which together with battery cells 103 forms a cell stack 105.

[0043] The cell stack 105 is arranged in a battery housing 107.

[0044] A first spring element 111 and a second spring element 113 are formed on a side wall 109 of the cell housing 101. The first spring element 111 engages in a receptacle 115 formed in a side wall 115 of the battery housing 107, so that a vertical movement of the cell stack 105 relative to the battery housing 107 is blocked by an overhang 117 through the first spring element 111.

[0045] The second spring element 113 is deflected from its home position and, due to its spring action or spring force, presses the cell stack 105 against a side wall 119 of the battery housing 107, so that a horizontal movement of the cell stack 105 relative to the battery housing 107 is blocked by the second spring element 113.

[0046] In Fig. 2 is a method 200 for manufacturing the battery system 100 according to Fig. 1 shown.

[0047] The cell stack 105 is automatically inserted into the battery housing 107 by means of a gripper 201. The gripper 201 engages in a pocket 207 formed by the first spring element 111.

[0048] When the cell stack 105 is inserted into the battery housing 107, the gripper 201 dips into a recess 203 of the battery housing 107, so that the cell stack 105 is completely guided on its path of movement into the battery housing 107 and a loose fall of the cell stack 105 into the battery housing 107 is prevented.

[0049] During the movement of the cell stack 105 into the battery housing 107, the first spring element 111 is deflected by the overhang 117 and then springs into the receptacle 115. Furthermore, the second spring element 113 is compressed by an inclined plane 205 of the battery housing 107, so that it builds up a spring force that fixes the cell stack 105 horizontally.

Claims

[1] Battery system (100) for storing electrical energy, the battery system (100) comprising: - a number of battery cells (103), - a cell housing (101) in which the number of battery cells (103) are arranged, - a battery housing (107) for receiving the cell housing (101), wherein the battery housing (107) comprises at least one receptacle (115), wherein the cell housing (101) comprises a number of first spring elements (111) and a number of second spring elements (113), wherein the number of first spring elements (111) is configured to engage in the at least one receptacle (115) and to secure the cell housing (101) against movement in the vertical direction relative to the battery housing (107), and wherein the number of second spring elements (113) is configured to press the cell housing (107) against a side wall of the battery housing (107) in order to secure the cell housing (101) against movement in a horizontal direction relative to the battery housing (107). [2] Battery system (100) according to claim 1, characterized by that the number of first spring elements (111) is configured to engage in an undercut in the at least one receptacle (115). [3] Battery system (100) according to claim 1 or 2, characterized by that the number of first spring elements (111) is configured to engage in the at least one receptacle (115). [4] Battery system (100) according to one of the preceding claims, characterized by that the number of first spring elements (111) and the number of second spring elements (113) are formed integrally from the cell housing (101). [5] Battery system (100) according to one of the preceding claims, characterized bythat the number of first spring elements (111) and the number of second spring elements (113) are formed on only one side of the cell housing (101). [6] Battery system (100) according to one of the preceding claims, characterized by that the at least one receptacle (115) of the battery housing (107) comprises an overhang (117) which overlies the at least one receptacle (115) and limits it at the top. [7] Battery system (100) according to one of the preceding claims, characterized by that the battery housing (107) comprises, on a side forming the at least one receptacle (115), an inclined plane (205) which continuously tapers a space for receiving the cell housing (101). [8] Battery system (100) according to claim 7, characterized by that the at least one receptacle (115) is arranged above the inclined plane (205), and the number of first spring elements (111) is arranged above the number of second spring elements (113). [9] Battery system (100) according to one of the preceding claims, characterized by that the battery housing (107) has a recess (203) on a second side which is opposite a second side forming the at least one receptacle (115). [10] Battery system (100) according to one of the preceding claims, characterized by that the number of first spring elements (111) and the number of second spring elements (113) are horizontally resilient and vertically stiff. [11] A method (200) for manufacturing a battery system (100) according to any one of claims 1 to 10, wherein the method (200) comprises: - Providing a cell housing (101) and a battery housing (107), in particular according to one of claims 1 to 10, - gripping the cell housing (101) by means of a gripper (201) which engages on a first side into a space (207) between a housing wall of the cell housing (101) and the number of first spring elements (111) and clamps the cell housing (101) on a second side opposite the first side, - Inserting the cell housing (101) into the battery housing (107) by means of the gripper (201), wherein the gripper (201) is shaped such that the number of first spring elements (111) initially deform in the direction of battery cells (103) arranged in the cell housing (101) when inserted into the cell housing (101) and then move away from the gripper (201) into the at least one receptacle (115) due to their spring force.

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