Method for producing a battery arrangement for a motor vehicle and battery arrangement for a motor vehicle

Abstract

The invention relates to a method for producing a battery arrangement (10) for a motor vehicle, wherein a housing component (14; 22, 22a) and a battery module (16) arranged relative to the housing component (14; 22, 22a) are provided. Furthermore, a bag (12) is arranged in an intermediate space (30) between the housing component (14; 22, 22a) and the battery module (16), said bag having a flexible sleeve (34) in which a filling substance (38) is located in a non-activated state (Z1) of the filling substance (38). After the bag (12) has been arranged in the intermediate space (30), the filling substance (38) is activated, causing the filling substance (38) to foam and the bag (12) to inflate.

Description

[0001] The invention relates to a method for producing a battery assembly for a motor vehicle, wherein a housing component and a battery module arranged relative to the housing component are provided. Furthermore, the invention also relates to a battery assembly for a motor vehicle.

[0002] Compared to vehicles powered by combustion engines, electric vehicles in particular struggle with range issues, as well as typically higher acquisition costs. Both of these factors are attributable to the vehicle's electrochemical energy storage system. The range of an electric vehicle is sometimes also influenced by its mass. Weight savings can be used to increase the range. Another aspect concerns the safety of such an energy storage system in the event of a crash. Ideally, the energy storage system should be as well protected as possible. To achieve this, measures are typically used, such as an additional profile frame with several absorbing chambers as part of a battery housing. However, such crash measures, in turn, increase the weight of the vehicle and also require a lot of installation space.

[0003] DE 10 2021 128 745 A1 describes a battery housing module for accommodating a battery unit. The battery housing module comprises a housing frame with a profile-shaped frame body, a stiffening body arranged in the interior, and a connecting means connected to the stiffening body to transmit forces to a vehicle structure supporting the battery housing module. An insulating material, for example, a cast material and / or powder material, can be filled into a cavity of the frame body.

[0004] DE 197 27 907 A1 describes a method for filling cavities in workpieces or semi-finished products, in which thermally foamable carbon powder is introduced into the cavity to be filled in a secure position and is heated together with the workpiece or semi-finished product in such a way that the carbon powder swells and fills the cavity as carbon foam.

[0005] The object of the present invention is to provide a method and a battery arrangement which make it possible to ensure the highest possible crash safety in the most weight-saving, simple and efficient manner possible.

[0006] This object is achieved by a method and a battery arrangement 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.

[0007] In a method according to the invention for producing a battery assembly for a motor vehicle, a housing component and a battery module arranged relative to the housing component are provided. Furthermore, a bag is arranged in at least one intermediate space between the housing component and the battery module. The bag has a flexible sleeve containing a filler substance in a non-activated state. After the bag is arranged in the at least one intermediate space, the filler substance is activated, causing the filler substance to foam and the bag to inflate.

[0008] The invention is based on several findings: Within a battery, there are often empty spaces and unfilled gaps.

[0009] For example, there is often a gap of several millimeters between battery modules and the tray, i.e. the lower section of the battery housing or its frame, due to component, process, and assembly tolerances. Such empty spaces and gaps act as potential acceleration paths in the event of a crash. In other words, other vehicle components that are pushed towards the battery modules by an accident-related force can accelerate unhindered in the area of such empty spaces or gaps. Accordingly, in the event of an intrusion in such an area, little to no energy is dissipated. Due to the nesting of the vehicle, which results from the connection of four-part components, the impact energy in the event of a crash is typically not dissipated evenly, but rather abruptly.For example, a first connection point tears open, then there is a short acceleration path before the crash object hits the next component, and so on. The method according to the invention now advantageously makes it possible to easily fill even the smallest gaps between such a battery module within a battery housing and a housing component, e.g., a frame side, with a crash structure, namely by means of the bag containing the filler substance that can be expanded and, in particular, cured upon activation. This bag containing the expandable filler substance advantageously makes it possible to easily insert the bag into the gap, since the filler substance is not yet expanded at the time of or during insertion.Due to its flexible outer shell, the bag can take up a smaller volume and can also easily adapt geometrically to a given gap geometry. Only after activation does the bag inflate due to the foaming of the filling substance. This allows the bag to advantageously fill the gap between the battery module and the housing component, either completely or at least partially. In particular, the inflated bag can press itself against both the battery module on the one hand and the housing component on the other, and thanks to its flexible outer shell, can at least partially conform. This advantageously reduces the amount of empty space within such a battery housing, which can act as acceleration paths in the event of a crash. The increased crash safety also makes it possible to design the battery housing itself or other crash structures in a simpler and therefore lighter design.The particularly great advantage, however, is that the foaming of the filler substance creates a porous structure that is extremely light, yet stable. The foamed and ultimately solidified filler substance thus creates a particularly weight-saving crash structure that can easily fill very small, already existing gaps. In the event of a crash, it is advantageously possible to use the bag with the now foamed filler substance to specifically counteract an external force, to dissipate energy and / or to specifically introduce and / or transmit this energy to stiffer areas of the battery or housing, or to distribute the impact energy particularly evenly.The bag containing the filler substance thus enables a particularly even distribution of forces in the ultimately foamed and, in particular, cured state of the filler substance, because the foaming of the filler substance allows the bag to conform essentially seamlessly and positively to the adjacent components. Even in the presence of screw connections and / or a point-based application of force, for example via the side skirts of a vehicle, a particularly even distribution of forces can be achieved thanks to the foamed filler substance. Point loads can thus be absorbed particularly well. Furthermore, the bag makes it possible to avoid having to fill existing gaps directly with a filler material, but instead to specifically retain the filler substance within the outer shell.Any potential sticking of the battery module or the gaps, as would be the case if a filling compound or similar were added, can thus be advantageously avoided. Furthermore, empty spaces or gaps do not have to be completely filled, but can be filled only partially in specific areas by specifically placing bags in such areas. Furthermore, the outer shell of the bag also advantageously makes it possible to specifically adjust the degree of foaming and / or the porosity of the ultimately foamed filler material or filling substance. Uncontrolled foaming can thus advantageously be prevented. This allows the desired properties of the ultimately foamed filler substance to be specifically provided.

[0010] The battery module can comprise one or more battery cells, for example lithium-ion cells. Furthermore, the battery arrangement produced by the method can have not only one such battery module, but also, for example, several battery modules. The housing component can be, for example, part of a battery housing. Such a battery housing can be designed to accommodate one or more battery modules. Receiving areas for respective battery modules can be spatially separated from one another by intermediate walls or partitions of the battery housing. The housing component can be, for example, a side wall, in particular as part of a frame, and / or partition of such a battery housing.

[0011] The battery assembly produced using the described method can be, for example, a high-voltage battery for a motor vehicle. In particular, it can be a traction battery for such a motor vehicle. The battery module can have a first module side facing a first housing side of the housing component. The intermediate space in which the bag is arranged can be delimited on both sides with respect to a specific direction by this first module side and the first housing side. The battery assembly can furthermore have a plurality of intermediate spaces, in each of which such a bag is arranged.

[0012] The flexible shell is preferably made of a polymeric material, in particular a plastic material. The flexible shell is designed to be flexible enough to change its geometric shape when the bag is inflated. The flexible shell does not necessarily have to be elastic and / or stretchable, although this is still possible. The flexible shell is designed in particular so that the shape and / or volume of the bag increases during inflation, whereby the surface area of the bag can optionally also increase or remain constant. An inelastic or nearly inelastic shell has the advantage that the foaming process of the filler substance can be defined and limited during foaming, making it easier to adjust a specific degree of foaming or a resulting pore density or density and other mechanical properties of the foamed and cured filler substance.

[0013] The filling substance is designed in such a way that it is unfoamed in its non-activated state and foams upon activation. The filling substance can therefore also have an activated state in which it foams. After activation, the filling substance can foam until it completely fills the bag's shell or the bag is maximally inflated, for example, until it has reached its maximum possible volume. This can be limited not only by the design of the bag itself, but also, for example, by the dimensions of the space in which the bag is arranged.

[0014] According to a further advantageous embodiment of the invention, the bag forms a positive fit to the housing component and the battery module upon inflation. In other words, the bag can be designed, i.e., at least its flexible shell can be designed to be so flexible that the bag can conform to the housing component on the one hand and the battery module on the other hand during or after inflation. This allows the bag to optimally fill the space and, when the filler substance has hardened, can ensure particularly even force distribution in the event of an external force being applied in an accident.

[0015] According to a further advantageous embodiment of the invention, the foamed filler substance hardens and forms a porous structural foam in the cured state. Thus, the filler substance is preferably not elastic and / or flexible in the cured state, but rather dimensionally stable, rigid, and / or inelastic. As a result, the foamed and cured filler substance can provide a particularly good crash structure for protecting the battery module.

[0016] According to a further advantageous embodiment of the invention, the filler substance is activated by contact with an activator substance, in particular, the activator substance being injected through the envelope of the bag. This allows the filler substance to be easily activated at any desired time. To inject the activator substance, which can be in liquid or viscous form, for example, through the envelope, a thin injection cannula or similar device can be used. This creates only a slight, extremely small opening in the envelope, through which the foamed filler substance cannot, or cannot significantly, escape.

[0017] The filler substance can be phenol-based, for example, to be activated by such an activator substance. Additionally or alternatively, the filler substance can also comprise polyester resins and / or aminoplasts. Water, for example, can be used as the activator substance. In particular, the filler substance can comprise Bakelite, a thermosetting plastic based on phenolic resin.

[0018] Activating the filler substance using an activator is particularly gentle on the battery module, as no heating or similar processes are required. Nevertheless, thermal activation is also conceivable.

[0019] Accordingly, a further advantageous embodiment of the invention provides for the filling substance to be thermally activated. For this purpose, the filling substance or the bag containing the filling substance can be heated. Filling substances that foam upon heating are also known from the prior art, such as carbon powder, which swells upon heating and forms a carbon foam.

[0020] According to a further advantageous embodiment of the invention, the filler substance comprises a powder, in particular a thermosetting powder, i.e., a powder made of thermosetting plastic. A thermosetting powder can advantageously provide, after foaming and curing, a porous and rigid plastic foam with very good crash properties. Providing it as a powder also makes it possible to impart further advantageous properties to the filler substance, for example, by mixing it with other powdered fillers.

[0021] It is therefore a further very advantageous embodiment of the invention if the filler substance comprises a powdery first component, e.g. a two-component powder. The first component can be designed to foam upon activation. Furthermore, the filler substance can additionally comprise a second component different from the first component, in particular a powdery and / or granular filler. The first powder component, ie the powdery first component, can therefore be provided to carry out the foaming reaction after activation and thereby form the plastic foam. In particular, the first powder component itself can again be designed as a multi-component powder, e.g. a 2K powder.The at least one second component may be intended to implement further advantageous properties, for example fire protection properties, flame retardant properties and / or additional stiffening properties.

[0022] According to a further advantageous embodiment of the invention, the second component represents or comprises at least one of the following fillers: expanded glass and / or hollow glass spheres, ceramic particles and / or hollow ceramic spheres, clay, in particular expanded clay and / or hollow clay spheres, metal, in particular metallic hollow spheres, foamed plastic beads or hollow spheres made of plastic, in particular high-temperature plastics, fibers, in particular hollow fibers, and / or spacer fabric. Precisely by forming hollow spheres and / or hollow fibers, the fillers mentioned can provide special properties of the foamed plastic in a very weight-saving manner. In particular, the foamed and cured filler substance can thereby be flame-retardant and highly temperature-resistant.In particular, reinforcing fibers such as aramid fibers and / or glass fibers and / or carbon fibers or similar can be used as fibers. This further stiffens the porous structure formed. Furthermore, other stiffening components can also be incorporated into the bag, for example, nonwovens or woven fabrics, in particular spacer fabrics, or laid scrims made of reinforcing fibers and / or organic sheets or similar. Such stiffening elements can additionally or alternatively be arranged outside the bag in the intermediate space, for example, before the bag is inflated. This also allows such stiffening elements to be additionally introduced into the intermediate space and integrated into the crash structure.

[0023] The material contained in the bag, i.e., the filler substance, can be a mixture of a powder and a lightweight filler, such as expanded glass, ceramic, hollow spheres, clay (expanded or in the form of hollow spheres), metallic hollow spheres, foamed beads, or hollow spheres made of high-temperature plastics or fibers, particularly hollow fibers, spacer fabrics, and so on. Such a bag integrated into the space can significantly improve the transfer of structural forces, provide significantly better insulation, for example, in the event of a thermal runaway of a battery cell in the battery module, close gaps caused by manufacturing tolerances or other factors, absorb crash energy in the event of a crash, and also absorb other forces, such as swelling forces when the battery cells swell, and so on.The integration of fillers in the form of hollow spheres or hollow fibers also offers significant potential for lightweight construction. This ultimately makes the bag a multifunctional component that, depending on the material combination, can be easily and efficiently adapted to a wide range of tasks.

[0024] There are also various options for producing the sleeve. For example, the sleeve can be made of a thermoplastic material and, in particular, be blow-molded. Additionally or alternatively, the sleeve can also be formed from laminated films, in particular by welding, and / or be reinforced with a nonwoven, and / or be designed as a thin-walled injection-molded body comprising, for example, polyolefins and / or thermoplastic elastomers and / or polyamide, and / or the sleeve can also comprise fillers. These can be embedded in a basic substance of the sleeve, which can then also be referred to as the matrix material of the sleeve. In this way, the sleeve itself can also be provided with the desired properties.

[0025] To seal cavities in the battery area in the event of a crash, a thin membrane, for example, can be filled with powder, preferably made of two components, and placed in the cavity. After the powder is activated, the housing, i.e., the shell, is pressed against the structural environment by internal pressure. Upon activation via temperature and / or an activator, which can be injected through the membrane, the granules or powder foam up and fill the cavity in the event of a crash, forming a structural foam that protects the battery module in the event of a crash and improves power transmission.

[0026] Furthermore, the invention also relates to a battery assembly for a motor vehicle, which was manufactured using a method according to the invention or one of its embodiments. The battery assembly can, in particular, be designed as already described in connection with the method according to the invention and its embodiments.

[0027] The invention also includes further developments of the battery arrangement according to the invention that have features already described in connection with the further developments of the method according to the invention. For this reason, the corresponding further developments of the battery arrangement according to the invention are not described again here.

[0028] Furthermore, the invention also relates to a motor vehicle with a battery arrangement according to the invention.

[0029] 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.

[0030] 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.

[0031] Exemplary embodiments of the invention are described below. Shown are: Fig. 1 a schematic and perspective view of a battery arrangement before inserting a bag between the battery module and a housing component according to an embodiment of the invention; Fig. 2 a schematic cross-sectional view of a battery arrangement with a bag arranged between the battery module and the housing component in a not yet inflated state according to an embodiment of the invention; and Fig. 3 a schematic representation of the battery arrangement from Fig. 2 in the inflated state of the bag according to an embodiment of the invention.

[0032] 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.

[0033] In the figures, the same reference symbols designate elements with the same function.

[0034] Fig. 1 shows a schematic representation of a battery arrangement 10 before the insertion of a bag 12 (cf. Fig. 2) according to an embodiment of the invention. The battery arrangement 10 comprises a battery housing 14, of which only a part is shown, and at least one battery module 16 accommodated in the battery housing 14. The battery module 16 can in turn comprise a plurality of battery cells. The battery housing 14 can also be subdivided into a plurality of receiving areas 18 for accommodating a plurality of battery modules 16, for example by corresponding partition walls 20. In addition to such partition walls 20, the battery housing 14 can also comprise side walls 22, which form a surrounding frame, for example, as well as a housing base 24 and / or a housing cover not shown here. A thermal interface material 25 can be located between the housing base 24 and the battery module 16 (cf. Fig. 2 and Fig. 3) in order to thermally connect the battery module 16 to the base 24, which can simultaneously be designed as a cooling device.

[0035] The battery module 16 can be fastened to the housing 14, for example via point connection areas 26, for example screw connections. When inserting such a battery module 16 into the housing 14, a gripping device can be used, for example, which engages the side of the battery module 16. This inevitably results in gaps 30 between the battery module 16 and the housing parts of the battery housing 14, since these are provided, for example, so that such a gripping device has sufficient space to insert the battery module 16 into the housing 14. However, such cavities, such as the gap 30 between a first module side 16a and the side wall 22a of the housing 14, have a disadvantageous effect in the event of a crash. As an example, such a crash load acting on the battery arrangement 10 against the x-direction is illustrated here by the arrow 32.The cavity 30 between the battery module 16 and the side wall 22a, on which such a crash load 32 acts, serves as a free acceleration path for other components, such as the side wall 22a itself.

[0036] In order to adequately protect such battery modules, conventional batteries require a robust design for the side walls or frame of such a battery housing, for example, with multiple walls and integrated chambers or similar. This requires a considerable amount of space and adds weight. Furthermore, such cavities remain unused in conventional batteries.

[0037] The invention or its embodiments now advantageously make it possible to ensure particularly high crash safety of such a battery arrangement 10, in a particularly efficient and weight-saving manner, in particular by allowing such cavities or intermediate spaces 30 to be filled as required, specifically with a crash structure that can be provided by the bag 12 described below.

[0038] Fig. 2 shows a schematic representation of a battery arrangement 10 according to an embodiment of the invention. The battery arrangement 10 can be Fig. 1. In the present case, the battery arrangement 10 additionally comprises the aforementioned bag 12. This has a flexible shell 34 that completely encloses an interior 36 of the bag 12. The geometry of this shell 34 can, in principle, be of any desired shape. A filler substance 38 is arranged in the interior 36 of the shell 34. This comprises, in particular, a multi-component powder 38a, for example, a 2K powder. The filler substance 38 also comprises a second component 38b. The first and / or second components 38a, 38b can each further comprise several individual components. The second component 38b can, in particular, be one or more fillers 40, for example, expanded glass, hollow ceramic spheres, hollow metal spheres, hollow plastic spheres made of high-temperature plastics, hollow fibers, and so on.In the interior 36, further structural components and / or stiffening components can also be integrated, for example spacer fabrics, nonwovens, scrims, knitted fabrics, in particular with reinforcing fibers, organic sheets or the like.

[0039] The first powder component 38a is, in particular, a substance 38a that can be expanded upon activation, for example, a phenol-based powder 38a, such as Bakelite. In the present example, the filler substance 38 is located inside 36 of the flexible casing 34 in a not yet activated state Z1. In this state Z1, the filler substance 38 is therefore still in powder form. The bag 12 is correspondingly flexible and can thus be easily introduced into the intermediate space 30 between the battery module 16 and the side wall 22a or any other housing component of the housing 14. The bag 12 is accordingly in a not yet inflated state Z1'. In this state Z1', the bag 12 therefore does not yet completely fill the intermediate space 30, at least with respect to the x-direction shown.

[0040] It is now advantageously possible to activate the filling substance 38 and thereby cause it to foam. Activation can occur thermally or by means of an activator substance 42, as shown in the present example, which can be injected, for example, through the shell 34 using an injection device 44 to inject the filling substance 38. Upon contact with this activator substance 42, the filling substance 38 foams, causing the bag 12 and in particular the shell 34 to inflate and thereby, in particular, filling the intermediate space 30 with respect to at least the x-direction shown. The extent to which the intermediate space 30 is filled with the substance 38 in the y-direction and / or z-direction can advantageously be determined by the dimensions of the shell 34.

[0041] Fig. 3 shows a schematic representation of the battery arrangement 10 from Fig. 2 in a now foamed state Z2 of the filling substance 38 and in a correspondingly inflated state Z2' of the bag 12. After foaming of the filling substance 38, it also hardens, whereby a porous and rigid crash structure 46 in the form of a porous structural foam 46 is provided in the intermediate space 40. The pores of this crash structure 46 are designated in particular by 48. In addition, the crash structure 46 further comprises the integrated fillers 40 provided by the second component 38b.

[0042] During the expansion of the filling substance 38 and before it hardens, the bag 12 can conform to the battery module 16 and the housing wall 22a and adapt geometrically due to the flexibility of the casing 34. The casing 34 can in principle be formed in any desired geometric shape. The casing 34 can, for example, be provided as a thin-walled injection-molded component, a blow-molded part, or in the form of laminated films or the like. The desired degree of foaming of the substance 38 can be influenced by the internal volume of the casing 34, its elasticity or inelasticity. This provides particularly good adaptation options. In the hardened state, i.e. when the crash structure 46 is provided by the substance 38, the intermediate space 30 is as shown in Fig.3, advantageously filled with this crash structure 46 or the bag 12. This advantageously counteracts an acting crash load 32, and crash energy can be specifically dissipated and / or redirected and / or distributed. Housing components of the battery housing 14 can be designed to be simpler and lighter in weight, since this crash component 46 can significantly increase the protective function for the battery module 16. Furthermore, the fillers 40 can implement many advantageous additional properties of the crash component 46, for example, fire-retardant and / or flame-retardant properties. This also increases the protection for the battery module 16 in the event of a thermal runaway of a cell.In particular, such a bag 12 or several such bags 12 can be placed anywhere inside or outside the battery assembly 10, and in particular also in cavities 30 between two adjacently arranged battery modules 16, so that a thermal barrier between the battery modules 16 can be provided by this bag 12. The sleeve 34 can also remain in the battery assembly 10 or it can also be designed so that it dissolves.

[0043] Overall, the examples show how the invention can be used to provide a crash component in the battery system of electric vehicles. A solution is proposed to increase functionality and productivity, particularly concerning the cell partition and / or side wall, which were previously made of stainless steel. The integral construction reduces the mass of the component, which has a positive effect on the vehicle's range, particularly since the component can be installed in large quantities in the battery. The invention makes it possible to reduce the number of crash measures that are normally implemented using an additional profile frame with several absorbing chambers, by using aA thermosetting powder-filled element, namely the bag, with a flexible housing, i.e., a flexible shell, is inserted into cavities required, for example, for assembly. These cavities can be filled by activating the powder. The powder reacts to form foam and presses the housing, i.e., the flexible bag shell, against the cavity walls, thus filling the cavity. Organic sheets or fiber-reinforced components, such as nonwovens and / or scrims, can also be used to reinforce the housing as part of the battery's load path technology in order to absorb the mechanical forces in the event of a crash.The housing can be blow-molded from thermoplastic material, welded from laminated films, or reinforced with nonwoven fabric. The housing can be injection-molded with thin walls, preferably from polyolefins, thermoplastic elastomers, polyamide, and so on. The housing can also be filled with fillers. This process allows for relatively inexpensive reinforcement of cavities, protection of the cell module, and optimization of the load path. The powder can be flame-retardant, providing additional fire protection. In summary, the advantages include weight reduction, fire protection, space savings, the absorption of forces and / or volume, good compressibility, cost savings, and a product design that is suitable for production. 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 2021 128 745 A1

[0003] DE 197 27 907 A1

[0004]

Claims

[1] Method for producing a battery arrangement (10) for a motor vehicle, - wherein a housing component (14; 22, 22a) and a battery module (16) arranged relative to the housing component (14; 22, 22a) are provided; characterized by , that - a bag (12) is arranged in at least one intermediate space (30) between the housing component (14; 22, 22a) and the battery module (16), said bag having a flexible sheath (34) in which a filling substance (38) is located in a non-activated state (Z1) of the filling substance (38), - after the bag (12) has been arranged in at least one intermediate space (30), the filling substance (38) is activated, whereby the filling substance (38) foams and the bag (12) inflates. [2] Method according to claim 1, characterized by that the bag (12) is shaped positively to the housing component (14; 22, 22a) and the battery module (16) by inflation. [3] Method according to one of the preceding claims, characterized by that the foamed filling substance (38) hardens and forms a porous structural foam (46) in the hardened state. [4] Method according to one of the preceding claims, characterized by that the filling substance (38) is activated by contact with an activator substance (42), in particular wherein the activator substance (42) is injected through the shell (34). [5] Method according to one of the preceding claims, characterized by that the filling substance (38) is thermally activated. [6] Method according to one of the preceding claims, characterized by that the filling substance (38) comprises a powder (38a, 38b), in particular a thermosetting powder (38a). [7] Method according to one of the preceding claims, characterized bythat the filling substance (38) comprises a powdery first component (38a), e.g. a two-component powder (38a), which is designed to foam upon activation, and a second component (38b) different from the first component (38a), in particular a powdery and / or granular filler (38b). [8] Method according to one of the preceding claims, characterized by that the second component (38b) represents or comprises at least one of the following fillers (40): - expanded glass and / or hollow glass spheres, - ceramic particles and / or hollow ceramic spheres, - Clay, in particular expanded clay and / or hollow clay spheres, - Metal, especially metallic hollow spheres, - foamed plastic beads or hollow spheres made of plastic, in particular high-temperature plastics, - fibers, especially hollow fibers, - Spacer fabric. [9] Method according to one of the preceding claims, characterized by that the shell (34) - is made of a thermoplastic material; and / or - is designed as a blow mold; and / or - is made of laminated films; and / or - is reinforced with a fleece; and / or - as a thin-walled injection-molded body comprising polyolefins and / or thermoplastic elastomers and / or polyamide; and / or - comprises fillers embedded in a matrix material of the shell (34). [10] Battery arrangement (10) for a motor vehicle, which was manufactured by means of a method according to one of the preceding claims.

Images