Method for leak testing of a high-voltage battery and use of a plant for the production of high-voltage batteries with a test station

Abstract

Method for leak testing of a high-voltage battery, characterized by the following features: A sealing lip (10) is attached to a component (11) of the high-voltage battery to be tested, The component (11) is inspected while the sealing lip (10) conforms to it, The sealing lip (10) is removed from the component (11) after inspection. The tested component (11) is replaced by a sacrificial component (12) of identical shape with an adhesive surface (14) facing the sealing lip (10), The sacrificial component (12) is checked so that dirt (13) adhering to the sealing lip (10) touches the adhesive surface (14) and The sealing lip (10) is removed from the sacrificial component (12) after contact with it and is thus freed from the dirt (13) which now adheres to the adhesive surface (14).

Description

[0001] The present invention relates to a method for leak testing a high-voltage battery. The present invention further relates to the use of a system for producing high-voltage batteries with a testing station. State of the art

[0002] Ensuring leak tightness is crucial in the production of high-voltage batteries, which play a key role in electromobility. These batteries, used as energy storage devices in electric vehicles, contain sensitive battery cells whose performance and safety can be compromised by the ingress of moisture or other foreign substances. To ensure the safety and functionality of these batteries, it is essential that they undergo a comprehensive leak test after assembly.

[0003] Common methods for testing the leak tightness of high-voltage batteries and their components are based on the use of test stations that test the component under test for leaks. These test stations are typically designed to have a mating contour to the surface of the test object, enabling the most seamless contact possible and thus effective testing. The sealing lips used for leak testing are often made of soft plastic materials such as rubber. These materials are chosen to achieve a high degree of adaptability to the contours of the components under test, thereby achieving optimal sealing and thus precise leak measurement.

[0004] CN 2 20 490 328 U and CN 2 16 978 273 U each disclose a test station with a sealing lip whose contour corresponds to the component of a high-voltage battery to be tested. The sealing lip is applied to the component, and the component is tested while the sealing lip adheres to it. The sealing lip is removed after the component has been tested.

[0005] From CN 2 18 546 030 U a test station for carrying out a leak test of a component of a high-voltage battery is known, which additionally has a cleaning device for cleaning the component of dirt.

[0006] CN 208902343 U, CN 210346998 U, CN 210741755 U and KR 101843708 B1 disclose various further embodiments of a leak testing device for a battery.

[0007] From CN 113546886 A a leak testing device for a hub bearing unit is known. Disclosure of the invention

[0008] A major problem with existing methods for leak testing high-voltage batteries (HVBs) is the contamination of the sealing lips used for the test. These sealing lips must ensure clean, contamination-free contact with the HVB component being tested to achieve valid results. However, any contamination on the sealing lips can produce false-negative results, in which intact components are incorrectly classified as leaking. This leads to unnecessary scrap rates, which in turn increases production costs and reduces efficiency.

[0009] The problem is exacerbated by the fact that cleaning the sealing lips in a continuous production process is not easy to accomplish. Manual cleaning methods are labor-intensive and often cannot be practically integrated into the production flow due to the high cadence and automation of production processes. Furthermore, manual cleaning requires regular interruptions of the production process, leading to a reduction in overall equipment effectiveness (OEE). The time and effort required for such cleaning are inconsistent with the goals of lean manufacturing and minimizing downtime.

[0010] Another challenge is ensuring consistent and effective sealing lip cleaning. Traditional cleaning methods can be inadequate when it comes to removing all types of contaminants, especially when these contaminants are embedded in the microstructures of the sealing lips. The need to ensure consistently high quality seal testing therefore requires a cleaning method that is both thorough and easily integrated into the ongoing production process.

[0011] The described problem is solved by a method for leak testing a high-voltage battery and by using a system for producing high-voltage batteries with a testing station according to the independent claims.

[0012] This approach offers the advantage that the sacrificial components, which are identical in shape and equipped with an adhesive surface, allow the sealing lips to be cleaned during the ongoing production process. These sacrificial components pass through the inspection stations, absorbing contaminants from the sealing lips. The adhesive surfaces of the sacrificial components act as dirt carriers, removing dust, fibers, and other particles from the sealing lips.

[0013] This method of cleaning using sacrificial components has the advantage of being implemented without interrupting the production process. Because the sacrificial components are seamlessly integrated into the production flow, overall production efficiency is not compromised. This avoids downtime that would be unavoidable with manual cleaning methods. Furthermore, this continuous and automated cleaning increases the consistency and reliability of leak testing, as it can significantly reduce the likelihood of contamination and the resulting measurement errors.

[0014] Another key advantage of this solution is the reusability of the sacrificial components. After the adhesive surfaces have absorbed the dirt, the sacrificial components are removed from the process, the used adhesive strips are removed, and replaced with new ones. This process can be repeated, reducing material consumption and thus saving costs.

[0015] Compared to the state of the art, this solution also stands out for its flexibility. Because the sacrificial components are adapted to the contours of the components to be tested, the process can be used for a wide variety of different components without requiring individual adjustments to the test stations. This makes it a universally applicable solution that can be adapted to different production conditions and component variants without significant additional effort.

[0016] Further advantageous embodiments of the invention are specified in the dependent patent claims. Short description of the drawings Fig. 1 shows how a sealing lip is applied to a component of the high-voltage battery to be tested. Fig. 2 shows how the component is tested while the sealing lip is pressed against it, Fig. 3 shows how the sealing lip is removed from the component after testing. Fig. Figure 4 shows how the tested component is replaced by a sacrificial component of the same shape with an adhesive surface facing the sealing lip. Fig. 5 shows how the sacrificial component is tested so that dirt adhering to the sealing lip touches the adhesive surface. Fig. 6 shows how the sealing lip is removed from the sacrificial component after it has touched it and thus freed from the dirt that now adheres to the adhesive surface. Embodiments of the invention

[0017] Fig. Figure 1 illustrates the first step of the process, in which a sealing lip (10) is applied to a component (11) of the high-voltage battery to be tested. The sealing lip (10) is designed to largely adapt to the contours of the component (11).

[0018] The following step is Fig. 2 illustrates the test of the component (11). During the test procedure, the sealing lip (10) fits tightly against the component (11) to create a sealed space and assess the tightness of the component (11).

[0019] Fig. Figure 3 shows the process by which the sealing lip (10) is removed from the component (11) after the test has been completed. Dirt particles adhere to the sealing lip (10).

[0020] In Fig. Figure 4 shows how the previously tested component (11) is replaced by a sacrificial component (12) of the same shape, the upper side of which, as shown, has a continuous adhesive surface (14). The adhesive surface (14) is thus positioned opposite the sealing lip (10), which is essential for the cleaning process.

[0021] The cleaning process itself is carried out in Fig. 5. Here, the sacrificial component (12) is introduced into the test station and treated analogously to the regular test procedure. This results in contact between the sealing lip (10) and the adhesive surface (14). The dirt (13) adhering to the sealing lip (10) is absorbed by the adhesive surface (14), resulting in a cleaning effect.

[0022] Finally, Fig.6, how the sealing lip (10) is released from the sacrificial component (12) after the sacrificial component (12) has served its purpose. The dirt (13) remains adhered to the adhesive surface (14) of the sacrificial component (12), effectively cleaning the sealing lip (10) of contaminants. After this process, the sacrificial component (12) can be removed from the process, freed from the contaminated adhesive surface (14), and provided with a new adhesive surface (14) for reuse in the cycle.

[0023] The specific design of the sealing lip (10) can be made of a soft material such as a polymer or rubber, which ensures high flexibility and adaptability to different contours of the component (11). To achieve optimal sealing, the sealing lip (10) can also have a concave design.

[0024] The test station, which supports these process steps, is designed to include all the necessary equipment to carry out the process as described. This test station is an integral component of a high-voltage battery production plant and allows the components (11) to be cleaned after the introduction of dirt (13) by the sacrificial component (12). The dirt is transported out of the plant by the adhesive pads, which form the adhesive surface (14). List of reference symbols 10 Sealing lip 11 Component 12 sacrificial component 13 Dirt 14 adhesive strips

Claims

[1] Method for leak testing of a high-voltage battery, characterized by following features: - a sealing lip (10) is applied to a component (11) of the high-voltage battery to be tested, - the component (11) is tested while the sealing lip (10) is pressed against it, - the sealing lip (10) is removed from the component (11) after testing it, - the tested component (11) is replaced by a sacrificial component (12) of the same shape with an adhesive surface (14) facing the sealing lip (10), - the sacrificial component (12) is tested so that dirt (13) adhering to the sealing lip (10) touches the adhesive surface (14) and - the sealing lip (10) is removed from the sacrificial component (12) after it has touched it and is thus freed from the dirt (13) which now adheres to the adhesive surface (14). [2] Method according to claim 1, characterized by following feature: - the adhesive surface (14) is formed by adhesive strips. [3] Use of a plant for the production of high-voltage batteries with a test station, characterized by following features: - Components (11) of the high-voltage batteries pass through the system and its test station, - the test station is designed to carry out a method according to claim 1, wherein the sealing lip (10) has a contour corresponding to the component (11), - when the components (11) have introduced the dirt (13), the sacrificial component (12) is fed to the test station and - with the sacrificial component (12) the dirt (13) is carried from the adhesive surface (14) out of the system. [4] Use according to claim 3, characterized by following feature: - the sealing lip (10) is concave. [5] Use according to claim 3 or 4, characterized by at least one of the following characteristics: - the sealing lip (10) consists of a polymer or - the sealing lip (10) is made of rubber. [6] Use according to claim 3, 4 or 5, characterized by following features: - before feeding, the sacrificial component (12) is produced from one of the standard components (11) by equipping it with adhesive pads which form the adhesive surface (14), and - after passing through the system, the sacrificial component (12) is removed, its adhesive pads contaminated with dirt (13) are removed and fitted with new adhesive pads in order to reuse it.

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