Electrical energy storage and manufacturing process

Abstract

The invention relates to an electrical energy storage device (1) with a housing (4) in which a plurality of electrically interconnected individual cells (3) are arranged, wherein adjacent individual cells (3) have a predetermined distance (a) from each other. According to the invention, each individual cell (3) is arranged sectionally in a charge carrier (6) within the housing (4), the respective charge carrier (6) is configured such that the predetermined distance (a) between adjacent individual cells (3) is set within the housing (4), the respective charge carrier (6) encompasses the individual cell (3) such that a predetermined further distance is set to both a housing base and a housing cover closing the housing (4), and at least one area between the charge carrier (6) and the housing base is filled with a potting compound (5). The invention further relates to a method for manufacturing such an energy storage device (1).

Description

[0001] The invention relates to an electrical energy storage device with a housing in which a plurality of electrically interconnected individual cells are arranged, wherein adjacent individual cells have a predetermined distance from one another. The invention further relates to a method for manufacturing such an electrical energy storage device.

[0002] From US patent 2014 / 0287297 A1, a battery cell, a battery, and a motor vehicle are known. The battery cell housing has a sandwich-like structure comprising an intermediate layer and two outer layers.

[0003] The invention is based on the objective of providing an electrical energy storage device and a method for manufacturing an electrical energy storage device.

[0004] 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.

[0005] Advantageous embodiments of the invention are the subject of the dependent claims.

[0006] An electrical energy storage device comprises a housing in which a plurality of electrically interconnected individual cells are arranged, wherein adjacent individual cells have a predetermined distance from one another. According to the invention, it is provided that each individual cell is arranged sectionally in a charge carrier within the housing, the respective charge carrier is configured such that the predetermined distance between adjacent individual cells is set within the housing, the respective charge carrier encompasses the individual cell such that a predetermined further distance is set to both a housing base and a housing cover closing the housing, and at least one area between the charge carrier and the housing base is filled with a thermally conductive potting compound.

[0007] Because each individual cell remains in its charge carrier and is arranged with the charge carrier in the housing, it is not necessary to dispose of the charge carrier, thus reducing and even eliminating waste. Potentially costly return transport of the charge carriers is also unnecessary.

[0008] For example, the charge carrier can be made from recycled material, thus contributing to environmental protection in addition to waste reduction. In particular, the charge carrier can be made from a comparatively lightweight material, thereby reducing the overall weight of the electrical energy storage device.

[0009] By integrating the charge carriers into the housing of the electrical energy storage device, costs and the contribution to environmental protection during the manufacture of the electrical energy storage device can be positively influenced.

[0010] Exemplary embodiments of the invention are explained in more detail below with reference to drawings.

[0011] This shows: Fig. 1. Schematic perspective view of manufacturing steps for the production of an electrical energy storage device using a packaging material, Fig. 2. Schematic perspective view of manufacturing steps for the production of an electrical energy storage device using single charge carriers, Fig. 3 schematically a cross-sectional view of a section of a cell module with charge carriers, Fig. 4 schematically a perspective view of manufacturing steps for the production of an electrical energy storage device with prismatic individual cells and charge carrier units, Fig. 5 schematically a top view of a section of positively interlocking adjacent load carriers or load carrier units and Fig. Figure 6 schematically shows a perspective view of the manufacturing steps for producing an electrical energy storage device with cylindrical cells and charge carrier units.

[0012] Corresponding parts are marked with the same reference symbols in all figures.

[0013] Fig. Figure 1 shows a perspective view of the manufacturing steps for producing an exemplary and highly simplified example in the Fig. 4 and Fig. Figure 6 shows an electrical energy storage device 1 using a packaging material 2, for example in the form of so-called polystyrene chips. Alternatively or additionally, the packaging material 2 can also be plastic and / or foam and / or a composite material and / or wood.

[0014] An electrical energy storage device 1 comprises a plurality of electrically interconnected individual cells 3, which according to Fig. 1 are formed as round cells and accordingly have a circular cylindrical cell body. The individual cells 3 are in a structure within the Fig. 4 and Fig. The housings 4 shown in 6 are arranged and electrically interconnected, with adjacent individual cells 3 being positioned at a predetermined distance a from each other.

[0015] The electrical energy storage device 1 is in particular a traction battery for an electric vehicle, a hybrid vehicle or a vehicle powered by fuel cells and is usually located in the area of ​​a vehicle floor.

[0016] Typically, the individual cells 3 are removed from packaging material 2, such as polystyrene chips, and / or from a transport vehicle or disposable charge carrier at their installation location, particularly at the point where they are inserted into the housing 4. The individual cells 3 are then either combined into cell modules or inserted individually into the housing 4. This necessitates several relatively complex handling steps, potentially resulting in a higher volume of equipment. Furthermore, the packaging material 2 and / or the transport vehicle must be disposed of or returned to their point of origin. To avoid or at least significantly reduce such effort, the electrical energy storage device 1 is manufactured as described below and is designed accordingly.

[0017] As in Fig. As shown in Figure 1, the individual cells 3, which are designed as round cells, are transported to the installation site using the packaging material 2. Depending on its shape, the packaging material 2 has dimensions that are smaller than the predetermined distance a to be set between adjacent individual cells 3, so that the packaging material 2 can be filled into the spaces formed by the spacing.

[0018] In particular, the packaging material 2 is filled and compressed into the spaces between adjacent individual cells 3 in such a way that the individual cells 3, together with the packaging material 2, can be inserted into the housing 4. An overall structure, for example, a cell module thus formed, is created using a curing potting compound 5, such as adhesive and / or foam. For example, the potting compound 5 is thermally conductive and electrically insulating. The packaging material 2 acts as a displacement body, reducing the amount of potting compound 5 required. Therefore, by using the packaging material 2 and reducing the amount of potting compound 5, the electrical energy storage device 1 can be manufactured more cost-effectively, in a more environmentally friendly manner, and with reduced weight.

[0019] In Fig. Figure 2 shows a perspective view of manufacturing steps for the production of an electrical energy storage device 1 using individual charge carriers 6.

[0020] The individual cells 3 are transported to the installation location by means of the individually formed charge carriers 6 and inserted into the housing 4 of the electrical energy storage device 1. Each charge carrier 6 has a cube shape, with a circular recess A, corresponding to a cross-section of the circular cylindrical cell housing, for receiving an individual cell 3.

[0021] The charge carrier 6 has such dimensions and is arranged in relation to the individual cell 3 such that the individual cell 3 projects out of the recess A of the charge carrier 6 by a predetermined amount on opposite sides. In particular, the charge carrier 6 is positioned centrally on the individual cell 3 with respect to a longitudinal axis of the individual cell 3 and is positively locked to it.

[0022] Furthermore, each charge carrier 6 is configured such that the predetermined distance a to the respective adjacent single cell 3 containing charge carrier 6 is set. Thus, the smallest distance between an edge region of the recess A and an edge of the cube-shaped charge carrier 6 is half the predetermined distance a, so that by means of two adjacent charge carriers 6, the predetermined distance a between two adjacent single cells 3 is set.

[0023] Fig. Figure 3 shows, in an exemplary and highly simplified manner, a cross-sectional view of a section of a cell module formed by several electrically connected individual cells 3, wherein each of the individual cells 3 is located in a recess A of a charge carrier 6 or in a recess A of a Fig. 4 or Fig. The charge carrier unit 7 shown in 6 is arranged or received in a form-fitting manner. The individual cells 3 are arranged according to the exemplary embodiment in Fig. 3 electrically connected in series by means of cell connectors.

[0024] It is shown that the charge carrier 6 or the charge carrier unit 7 is positioned centrally with respect to a longitudinal axis of the individual cells 3, such that a further distance is set between the charge carrier 6 or the charge carrier unit 7 and a housing base of the housing 4 of the electrical energy storage device 1. A further distance is also set between the charge carrier 6 or charge carrier unit 7 and the top surface of the cell housing of the respective individual cell 3 of the cell module.

[0025] In Fig. Figure 4 shows a perspective view of the manufacturing steps for producing an electrical energy storage device 1 with individual cells 3 with a prismatic cell housing and charge carrier units 7. For example, the charge carrier unit 7 is formed from a predetermined number of charge carriers 6.

[0026] According to Fig. 4. A charge carrier unit 7 is used, which has a number of recesses A, wherein a shape of the respective recess A corresponds to a cross-section of the prismatically shaped individual cell 3. The individual cells 3 are arranged in the recesses A of the charge carrier unit 7, wherein the individual cells 3 received in the recesses A have the specified distance a from each other.

[0027] Such a charge carrier unit 7 is made of a plastic and / or foam and / or composite material and / or wood and / or similar material, and the charge carrier unit 7 is arranged centrally with respect to a vertical axis of the individual cells 3, so that the further distance between charge carrier unit 7 and housing base is set.

[0028] To manufacture the electrical energy storage device 1, the respective charge carrier unit 7 with the electrically interconnected individual cells 3 is arranged in the housing 4, wherein, for example, four such charge carrier units 7 equipped with individual cells 3 can be arranged in the housing 4, as shown in Fig. 4 is shown.

[0029] Fig. Figure 5 shows a top view of a section of positively interlocking adjacent charge carriers 6 or charge carrier units 7.

[0030] Both the charge carrier 6 and the charge carrier unit 7 have corresponding features F on sides facing an adjacent charge carrier 6 or an adjacent charge carrier unit 7.

[0031] According to the in Fig. In the embodiment shown in Figure 5, the features F are designed as toothed sections that interlock to form a positive connection between adjacent charge carriers 6 and / or charge carrier units 7. Thus, the adjacent charge carriers 6 and / or charge carrier units 7 are positioned relative to each other and arranged in a positive-locking manner.

[0032] Fig.Figure 6 shows a perspective view of the manufacturing steps for producing an electrical energy storage device 1 with charge carrier units 7, which are designed for individual cells 3 configured as cylindrical cells. The charge carrier units 7 have a predetermined number of recesses A for receiving individual cells 3, the shape of which corresponds to a cross-section of the individual cells 3. Adjacent recesses A are formed at a predetermined distance a from each other, so that the individual cells 3 inserted into the recesses A have the predetermined distance a from each other. Reference symbol list 1 electrical energy storage device 2 Packaging material 3 single cells 4 cases 5 Potting compound 6 load carriers 7 load carrier unit 8 cell connectors A recess F shape a predetermined distance 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] US 2014 / 0287297 A1

[0002]

Claims

[1] Electrical energy storage device (1) with a housing (4) in which a plurality of electrically interconnected individual cells (3) are arranged, wherein adjacent individual cells (3) have a predetermined distance (a) from each other, characterized by , that - each individual cell (3) is arranged section by section in a charge carrier (6) in the housing (4), - the respective charge carrier (6) is designed such that the specified distance (a) between adjacent individual cells (3) within the housing (4) is set, - the respective charge carrier (6) encompasses the individual cell (3) in such a way that a predetermined further distance is set to both a housing base and a housing cover closing the housing (4), and - at least one area between the charge carrier (6) and the housing base is filled with a potting compound (5). [2] Electrical energy storage device (1) according to claim 1, characterized by, that the load carrier (6) is made of plastic and / or of a solid foam and / or of a composite material and / or of wood and / or of polystyrene. [3] Electrical energy storage device (1) according to claim 1 or 2, characterized by , that a plurality of charge carriers (6) is configured as a charge carrier unit (7) to accommodate a predetermined number of individual cells (3). [4] Electrical energy storage device (1) according to any one of the preceding claims, characterized by, that the respective load carrier (6) or load carrier units (7) comprising a plurality of load carriers (6) has, for positive locking connection with an adjacent load carrier (6) and / or an adjacent load carrier unit (7), projections (F) on a respective side facing an adjacent load carrier (6) and / or a load carrier unit (7) which correspond to projections (F) formed on a side of the adjacent load carrier (6) and / or the load carrier unit (7). [5] Method for manufacturing an electrical energy storage device (1) which is designed according to one of the preceding claims, characterized by , that - the respective individual cell (3) is arranged in a load carrier (6) and transported to an installation location of the individual cell (3), - the respective individual cell (3) remains in the charge carrier (6) and is arranged with the charge carrier (6) in the housing (4) of the electrical energy storage device (1), wherein - the specified distance (a) between adjacent individual cells (3) is set by means of adjacent charge carriers (6).

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