High-voltage storage and methods for manufacturing a high-voltage storage system

Abstract

The invention relates to a high-voltage storage device (10) for a motor vehicle (50), comprising a cell pack (15) of battery cells (16), wherein the battery cells (16) are electrically connected by means of a cell contacting device (18) and the battery cells (16) each have a predetermined breaking point (46) for providing a degassing opening on their side facing the cell contacting device (18), wherein the cell pack can be arranged on the motor vehicle (50) by means of the high-voltage storage device (10).

Description

[0001] The invention relates to a high-voltage storage device for a motor vehicle, comprising a cell pack of battery cells, wherein the battery cells are electrically connected by means of a cell contacting device and each battery cell has a predetermined breaking point for providing a degassing opening on its side facing the cell contacting device, wherein the cell pack can be arranged on the motor vehicle by means of the high-voltage storage device. The invention further relates to a method for manufacturing a high-voltage storage device, comprising the steps of providing a housing cover for a housing of the high-voltage storage device; arranging a cell pack of battery cells in the housing cover; providing a housing tray for a housing of the high-voltage storage device; and arranging the housing cover on the housing tray.

[0002] High-voltage storage systems, also known as traction batteries or accumulators, are used to provide electrical energy for powering electric vehicle drives. A vehicle battery or high-voltage storage system typically comprises battery cells connected in parallel and series, arranged in packing configurations. Electrically conductive cell connectors or cell contacting devices can be used to connect the battery cells. These connectors can be connected to the end faces of several battery cells in a cell row of the packing configuration. To join these cell connectors and the battery cells into a mechanically stable unit, the interior of the housing, and thus the cavities between the packing configuration and the cell connectors, is filled with a structural compound or foam.

[0003] Since these battery cells can release a considerable amount of energy in the event of a failure, the battery cells of a high-voltage storage system, especially lithium-ion batteries, have predetermined breaking points or vents that serve as a safety mechanism. These vents allow gases to escape that can form under predetermined conditions, such as overcharging, overheating, or an internal short circuit. These high-temperature and high-pressure gases, as well as liquid and solid contaminants, must be vented quickly and effectively, even in the presence of structural foam.

[0004] Against this background, an object of the invention is to improve a method for manufacturing a high-voltage storage device and / or a high-voltage storage device for a motor vehicle. In particular, a method for manufacturing a high-voltage storage device is to be improved in such a way as to enable cost- and / or effort-reduced production of the high-voltage storage device.

[0005] This problem is solved by a high-voltage storage device with the features of claim 1 and a method for manufacturing a high-voltage storage device with the features of claim 11. The dependent claims relate to advantageous embodiments of the invention.

[0006] According to a first aspect, a high-voltage storage device for a motor vehicle is proposed, comprising a cell pack of battery cells, wherein the battery cells are electrically connected by means of a cell contacting device and the battery cells each have a predetermined breaking point to provide a degassing opening on their side facing the cell contacting device, wherein the cell pack can be arranged on the motor vehicle by means of the high-voltage storage device in such a way that the cell contacting device and in particular the predetermined breaking points of the battery cells are arranged facing away from the interior of the motor vehicle.

[0007] A high-voltage battery is, in particular, an energy storage device or traction battery for a motor vehicle, comprising multiple battery cells for storing electrical energy. Cylindrical battery cells are primarily used, which can be arranged in a packing configuration or cell pack. A cylindrical battery cell can, for example, have a circular cross-section and a longitudinal axis perpendicular to it, and can be bounded longitudinally by two end faces, which are connected by a cell shell or surface. Of course, prismatic battery cells and / or battery cells with other cross-sections, such as rectangular, hexagonal, or prismatic cross-sections, can also be used.

[0008] Typically, such a battery cell has a geometrically recessed or slightly raised first electrical pole or cell terminal on one of its end faces or first side for electrical contact via the cell contacting device. The remaining part of the end face or first side, as well as the cell shell of the battery cell, can form the second electrical pole of the battery cell. The portion of the end face surrounding the cell terminal, or this area of ​​the second electrical pole, forms a so-called cell shoulder. In other embodiments, particularly in prismatically shaped battery cells, the second electrical pole can also be designed as a recessed second cell terminal.

[0009] In an installation situation in a motor vehicle, the high-voltage storage system and / or the battery cells can be arranged such that the longitudinal axes of the battery cells are arranged parallel to a vehicle vertical.

[0010] The invention is based, among other things, on the idea of ​​using a predetermined breaking point or a degassing opening provided by means of the predetermined breaking point to interrupt the current flow to and / or from a damaged or failing battery cell. For this purpose, it is proposed to arrange the degassing opening in the area of ​​the electrical terminals or on an end face of the battery cell, which in particular has both electrical terminals for contact with a cell contacting device. The battery cells or the cell pack are arranged or can be arranged on / in the vehicle such that the predetermined breaking points or degassing openings point away from the vehicle interior, in particular towards the surrounding environment or a surface, thereby allowing the battery cells to degas away from the vehicle in the event of a defect, thus increasing safety.

[0011] The respective predetermined breaking point is designed to provide a degassing opening in order to release gases that may form during overcharging, overheating, and / or an internal short circuit. The predetermined breaking point or degassing opening is designed, in particular by means of at least one safety valve and / or predetermined breaking point integrated into the cylindrical battery cell, to release the degassing flow from a predetermined internal pressure, in particular in a controlled manner, without the battery cell itself rupturing or exploding.

[0012] The cell contacting device can be designed as a single unit or in multiple parts to electrically connect a large number of battery cells, or it can comprise (several) individual contact elements that are electrically and / or mechanically connectable or connected to one another. The respective contact element can be arranged on the end face of the respective battery cell of the high-voltage storage system or its cell terminal and can be designed, in particular, as an electrically conductive track, strip, or sheet metal configured to connect the positive and / or negative contacts or poles of battery cells, especially across individual cells and / or cell rows.The cell contacting device can be at least partially accommodated by a support device, in particular a support device for the battery cells, which can serve at least partially as an electrical insulation for the cell contacting device from at least one electrical pole of the battery cell(s).

[0013] The cell contacting device can be positioned in the area of ​​the battery cell's predetermined breaking point while simultaneously contacting the electrical pole(s) of the battery cell(s). This allows for mechanical separation of the cell contacting device when the predetermined breaking point or the vent is triggered, resulting in movement of the predetermined breaking point, movement of the battery cell parts located in the area of ​​the predetermined breaking point, and / or the escape of hot gases from the vent. The cell contacting device can, for example, be designed with a mechanical weak point in the form of a cross-sectional reduction and / or at least a recess to facilitate mechanical separation of the contacting element or the cell contacting device, thus enabling current flow through the predetermined breaking point opening.This can cause, or at least facilitate, a mechanical separation of the cell contacting devices when the predetermined breaking point is opened, thus interrupting current flow between the damaged battery cell (or the cell opened for degassing) and other surrounding or adjacent battery cells. This interrupts short-circuit currents that could flow from the damaged battery cell to another battery cell, preventing propagation and / or progressive damage to the high-voltage storage system.

[0014] In one embodiment, the battery cells have a first electrical pole designed as a cell terminal for electrical contact, a second electrical pole for electrical contact, and a predetermined breaking point to provide a degassing opening, wherein the cell terminal, the second electrical pole, and the predetermined breaking point are arranged on a first side of the battery cell. The cell contacting device can be configured to contact the battery cells at their first electrical pole and / or their second electrical pole. The cell contacting device enables parallel and series connection of these battery cells in a cell assembly on the first side of the battery cells, and thus on those sides of the battery cells where the first electrical pole, the second electrical pole, and the predetermined breaking point are located.This allows the cell contacting device to be arranged in the area of ​​the predetermined breaking point of the battery cell while simultaneously contacting the electrical poles of the battery cells, so that if the predetermined breaking point or the degassing opening is triggered, a movement of the predetermined breaking point, the parts of the battery cell located in the area of ​​the predetermined breaking point and / or an escape of hot gases from the degassing opening can cause a mechanical separation of the cell contacting device.

[0015] In one embodiment, the cell packing is arranged in an interior space bounded by a housing of the high-voltage storage device, wherein the housing can be configured to allow an arrangement of the high-voltage storage device, the cell packing or the battery cells in which the cell contacting device and / or the predetermined breaking points or degassing openings are arranged on a side of the cell packing opposite the vehicle interior.

[0016] In one embodiment, the housing is formed by means of a housing cover and a housing tray. The housing, by means of the housing tray and the housing cover of the high-voltage storage unit, defines an interior space in which the battery cells or cell pack are received, accommodated, or arranged. The housing cover is typically arranged or can be arranged facing the interior of a vehicle, and the housing tray is arranged or can be arranged facing the underbody of the vehicle or a surface.

[0017] In one embodiment, the battery cells are thermally connected to a heat exchanger. The heat exchanger can, for example, be arranged between or on the casing or side surfaces of the battery cells to enable cooling of the battery cells during operation.

[0018] In one embodiment, the battery cells are connected to the heat exchanger on their side opposite the cell contacting device, or the heat exchanger is arranged on a flat side of the cell pack. The heat exchanger and / or at least one of the heat exchange elements can be arranged on the battery cells or cell assembly in such a way that heat conduction can occur through mechanical contact. A flat side of a cell pack is, in particular, a side of the cell pack with the largest surface area and can be located below or above the cell assembly or high-voltage storage device in an installation situation within the vehicle. Particularly with a plate-shaped design of the heat exchange element or the heat exchanger, this allows for the distribution of the refrigerant over all the battery cells and thus enables heat dissipation.

[0019] In one embodiment, the heat exchanger is formed in the housing cover, or the housing cover has at least one heat exchanger. The housing cover can be at least partially designed as a flow-through heat exchanger and / or have a channel structure so that a cooling fluid flowing in the channel structure can be in thermal contact with at least one battery cell of the cell pack in order to transfer heat from the at least one battery cell to the coolant flowing in the housing cover and thus dissipate it. The channel structure can be designed for fluid guidance or have a number of cooling fluid channels through which a pre-tempered cooling fluid can flow to enable heat transfer between the battery cells and the housing cover. The channel structure can be multi-flow and can include a distribution device with a supply channel or...The channel has an inlet and an outlet channel, wherein the supply channel is configured to supply a feeder of the channel structure with cooling fluid and the outlet channel is configured to discharge cooling fluid from a return of the channel structure.

[0020] The housing cover, or more specifically its heat exchange surface facing the interior of the housing, can be arranged on the battery cells in such a way, or conversely, the battery cells can be arranged on the housing cover, such that heat conduction can occur through mechanical contact. For example, the battery cells can be attached to or bonded to the housing cover using a thermally conductive paste or layer. In addition to enabling fluid flow via the channel structure, this can improve the flexural rigidity and / or strength of the housing cover, particularly when weight is low.

[0021] In one embodiment, a degassing chamber is formed within the high-voltage storage device. Here, the battery cells or cell pack are arranged in the housing or housing tray such that the degassing openings face the degassing chamber to allow gases to escape. This degassing chamber is specifically designed to receive a degassing flow from a degassing opening of a battery cell and can be connected to a flow channel to direct the degassing flow from the interior or the degassing chamber to the outside and release it into the environment. The flow channel can be configured to influence at least one flow characteristic, such as velocity, pressure, and / or direction, of the degassing flow in order to achieve a desired cooling effect and / or to reduce the temperature of the degassing flow.

[0022] In one embodiment, a support structure is arranged in the degassing chamber. This support structure can be designed to protect the battery cells and / or the cell contacts from mechanical stresses, particularly those acting externally on the housing or housing tray. The support structure can be positioned between the battery cells, their terminals, or the cell contacting device and the housing or housing tray to establish a distance between the battery cells or their degassing openings and the housing, thus defining a degassing chamber within the high-voltage storage system.

[0023] In one embodiment, the battery cells are at least partially embedded in a structural medium, wherein at least one area of ​​the battery cells can be arranged in a volume of the interior free of structural medium.

[0024] The structural medium can, for example, form a plane or layer of a predetermined height in which the battery cells or cell pack are partially contained or embedded, particularly along the longitudinal axes of the battery cells. This allows for the separation of areas within the housing by means of the structural medium, thus enabling, for example, the separation of a degassing area or degassing chamber within the housing from an area of ​​the interior where no structural medium is present, i.e., a free volume. This allows for the separation of safety-relevant areas of the batteries or...Cell packing, such as electrical connections with a cell contacting device, can be surrounded by the structural medium. The proposed partial foaming separates the degassing space from the remaining free air volume of the storage device. This allows live components to be separated from the degassing space by the layer of structural medium, particularly in the case of cell propagation. This prevents secondary short circuits between adjacent battery cells and thus improves the safety of the battery cells, the cell packing, and / or a high-voltage storage device. In other embodiments, the battery cells can be completely embedded in the structural medium, or the housing interior can be at least substantially completely filled with the structural medium. Still other embodiments may contain no structural medium in the housing interior.

[0025] According to another aspect, a method for manufacturing a high-voltage storage device is specified, comprising steps of providing a housing cover for a housing of the high-voltage storage device; arranging at least one cell pack of battery cells in the housing cover; providing a housing tray for a housing of the high-voltage storage device; introducing a structural medium into the housing tray; and arranging the housing cover on the housing tray.

[0026] In this process, the battery cells or cell pack(s) can be arranged in the housing lid in such a way that they are firmly connected to the housing lid and can be grasped and / or moved together with it, particularly by means of a tool. Using the proposed method, the structural medium or a liquid structural foam can be introduced directly into the housing tray, in which the cell pack(s) or battery cells can be arranged by means of the housing lid. The structural medium or foam can expand freely within the housing tray, in particular, or rise towards the battery cells. The housing tray can be used as at least a partial spatial boundary or shape for the structural medium, thus eliminating the need for a separate tool for encasing the battery cells or for a foaming process.The structural medium can provide a structural connection between the battery cells and, in particular, a cell contacting device arranged on the battery cells, in order to increase mechanical stability and, if necessary, to provide protection for neighboring battery cells in the event of a short circuit of a battery cell.

[0027] According to another aspect, a high-voltage storage device is proposed which is manufactured using a method described herein.

[0028] The proposed method allows the housing or housing components, such as the housing cover and the housing tray, to be integrated into the manufacturing process. To this end, it is proposed that battery cells, grouped together in a cell pack, are first placed in a housing cover, in particular such that the battery cells and the housing cover can be moved as a unit and, in particular, rotated 180° around the horizontal. For foaming the battery cells, a structural medium is provided in a tray interior defined by the housing tray, and the battery cells are arranged in the housing tray by means of the housing cover in such a way that the structural medium is positioned around or between the battery cells during foaming or expansion, in particular only in areas of the energy cluster or cell pack that require increased structural integrity.

[0029] In one embodiment, the battery cells are arranged as a cell pack by means of a carrier structure. For this purpose, the carrier structure can have receiving openings for the battery cells, separated from one another, in particular by structural walls. Each receiving opening can be configured to receive a battery cell along its longitudinal axis and / or have a cross-section that corresponds at least substantially to a cross-section of the battery cell in order to receive and / or hold it. For example, a receiving opening for a cylindrical battery cell can have a substantially circular cross-section. The carrier structure can be configured to completely or partially enclose the battery cells circumferentially and / or longitudinally, for example, to allow only partial reception of the battery cells along the receiving direction.Such a carrier device makes it possible to arrange a plurality of battery cells in a cell pack and thus in a mountable unit, in order to simplify and / or accelerate the manufacturing process.

[0030] In one embodiment, the carrier device has a cell contacting device for electrically contacting at least one battery cell. The cell contacting device is arranged, in particular, at an end face of the receiving opening, thereby at least partially delimiting the receiving opening. The cell contacting device can extend essentially in a plane perpendicular to a receiving direction of the receiving opening. This allows the cell contacting device, or individual contacting elements of the cell contacting device, to be positioned such that when the battery cells are inserted or pushed into the receiving openings, which allow for movement of the battery cells along their longitudinal axis, the electrical poles of the battery cells can be arranged for electrical contact relative to the cell contacting device.The terminals of the battery cells are in contact with each other in a final position. At these physical or mechanical contact points, the poles of the battery cells can be permanently electrically connected to each other in a further step, for example by welding or soldering, in order to provide a functional cell pack or (partial) cluster of battery cells. This allows a functional and / or safety test of the cell pack to take place outside of or before assembly of the high-voltage storage system, enabling the early detection of defects and / or rejects.

[0031] In one embodiment, the method comprises further steps of providing a carrier device, particularly as described herein, which is configured to hold a number of battery cells spaced apart from one another, wherein the battery cells can be arranged in a cell pack, and the carrier device has at least one cell contacting device for electrically contacting at least one battery cell; arranging a number of battery cells in or by means of the carrier device; and connecting the at least one cell contacting device to the battery cells. Such (partial) cell packs can be connected to form a complete cluster, particularly when these are arranged in the housing cover of the high-voltage storage system. Overall, this can reduce the number of production steps and / or production costs, particularly by enabling early testing and / or detection of defective battery cells.electrical connections are made possible.

[0032] In one embodiment, the method includes the further step of arranging a support structure in the housing tray. This allows the support structure to be positioned between the battery cells and the housing or housing tray, and to define a distance between the battery cells or their degassing openings, thus defining, in particular, a degassing space within the high-voltage storage unit. Accordingly, the battery cells or the cell pack are arranged in the housing or housing tray such that the degassing openings face the degassing space formed by the support structure, in order to allow the gases to escape.

[0033] The battery cells may be provided with a vent in the area of ​​the electrical terminals or on one end face of the battery cell, which also accommodates both electrical terminals for contact with a cell contacting device. This vent is designed to release gases that may form during overcharging, overheating, and / or an internal short circuit. Such venting prevents the increasing pressure from damaging the internal structures of the battery cell, thus preserving the integrity of the battery cell and reducing the likelihood of a short circuit and / or other mechanical damage.

[0034] In one embodiment, the method includes the further step of arranging a separating layer on the support structure. This separating layer can, for example, be designed as a film, which may be configured to prevent the penetration of foam or structural medium into the area of ​​the support structure during the foaming process. This allows a degassing chamber and / or degassing areas, which may be associated with the discharge openings of the battery cells and formed by the structure, to remain free of structural medium, thus enabling unimpeded degassing of the battery cells. Because the support structure and thus the degassing chamber are free of structural medium, the degassing flow can pass through the support structure or the degassing chamber to an inlet of a flow channel, enter it, and exit the high-voltage storage system through an outlet of the flow channel to be released into the surrounding environment.This flow channel is specifically designed to direct the degassing flow from the interior to the outside and release it into the environment. The flow channel has an inlet with a predetermined cross-sectional area through which the degassing flow can enter the channel, and an outlet through which the degassing flow can exit the channel. It can also be configured to influence at least one flow characteristic, such as velocity, pressure, and / or direction of the degassing flow, in order to achieve a desired cooling effect.

[0035] In one embodiment, the cell pack is arranged on the separating layer. The battery cells are arranged on the separating layer such that their poles, and thus the cell contacting device, face the separating layer. This allows the cell contacting device, or its electrical poles, to be embedded in the structural medium for electrical connection of the battery cells. The cell contacting device can be attached to the battery cells or their poles, or welded to them, before the cell pack is arranged in the housing, in order to provide a testable battery cell pack. By encapsulating the cell contacting device together with the battery cells or the cell pack, an integrated structure can be created that increases stress resistance and reduces the risk of propagation.

[0036] In one embodiment, the structural medium is introduced above the separating layer, wherein the structural medium is introduced into the housing tray in such a way that at least a region of the battery cells is arranged in a volume of the housing interior free of structural medium. Here, the structural medium can, for example, form a plane or layer of a predetermined height in which the battery cells or the cell pack are partially received or embedded, particularly in the direction of the longitudinal axes of the battery cells. This allows a region or volume of the interior bounded by the housing to remain free of structural medium, and in particular, allows regions of the interior to be separated by means of the structural medium, thus enabling, for example, the separation of a region of the interior intended for degassing from another region, i.e., the free volume.In this process, safety-relevant areas of the batteries or cell pack, such as electrical connections with a cell contacting device, can be encased in the structural medium. This allows live components to be separated from the degassing chamber by the layer of structural medium, particularly in the case of cell propagation. This prevents secondary short circuits between adjacent battery cells and thus improves the safety of the battery cells, the cell pack, and / or a high-voltage storage system.

[0037] In one embodiment, the method includes the further step of rotating the housing cover to position it on the housing tray such that the battery cells are at least partially accommodated by the housing tray. Here, the housing cover can be rotated 180° around the horizontal from a mounting position used to arrange the battery cells within the housing cover into a second position. This allows the cell pack or battery cells to be positioned in the housing tray by means of the housing cover such that their electrical poles, cell contacting device, and / or degassing openings face the housing tray. This allows the structural medium to be arranged around or between the battery cells and / or the cell contacting device during foaming or expansion to form a structural composite.

[0038] Further advantages and application possibilities of the invention will become apparent from the following description in conjunction with the figures. Fig. Figure 1 shows a schematic representation of an embodiment of a motor vehicle according to the invention comprising a high-voltage storage device according to the invention. Fig. Figure 2 shows a schematic representation of an embodiment of a high-voltage storage device according to the invention in accordance with an exemplary embodiment of the invention. Fig. Figure 3 shows a schematic flowchart of an exemplary embodiment of a method for manufacturing a high-voltage storage device according to an exemplary embodiment of the invention.

[0039] Fig. Figure 1 shows an embodiment of a motor vehicle 50 with a high-voltage storage device 10 for a motor vehicle 50 according to the present disclosure in a schematic sectional view in the longitudinal direction of the vehicle.

[0040] The motor vehicle 50 has a high-voltage storage unit 10 in its underbody area, which comprises a housing 11 with a housing cover 12 and a housing tray 13. The housing 11 encloses or delimits an interior space 14 in which a cell pack 15 of battery cells 16 is arranged. The battery cells 16 are received in the high-voltage storage unit 10 or its housing 11 such that flat sides or flat walls or end faces of the battery cells 16 abut the housing cover 12. In the present embodiment, the end faces of the battery cells 16, which have offset cell terminals 26 for electrical contact, are arranged facing away from the housing cover 12 or a vehicle interior 17. The remaining part of the first (end) face, or a cell shoulder 36, forms a second electrical pole 36 of the battery cell.Here, the electrical poles 26, 36 of the battery cells 16 are electrically connected to each other by means of a cell contacting device 18. Breakaway points 46 can be provided on these end faces of the battery cells 16 to provide a degassing opening, so that they can degas towards the housing tray 12.

[0041] The end faces of the battery cells 16 or the cell pack 15 opposite the electrical poles 26, 36 are in thermally conductive contact with or abut the housing cover 12 to enable heat transfer between the battery cells 16 and the housing cover 12. For this purpose, the housing cover 12 can be arranged facing the vehicle interior 57 of the motor vehicle 10 and can form a heat exchanger 22 with a channel structure through which a cooling fluid flows. The heat exchanger 22 or the channel structure can, for example, be supplied with cooling fluid via a coolant circuit of the motor vehicle 50.

[0042] The cell contacting device 18 and the cell packing 15 are partially embedded in a structural medium 19 (illustrated by dotted lines), such that at least a region of the battery cells 16 is arranged in a volume 29 of the interior 14 free of structural medium 19. A support structure 17 is arranged between the battery cells 16 and the housing tray 13, which is configured to form a degassing chamber 37 for the battery cells 16. A separating layer 27 in the form of a film is arranged between this support structure 17 and the battery cells 16 or the structural medium 19, in order to keep the structural medium 19 out of the degassing chamber 37 during a foaming process.This allows a separation between the free air volume 29 and the degassing space 37 created by the support structure 17 to be created by means of the layer of structural medium 19, while at the same time improving the structural strength in the area of ​​the cell packing 15 and in particular the connection with the cell contacting device 18.

[0043] Fig. Figure 2 shows an enlarged detail view of the high-voltage storage unit 10. Fig. 1 in a sectional view along a transverse direction of the vehicle.

[0044] The cell pack 15 comprises battery cells 16, each battery cell 15 having, in the present embodiment, a predetermined breaking point 46 on its end faces, which have the electrical poles 26, 36, to provide a degassing opening. The cell pack 15 also has a cell contacting device 18 arranged on this side of the battery cells 16, which electrically connects the battery cells 16. In the event of overpressure in the battery cell 16, the predetermined breaking point 46, or the area of ​​the battery cell 16 surrounded or enclosed by the predetermined breaking point 46, in particular including the cell terminal 26, can open and / or detach completely from the battery cell 16, allowing hot gases and / or particles to escape from the battery cell 16 and flow into the degassing chamber 37.Through this movement of at least part of the predetermined breaking point 46, the cell contacting device 18 can undergo mechanical separation, thereby interrupting the current flow and protecting surrounding battery cells 16 from overcurrent. The hot gases can then flow via the degassing chamber 37, which is spanned by the support structure 17, to an inlet of a flow channel 47, flow into it, and exit the high-voltage storage device 10 through an outlet 447 of the flow channel 47. In particular, live components can be separated from the degassing chamber 37 by the layer of structural medium 19, thus preventing cell propagation and / or secondary short circuits.

[0045] The illustration shows that the cell pack 15, which is housed in the casing 11, is arranged such that the battery cells 16 are spaced apart from the casing 11 and the housing tray 13 by means of the support structure 17, thereby providing the degassing space 37 for the battery cells 16 and the cell pack 15. This degassing space 37 is separated from the structural medium 19 by the separating layer 27. The structural medium 19 surrounds the battery cells 16 and the cell contacting device 18, thus forming a mechanically stabilized structure. The structural medium 19 forms a layer that separates the degassing space 37 from the free volume 29. The structural medium 19 covers less than 50% of a height H along a longitudinal axis L of the battery cells 16 and fills less than 50% of the total volume of the interior 14. This allows the necessary mass of structural medium 19 and thus the overall weight of the high-voltage storage device 10 to be reduced.

[0046] It may be provided that a heat exchange device 20 is arranged in the housing cover 12 and adjacent to the free volume 29 to enable heat exchange and / or a cooling effect at the battery cells 16. In some embodiments, a heat exchange device 20 may be arranged between battery cells 16 or cell rows on battery cells 16 and / or on a flat side of the cell packing 15.

[0047] Fig. Figure 3 shows a schematic flowchart of a process 100 for manufacturing a high-voltage storage device according to the present disclosure.

[0048] In a first step a, a housing cover 12 is provided for a housing 11 of the high-voltage storage device 10. The housing cover 12 can have a trough-shaped geometry and thus define a receiving space. In a second step b, at least one cell pack 15 of battery cells 16 is arranged in the housing cover 12. The housing cover 12 can have a heat exchange device 22, particularly an integrated one, with a cooling structure. The cell pack 15 or the battery cells 16 can be bonded to the housing cover 12, for example, by means of a thermally conductive adhesive, thus enabling cooling and allowing the battery cells 16 to be moved together with the housing cover 12.

[0049] To provide the cell pack 15, a carrier device can be provided in a step that is carried out, in particular, outside the housing cover 12 and / or prior in time. This carrier device has at least one cell contacting device 18 for electrically contacting at least one battery cell 16 and is configured to receive a number of battery cells 16, wherein the battery cells 16 can be arranged in a cell pack 15. In a further step b2, a number of battery cells 16 can be arranged in the cell pack 15 by means of the carrier device, wherein the battery cells 16 can be inserted, in particular, along a receiving direction along the longitudinal axes of the battery cells 16, and in a further step b3, can be electrically and mechanically connected to the at least one cell contacting device 18 of the carrier device.This allows the cell pack 15 to be tested before further use in order to prevent rejects.

[0050] In a further step c, a housing tray is provided for the housing 11 of the high-voltage storage device 10. In a further step c1, a support structure 17 can be arranged in the housing tray 12, and in a further step c2, a separating layer can be arranged on the support structure 17. In some embodiments, the separating layer 27 can comprise a soft foam / EPP or a foam board, or be designed as such, while in further embodiments the separating layer 27 can be integrated with the support structure 17.

[0051] In step d, a structural medium 19 is introduced into the housing tray 13, in particular onto or above the support structure 17 and / or the separating layer 27, and in step e, the housing cover 12 is attached to the housing tray 13 to arrange the battery cells 16 or the cell pack(s) 15 in the interior 14 of the housing 11, so that they can be embedded in the expanding structural medium 19. The housing cover 13 can be picked up by a tool and rotated 180° from the horizontal to position it on the housing tray 12, such that the battery cells 16 are at least partially received by the housing tray 19.In this process, the structural medium 19 is introduced in such a way that it can expand to the point that a region of the battery cells 19 facing the housing cover 12 is located within a volume 29 of the interior 13 of the housing 10 that is free of structural medium 19. The structural medium 19 can, for example, form a plane or layer of a predetermined height, thereby separating regions of the interior. This allows, for instance, the separation of a degassing area (support structure 17) of the interior 14 from another region, i.e., the free volume 29. This reduces the amount of structural medium 19 required and thus the weight of the high-voltage storage device 10. REFERENCE MARK LIST 10 high-voltage storage units 11 cases 12 Case covers 13 Housing tray 14 Interior of the housing 15 cell pack 16 battery cells 17 Support structure 18 Cell contacting device 19 Structural medium 22 Heat exchanger 26 first electrical pole / cell terminal 27 Separation layer 29 free volume 36 second electrical pole / cell shoulder 37 Degassing room 46 Breakaway point / Degassing opening 50 motor vehicles 57 Vehicle interior

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