Electrical energy storage device for a vehicle and method for manufacturing an electrical energy storage device

Abstract

The invention relates to an electrical energy storage device for a vehicle, comprising a housing base and a housing cover (1), in which at least one cell module is arranged with a plurality of individual cells electrically connected by means of at least one cell contact module (2), wherein the at least one cell contact module (2) is arranged between the individual cells and the housing cover (1). According to the invention, the at least one cell contact module (2) has an absorption structure (A) on a surface facing the housing cover (1) to increase the structural stiffness of the housing. The invention further relates to a method for manufacturing such an electrical energy storage device.

Description

[0001] The invention relates to an electrical energy storage device for a vehicle, comprising a housing base and a housing cover, in which at least one cell module is arranged with a plurality of individual cells electrically connected by means of at least one cell contact module, wherein the at least one cell contact module is arranged between the individual cells and the housing cover. The invention further relates to a method for manufacturing such an electrical energy storage device.

[0002] From DE 10 2018 125 618 A1, a protective unit for a battery module of a high-voltage battery, a battery module, and a high-voltage battery are known. The protective unit for electrically insulating the cell housings of prismatic battery cells stacked in a cell stack of the battery module and a cell contacting system of the battery module, which connects the battery cells by electrically connecting the cell terminals of the battery cells, comprises a pre-formed intermediate layer made of an electrically insulating material. The intermediate layer can be placed against a side of the cell stack having the cell terminals and can be arranged between the side of the cell stack having the cell terminals and the cell contacting system. Furthermore, the intermediate layer has a number of cutouts corresponding to a number of cell terminals for guiding the cell terminals through when the intermediate layer is placed on the cell stack.

[0003] Furthermore, DE 10 2021 120 655 A1 describes a battery module, a battery system, and a method for manufacturing a battery module. The battery module comprises a module frame element in which a base plate and a top plate are supported by a reinforcing beam, resulting in an I-profile. The reinforcing beam divides the battery module into two receiving chambers in which battery cells are stored and encapsulated.

[0004] The invention is based on the objective of providing a novel electrical energy storage device for a vehicle and a method for manufacturing the electrical energy storage device.

[0005] The problem is solved according to the invention by an electrical energy storage device which has the features specified in claim 1, and by a method which has the features specified in claim 5.

[0006] Advantageous embodiments of the invention are the subject of the dependent claims.

[0007] An electrical energy storage device for a vehicle comprises a housing base and a housing cover, in which at least one cell module is arranged with a plurality of individual cells electrically connected by means of at least one cell contact module, wherein the at least one cell contact module is arranged between the individual cells and the housing cover. According to the invention, the at least one cell contact module has an absorption structure on a surface facing the housing cover to increase the structural stiffness of the housing.

[0008] The absorption structure increases the structural stiffness of the housing and thus of the electrical energy storage device, thereby significantly reducing the risk of mechanical stress on the housing due to collisions and any associated deformation.

[0009] Since the absorption structure is located on the surface of the cell contacting module facing the housing cover, an additional component to increase the housing's structural rigidity is unnecessary. This allows for a reduction in the weight and / or cost of the electrical energy storage device.

[0010] In particular, the absorption structure serves to introduce shocks acting on the housing cover from an underside, i.e. in the installed position, during the vehicle's operation into a structural unit formed by means of at least one cell module, the cell contacting modules and a potting compound that may be introduced into the housing, in such a way that the respective shock does not cause any significant damage in the area of ​​a respective cell contacting and / or the individual cells themselves.

[0011] For this purpose, the absorption structure is formed, for example, from a fiber-reinforced thermoplastic material and is also integrated, at least partially, into the cell contacting module. If the absorption structure is integrated into the cell contacting module, and this in turn is embedded in a potting compound that forms a material bond around the individual cells, this results in an optimized lid connection with a significant increase in the stiffness of the entire electrical energy storage device.

[0012] In one embodiment of the electrical energy storage device, at least one cell contact module is bonded to the inside of the housing cover. Due to this bonded connection, no fasteners such as screws and nuts are required, so the number of parts in the electrical energy storage device does not increase.

[0013] In another embodiment, at least one cell contact module is bonded to the inside of the housing cover using an adhesive and / or potting compound. The use of adhesive and / or potting compound allows for the utilization of at least one of its material properties, such as thermal and / or electrical insulation. The adhesive or potting compound can also possess flame-retardant properties, thus increasing safety during handling of the electrical energy storage device. Optimized application of the adhesive and / or potting compound to the inside of the housing cover may reduce the weight of the amount of adhesive and / or potting compound used.

[0014] In one possible embodiment, the absorption structure comprises structural elements arranged at regular intervals, projecting vertically from the surface of at least one cell contacting module of a predetermined length, which increase the structural rigidity of the housing. Furthermore, these structural elements, which deform under impact and thus largely absorb the impact force, can reduce the risk of damage to electrically conductive components of the electrical energy storage device, thereby also reducing the danger to living beings in the immediate vicinity of the electrical energy storage device.

[0015] The invention further relates to a method for manufacturing an electrical energy storage device for a vehicle, comprising a housing base and a housing cover, in which at least one cell module is arranged with a plurality of electrically interconnected individual cells by means of at least one cell contact module, wherein the at least one cell contact module is arranged between the individual cells and the housing cover. According to the invention, the method provides that an absorption structure is arranged or formed on the surface of the at least one cell contact module facing the housing cover, and that the at least one cell contact module is bonded to the inside of the housing cover. The cell contact module is bonded to the inside of the housing cover via the surface of the absorption structure.By arranging the absorption structure towards the housing cover, the structural stiffness, especially of the housing cover, can be increased, while the absorption structure can reduce the mechanical stress acting on the housing cover, particularly through deformation of the absorption structure.

[0016] In one embodiment of the method, the at least one cell module is inserted into the lower housing part, and the at least one cell contacting module for electrically connecting the individual cells is placed onto the individual cells of the at least one cell module. An adhesive and / or a potting compound is applied over a surface area to the inside of the housing cover. The lower housing part, with the at least one cell module and the at least one attached cell contacting module, is rotated 180° and positioned on the housing cover so that the absorption structure for the metallurgical bonding of the at least one cell contacting module to the housing cover is immersed, at least partially, in the adhesive and / or potting compound.

[0017] By applying this method, the material bond between the absorption structure and the inside of the housing cover is optimized to increase the structural rigidity of the housing cover and thus of the housing of the electrical energy storage device, making it at least more difficult for an object to penetrate the housing, especially in the event of a vehicle collision. This allows for optimal protection of electrically conductive components of the electrical energy storage device against damage.

[0018] In another embodiment, the adhesive and / or potting compound is applied to the inside of the housing cover up to a predetermined height, so that the absorption structure is optimally contacted with the adhesive and / or potting compound, thus optimizing the material bond between the housing cover and the cell contacting module.

[0019] In one possible embodiment of the process, to increase the contact area between the absorption structure and the adhesive and / or potting compound applied to the inside of the housing cover, the adhesive and / or potting compound is applied to the inside of the housing cover with a predetermined viscosity and / or temperature. This also makes it possible to optimize the material bond between the housing cover and the cell contacting module.

[0020] Exemplary embodiments of the invention are explained in more detail below with reference to drawings.

[0021] This shows: Fig. 1. Schematic cross-sectional view of an enlarged section of a housing cover of an electrical energy storage device, spaced apart from an absorption structure of a cell contacting module. Fig. 2 schematically a cross-sectional view of an enlarged section of the housing cover which is materially bonded to the absorption structure of the cell contacting module.

[0022] Corresponding parts are marked with the same reference symbols in all figures.

[0023] Fig. Figure 1 shows, by way of example and in a highly simplified manner, a sectional view of an enlarged section of a housing cover 1 of a box-shaped housing of an electrical energy storage device (not shown in detail) for a vehicle and an absorption structure A of a cell contacting module 2 of the electrical energy storage device. The cell contacting module 2 with the absorption structure A is spaced apart from the housing cover 1.

[0024] The electrical energy storage device is in particular a vehicle battery, especially a traction battery, of an electric vehicle, a hybrid vehicle or a vehicle powered by fuel cells.

[0025] The electrical energy storage device comprises at least one cell module (not shown in detail) which includes a plurality of individual cells, the individual cells being electrically connected in series and / or parallel by means of at least one cell contacting module 2. The respective cell module is inserted into a lower housing section of the housing.

[0026] The cell contacting module 2 is essentially plate-shaped and has a number of electrical contacting elements (not shown) by means of which the individual cells are electrically connected in series and / or parallel. After the cell module is inserted into the lower housing part, the cell contacting module 2 is placed onto the individual cells and electrically connected to them, in particular to connect the individual cells electrically in series and / or parallel. The cell contacting module 2 is connected to the individual cells, in particular by a force-fit connection.

[0027] To increase the structural rigidity of the electrical energy storage device, the cell contacting module 2 is arranged on an inner side of the housing cover 1, i.e., it is bonded to it, and has an absorption structure A comprising a number of structural elements 3, in particular regularly spaced apart from one another. The structural elements 3 project vertically from a surface of the cell contacting module 2 facing the housing cover 1 and have predetermined dimensions, particularly with respect to length.

[0028] In one embodiment, the absorption structure A is formed from a fiber-reinforced thermoplastic material and can also be integrated, at least partially, into the cell contacting module 2.

[0029] In one possible embodiment, the structural elements 3 are deformation elements that deform under mechanical stress, particularly on the housing cover 1, in order to absorb energy. This protects the cell contacting module 2.

[0030] To connect the cell contacting module 2 to the housing cover 1, it is provided that an adhesive 4 and / or a potting compound in a specified quantity is applied to an inside surface of the housing cover 1.

[0031] The lower housing section, with the inserted cell module and the cell contacting module 2 attached to it, is rotated 180° and placed onto the housing cover 1, the inside of which is coated with the adhesive 4 and / or the potting compound. Thus, when the lower housing section with the cell module and the cell contacting module 2 is placed on top, the structural elements 3 forming the absorption structure A are immersed in the adhesive 4 and / or the potting compound. The electrical energy storage device is therefore rotated before the housing cover 1 is placed onto the lower housing section, i.e., before the housing is closed. Only then can the adhesive 4 and / or the potting compound be applied to the inside of the housing cover 1.

[0032] To increase the effective contact area between the structural elements 3 of the absorption structure A of the cell contacting module 2 and the adhesive 4 and / or potting compound applied to the inside of the housing cover 1, the adhesive 4 and / or potting compound is applied to the inside of the housing cover 1 at a predetermined viscosity and / or temperature. In particular, by means of suitable property settings, especially flow behavior, and targeted temperature control during the process, the wetting of the structural elements 3, i.e., the absorption structure A, is increased beyond a certain immersion depth. Capillary forces are used for this purpose, causing a surface of the adhesive 4 and / or potting compound to bulge concavely, as shown in Fig.2 shows, for example, that part of the adhesive 4 and / or part of the potting compound is drawn towards at least one structural element 3.

[0033] The features and advantages described herein relating to an electrical energy storage device for a vehicle also apply to a method for manufacturing an electrical energy storage device described herein, and vice versa. Reference symbol list 1 Housing cover 2 cell contacting module 3 structural element 4 Adhesive A absorption structure QUOTES INCLUDED IN THE DESCRIPTION

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

[0000] DE 10 2018 125 618 A1

[0002] DE 10 2021 120 655 A1

[0003]

Claims

[1] Electrical energy storage device for a vehicle comprising a housing base and a housing cover (1), in which at least one cell module is arranged with a plurality of individual cells electrically connected by means of at least one cell contact module (2), wherein the at least one cell contact module (2) is arranged between the individual cells and the housing cover (1), characterized by , that at least one cell contacting module (2) has an absorption structure (A) on a surface side facing the housing cover (1) to increase the structural stiffness of the housing. [2] Electrical energy storage device according to claim 1, characterized by , that at least one cell contacting module (2) is materially bonded to an inside of the housing cover (1). [3] Electrical energy storage device according to claim 2, characterized by, that at least one cell contacting module (2) is bonded to the inside of the housing cover (1) by means of an adhesive (4) and / or a potting compound. [4] Electrical energy storage device according to any one of the preceding claims, characterized by , that the absorption structure (A) has structural elements (3) arranged at regular intervals from each other and projecting vertically from the surface side of the at least one cell contacting module (2) with a predetermined length. [5] Method for manufacturing an electrical energy storage device designed according to one of the preceding claims, characterized by , that - an absorption structure (A) is arranged or formed on the surface side of the at least one cell contacting module (2) facing the housing cover (1) and - that at least one cell contacting module (2) is materially connected to the inside of the housing cover (1). [6] Method according to claim 5, characterized by , that - that at least one cell module is inserted into the lower part of the housing and that at least one cell contacting module (2) is placed on the individual cells of the at least one cell module for electrical interconnection of the individual cells, - an adhesive (4) and / or a potting compound is applied or is applied over a surface area to the inside of the housing cover (1), - the lower part of the housing with the at least one cell module and the at least one attached cell contacting module (2) is rotated by 180° and arranged on the housing cover (1), so that the absorption structure (A) for the material-bonded connection of the at least one cell contacting module (2) with the housing cover (1) is immersed at least section by section in the adhesive (4) and / or the potting compound. [7] Method according to claim 5 or 6, characterized by, that the adhesive (4) and / or the potting compound is applied to the inside of the housing cover (1) up to a specified height. [8] Method according to any one of claims 5 to 7, characterized by , that to increase the contact area between the absorption structure (A) and the adhesive (4) and / or potting compound applied to the inside of the housing cover (1), the adhesive (4) and / or potting compound is applied to the inside of the housing cover (1) with a predetermined viscosity and / or temperature.

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