Battery module comprising a space filled with a thermally conductive filling material and a method for injecting a fluid filling material into a space

Abstract

The present invention relates to a battery module (1) comprising a cavity (40) filled with a thermally conductive filling material (41). The invention further relates to a method for injecting a fluid filling material (41) into a cavity (40). The battery module (1) has a housing body (10) and a battery cell stack (3) with several battery cells (4), wherein the housing body (10) has an upper housing wall (11), a lower housing wall (12) opposite the upper housing wall (11) in a vertical direction (Z), a left housing wall, and a right housing wall opposite the left housing wall in a transverse direction, wherein the housing walls (11, 12) circumferentially define a receiving space (15) for the battery cell stack (3), and wherein the housing body (10) has an end-face insertion opening (16) for inserting the battery cell stack (3) into the receiving space (15) along a longitudinal direction (X).wherein the battery cell stack (3) is arranged in the receiving space (15), wherein a first insertion aid (31) is attached to the battery cell stack (3), wherein the first insertion aid (31) has a first sealing plate (33), wherein the first sealing plate (33) covers a top surface of the battery cell stack (3) facing the upper housing wall (11) in the area of ​​a first end section.

Description

[0001] The present invention relates to a battery module comprising a cavity filled with a thermally conductive filling material. The invention further relates to a method for injecting a fluid filling material into a cavity.

[0002] In battery modules for use in motor vehicles or aircraft, the individual battery cell must be kept at the optimal temperature during power input or output to prevent damage and / or optimize power output. Particularly during charging or discharging processes in traction batteries, heat is generated, which can damage the battery cells. To facilitate heat dissipation, a thermally conductive filler material, often a highly thermally conductive fluid such as thermal paste or gap filler, is inserted between the battery cell and the module's inner wall (usually metallic). This ensures heat transfer from the battery cell to the actual heat transfer medium, such as water flowing in a cooling plate attached to the module wall.

[0003] The thermally conductive filler material often also serves to compensate for manufacturing tolerances in the module housing and the battery cells themselves, ensuring optimal contact between the heat-dissipating battery cell surfaces and the module housing. Cylindrical, pouch, or prismatic cells can be used as battery cells.

[0004] In integral housing assemblies, which represent a self-contained geometry, the thermally conductive filler material is typically introduced into the spaces between the battery cell stack and the housing assembly by injecting the flowable thermally conductive filler material. For this purpose, one or more injection openings are often provided in the housing assembly to fill the space(s) between the battery cell stack and the housing assembly with the thermally conductive filler material.

[0005] The injection opening or openings leading into the cavity to be filled should be selected so that the injection process is not hindered by differing cell geometries or other geometry-influencing tolerances during filling. Preferably, injection is performed from an end face, so that the filling material then displaces the air in the cavity upwards, ideally via a distributor, over a wide area against gravity. It is desirable that a uniform flow front is formed, as strongly leading areas of the flow front can lead to air bubbles being trapped, resulting in the battery module being rejected due to insufficient local cell cooling.An end-face injection has the advantage of a simpler flow front design, but it also has the disadvantage that the injection pressure, which drives the typically very viscous filler material, increases linearly with the flow path. The highest injection pressure is therefore present at the injection port, which can then lead to battery cells located in this area being subjected to pressures locally exceeding their permissible limits.

[0006] DE 10 2022 107 635 A1 discloses a method for filling a viscous thermal conductivity compound into a space between a battery module and a battery arrangement.

[0007] DE 10 2022 114 834 A1 discloses a method for applying a fluid filling material into a cavity.

[0008] DE 10 2018 221 988 A1 discloses a method for introducing a heat-conducting element into a battery housing by injection.

[0009] EP 3 754 744 A1, DE 10 2022 103 618 A1 and DE 10 2019 132 395 A1 disclose further state of the art.

[0010] DE 10 2021 109 282 A1 discloses a battery module which has the features of the preamble of claim 1.

[0011] DE 10 2023 119 746 A1 represents the subsequently published state of the art.

[0012] DE 10 2020 105 607 B3, DE 10 2021 115 657 A1, EP 3 346 518 A1, EP 2 901 047 B1, DE 10 2019 109 208 B3 and DE10 2021 123 434 A1 disclose further prior art.

[0013] Due to the injection pressure present during the injection process, any seals designed to prevent leakage of filler material from the cavity being filled are subjected to considerable stress. Furthermore, sealing the cavity to prevent leakage of filler material during the injection process is particularly problematic in integral housing assemblies, such as extruded profiles, where the battery cell stack is inserted into the completely closed housing profile by sliding the stack in. This is because any seals are subjected to mechanical stress, especially shear stress.

[0014] The object of the present invention is to provide a battery module that solves the problem described above. Furthermore, it is an object of the invention to provide a novel method for injecting a fluid filling material into a space between a battery cell stack and a housing base body using an injection device.

[0015] These tasks are solved by the subject matter of the independent claims. The dependent claims concern advantageous further training.

[0016] The battery module according to the invention is a battery module for a traction battery of an electrically or partially electrically powered motor vehicle. The battery module is designed such that it comprises a housing base and a battery cell stack with several battery cells. The housing base has an upper housing wall, a lower housing wall opposite the upper housing wall in a vertical direction, a left housing wall, and a right housing wall opposite the left housing wall in a transverse direction. The housing walls circumferentially define a receiving space for the battery cell stack. The housing base has an end-face insertion opening for inserting the battery cell stack into the receiving space along a longitudinal direction. The battery cell stack is arranged in the receiving space, and a first insertion aid is attached to the battery cell stack.wherein the first insertion aid comprises a first sealing plate, wherein the first sealing plate covers an upper surface of the battery cell stack facing the upper housing wall in the region of a first end section, wherein the first sealing plate has a front surface facing away from the upper surface and a rear surface opposite the front surface and facing the upper surface, wherein a gap extending longitudinally from the first insertion aid and formed between the upper surface of the battery cell stack and the upper housing wall is filled with a thermally conductive filler material, for example a gap filler or thermal paste, wherein the front surface of the first sealing plate abuts a sealingly inside surface of the upper housing wall of the housing body facing the receiving space, and wherein a sealant is introduced between the rear surface of the first sealing plate and the upper surface of the battery cell stack.wherein the sealant interacts sealingly with the top of the battery cell stack and sealingly with the back of the first sealing plate to seal the gap against leakage of the thermally conductive filler material between the top of the battery cell stack and the upper housing wall in the area of ​​the first end section.

[0017] The design described above, incorporating a sealing plate, prevents damage to the sealant during the insertion of the battery cell stack into the receiving space of the housing base, as the sealing plate protects the sealant from mechanical contact. This prevents unwanted leakage in the area of ​​the first end section. It also prevents leakage of the filler material from the cavity during the process of filling the cavity with the thermally conductive filler material. Furthermore, it prevents defects in the thermally conductive filler material caused by leakage in the cavity, which would negatively impact heat dissipation.

[0018] In practice, it has been shown that the relatively high contact pressure of the sealing plate against the inside of the upper housing wall provides sufficient sealing to prevent leakage of the filler material. Since the sealing plate covers the sealant, the sealant is not subjected to mechanical stress, particularly shear stress, during insertion. Sealants, especially adhesives, are generally extremely sensitive to shear forces after curing, so shear or mechanical forces acting on them can damage the adhesive and result in a leak.Generally, it is neither feasible nor practical to apply the sealant to the battery cell stack and then insert the stack, with the sealant still uncured, into the housing body to create a direct, bonded connection between the sealant and the inside of the upper housing wall. The typical curing times of chemically suitable adhesives for this application are usually insufficient for this purpose. Furthermore, inserting the battery cell stack with uncured sealant can lead to undesirable contamination of the battery module. It is also impossible to guarantee, nor can it be easily verified, that a fluid-tight seal has actually been achieved between the top of the battery cell stack and the upper housing wall.

[0019] The insertion aid, through its design, supports the correct insertion of the battery cell stack into the receiving space of the housing base without damaging the sealant.

[0020] Against this background, the provision of a sealing plate coming towards the system on the upper housing wall can be considered particularly safe and reliable in order to seal the gap at the end.

[0021] It is considered particularly advantageous if the thermally conductive filling material is a gap filler and / or a thermal paste.

[0022] In an advantageous further development, it is provided that the thermally conductive filling material is a fluid filling material.

[0023] It is quite conceivable that the filling material is a dispersion. For example, it is possible that the filling material is multi-component with a solid phase and a liquid phase (suspension).

[0024] Preferably, the sealing plate is made of a plastic material.

[0025] It is considered particularly advantageous if the sealing plate has a thickness of 0.5 mm to 2 mm. This ensures that the sealing plate has sufficient flexibility to seal against the upper housing wall.

[0026] In a preferred embodiment, a second insertion aid is provided on the battery cell stack, the second insertion aid comprising a second sealing plate, the second sealing plate covering the top of the battery cell stack in the region of a second end section opposite the first end section in the longitudinal direction, the second sealing plate having a front facing away from the top and a back facing the top opposite the front, the space filled with the thermally conductive filler material extending to the second insertion aid, the front of the second sealing plate sealingly abutting the inside of the upper housing wall of the housing body facing the receiving space, and a sealant being introduced between the back of the second sealing plate and the top of the battery cell stack.wherein the sealant interacts sealingly with the top of the battery cell stack and sealingly with the back of the second sealing plate to seal the gap against leakage of the thermally conductive filler material between the top of the battery cell stack and the upper housing wall in the area of ​​the second end section.

[0027] It is generally not necessary to seal the gap in the transverse direction, as the battery cell stack is typically stacked transversely, i.e., perpendicular to the insertion direction or longitudinal direction. The battery cell stack and the receiving chamber are usually designed such that the battery cell stack has an excess dimension compared to the receiving chamber in the transverse direction, so that it is compressed transversely within the receiving chamber. This is to create tension in the battery cells in the stacking direction. As a result, the battery cell stack typically seals against the left and right housing walls in the transverse direction, so that no or only negligible leakage of the filling material can occur during the filling process.

[0028] It is considered particularly advantageous if the thermally conductive filling material is a substance introduced into the space in a flowable form.

[0029] It is considered particularly advantageous if the thermally conductive filling material remains in a flowable state even after the injection or insertion into the space has been completed.

[0030] It is considered particularly advantageous if the housing base body is an extruded profile.

[0031] The battery module according to the invention has particular advantages especially in the case of an extrusion profile, since in the case of an extrusion profile the insertion of the battery cell stack into the receiving space can only be done by pushing it in.

[0032] The housing base is preferably an extruded profile. It is considered particularly advantageous if the housing base is made of an aluminum extruded profile.

[0033] In an advantageous embodiment, it is provided that the upper housing wall is a cooling wall, wherein the cooling wall has a cooling channel structure for a cooling fluid and / or wherein a cooling plate is attached to an outer surface of the cooling wall opposite the inner surface.

[0034] In connection with a cooling plate, it is considered particularly advantageous if the cooling plate has cooling fins and / or a cooling channel structure for a cooling fluid.

[0035] In an advantageous further development, it is provided that a material which is compressible at least in the vertical direction is formed between the back of the first sealing plate and the top of the battery cell stack and / or between the back of the second sealing plate and the top of the battery cell stack.

[0036] Such a design allows for high compressibility of the corresponding insertion aid while still minimizing stress on the sealant, which may be an adhesive, for example.

[0037] However, it is also quite conceivable that the sealant itself forms the compressible material, preferably elastic. For example, the sealant could be a foam material bonded to the top of the battery cell stack and the back of the respective sealing plate.

[0038] Generally, it is considered advantageous if the sealant is a foam material.

[0039] Basically, the sealant can be a sealing element introduced in solid form, for example in the form of an insert gasket.

[0040] The top surface of a battery cell stack is often not flat, but may exhibit protrusions and / or recesses, for example, in the form of grooves and overhangs. In particular, the top surface may have raised, strip-like features due to compression pads positioned between the battery cells, as these pads often protrude from the top of the battery cell stack relative to the cells themselves. Furthermore, manufacturing tolerances can cause the surface structure of the top of the battery cell stack to vary from one stack to another. Therefore, when using insert gaskets or solid gaskets as sealants, these manufacturing tolerances can lead to undesirable leakage points.To avoid the formation of leaks of the aforementioned type, it is considered particularly advantageous if the sealant is a flowable gasket. In particular, the gasket can be a Formed In Place Gasket (FIPG) gasket, especially a Formed In Place Foam Gasket (FIPFG) gasket.

[0041] Preferably, the sealant is an adhesive. For example, the sealant could be a polyurethane-based adhesive. A polyurethane adhesive foam is considered particularly advantageous.

[0042] It is considered particularly advantageous if the sealant is an adhesive.

[0043] In a particularly preferred embodiment, it is provided that the sealant is bonded to the top of the battery cell stack and the back of the first sealing plate and / or wherein the sealant is bonded to the top of the battery cell stack and the back of the second sealing plate.

[0044] To improve the sealing effect between the respective sealing plate and the inside of the upper housing wall, it is considered advantageous if a sealing lip is formed at an end of the first sealing plate facing the gap and / or at an end of the second sealing plate facing the gap.

[0045] In a particularly preferred embodiment, the first sealing plate and / or the second sealing plate extend in a wedge shape towards the top of the battery cell stack, such that the distance between the sealing plate and the top of the battery cell stack increases towards the gap. This wedge-shaped design has the advantage that when the filler material flows towards the respective sealing plate, it causes the sealing plate to move away from the top of the housing, effectively pressing the sealing plate against the top of the housing.

[0046] Therefore, it is quite conceivable that the respective sealing plate is underflowed by the filling material up to the sealant, and that the sealing plate is thereby pressed against the upper housing wall.

[0047] The battery cell stack is provided for in a carrier housing, wherein the carrier housing has a left support wall, a right support wall opposite the left support wall in the transverse direction, and a first end wall connecting the left support wall to the right support wall, wherein the first sealing plate is pivotally connected to the first end wall. Preferably, the carrier housing has a second end wall connecting the left support wall to the right support wall, wherein the second sealing plate is pivotally connected to the second end wall.

[0048] In a particularly advantageous embodiment, the upper housing wall has a filling opening that leads into the cavity for injecting the filling material. This design allows for surface injection of the filling material. With surface injection, the injection pressure can be approximately halved when filling the cavity, assuming the same geometry. This reduces the stress on the sealant during injection. Preferably, the injection opening is positioned approximately centrally to the cavity to be filled.

[0049] The method according to the invention relates to a method for injecting a fluid filling material into a space between a battery cell stack and a housing base body by means of an injection device. The method according to the invention is particularly suitable for manufacturing the battery module according to the invention. In this respect, the descriptions of the battery module according to the invention, its advantages and advantageous embodiments apply accordingly to the method and vice versa.

[0050] The method according to the invention comprises the following process steps: - Providing the battery cell stack with multiple battery cells, wherein a first insertion aid is attached to the battery cell stack, the first insertion aid comprising a first sealing plate, the first sealing plate covering a top surface of the battery cell stack in the region of a first end section, the first sealing plate having a front surface facing away from the top surface and a rear surface opposite the front surface and facing the top surface, wherein a sealant is introduced between the rear surface of the first sealing plate and the top surface of the battery cell stack, the battery cell stack comprising a support housing, the support housing comprising a left support wall, a right support wall opposite the left support wall in the transverse direction, and a first end wall connecting the left support wall to the right support wall, wherein the first sealing plate is hingedly connected to the first end wall. - Providing the housing base body, wherein the housing base body has an upper housing wall, a lower housing wall opposite the upper housing wall in a vertical direction, a left housing wall and a right housing wall opposite the left housing wall in a transverse direction, wherein the housing walls circumferentially define a receiving space for the battery cell stack, wherein the housing base body has an end-face insertion opening for inserting the battery cell stack into the receiving space along a longitudinal direction, - Providing the injection device, - Inserting the battery cell stack with the attached first insertion aid through the insertion opening along the longitudinal direction into the receiving space such that a gap is formed between the top of the battery cell stack and the upper housing wall, adjoining the first insertion aid in the longitudinal direction, wherein the first sealing plate comes into contact with a sealing surface on the inner side of the upper housing wall of the housing body facing the receiving space, and the sealant interacts sealingly with the top of the battery cell stack and sealingly with the rear side to seal the gap against leakage of the thermally conductive filler material to be injected into the gap between the top of the battery cell stack and the upper housing wall in the area of ​​the first end section. - Injecting the thermally conductive filling material into the space using the injection device, wherein the injection takes place after the battery cell stack has been inserted into the receiving space.

[0051] In a particularly preferred advanced training program, the procedure additionally includes the following procedural steps: - Capturing an injection pressure of the filling material during the injection process, wherein the injection is terminated based on a shutdown criterion, the shutdown criterion being met when a predefined limit for the injection pressure is exceeded and / or when a predefined limit for the gradient of the injection pressure is exceeded.

[0052] The directional terms used, such as "top," "bottom," "left," and "right," serve only to distinguish the structures specified and their position and orientation relative to one another. In particular, these directional terms should not be interpreted as indicating the orientation of the battery module or its structures in space. For example, the upper housing wall may well be located below the lower housing wall when the module is installed in a motor vehicle.

[0053] The following figures explain the invention in more detail with reference to exemplary embodiments, without being limited to these. They show: Fig. 1. A battery module in cross-section in a schematic representation, Fig. 2 the battery module according to Fig. 1 in a longitudinal section in a schematic representation, Fig. 3 another embodiment of a battery module during the process of inserting a battery cell stack into a housing base body, Fig. 4 an end section of the battery cell stack according to Fig. 3 in a top view, Fig. 5 the end section of the battery cell stack according to Fig. 4 without cover plate in a perspective view, Fig. 6. A flowchart.

[0054] The Fig. 1 and Fig. Figure 2 shows a schematic representation of a battery module 1. The battery module 1 has a housing base body 10 formed as an extruded profile. The extrusion direction of the housing base body 10 runs along a longitudinal direction X of the battery module 1. A transverse direction Y and a vertical direction Z are each perpendicular to each other and perpendicular to the longitudinal direction X.

[0055] The battery module 1 has a battery cell stack 3 with several battery cells 4. The battery cells 4 of the battery cell stack 3 are stacked next to each other in the transverse direction Y. Compression pads can be arranged between the battery cells 4, but these are not shown for clarity.

[0056] The housing body 10, designed as an extruded profile, has an upper housing wall 11, a lower housing wall 12 opposite the upper housing wall 11 in the vertical direction Z, a left housing wall 13, and a right housing wall 14 opposite the left housing wall 13 in the transverse direction Y. The upper housing wall 11 and the lower housing wall 12 are parallel to each other. The left housing wall 13 and the right housing wall 14 are also parallel to each other. A rectangular receiving space 15 for the battery cell stack 3 is enclosed by the four housing walls 11, 12, 13, 14. The housing body 10 has an end-face insertion opening 16 for inserting the battery cell stack 3 into the receiving space 15 along the longitudinal direction X.

[0057] The Fig. 1 and Fig. Figures 2 show the battery module 1 in a state where the battery cell stack 3 is inserted into the receiving space 15. As shown in particular by the Fig. As can be seen from Figure 2, a first insertion aid 31 and a second insertion aid 32 are attached to the battery cell stack 3. The first insertion aid 31 has a first sealing plate 33, the first sealing plate 33 covering a top surface of the battery cell stack 3 facing the upper housing wall 11 in the region of a first end section. The second insertion aid 32 has a second sealing plate 34, the second sealing plate 34 covering a top surface of the battery cell stack 3 facing the upper housing wall 11 in the region of a second end section opposite the first end section in the longitudinal direction X. Each sealing plate 33, 34 has a front surface facing away from the top surface of the battery cell stack 3 and a back surface opposite the front surface, facing the top surface of the battery cell stack 3.

[0058] Between the first insertion aid 31 and the second insertion aid 32, a gap 40 extends longitudinally X to each insertion aid 31, 32. This gap is formed between the top of the battery cell stack 3 and the upper housing wall 11 and extends transversely Y from the left side wall 13 to the right side wall 14. This gap 40 is filled with a thermally conductive filler material 41, namely thermal paste. The gap 40 is filled with the filler material 41 via a filling opening 111 located centrally in the upper housing wall 11.

[0059] To prevent the filling material 41 from escaping from the space 40 in the area of ​​the first end section and / or in the area of ​​the second end section during the filling process, the first insertion aid 31 and the second insertion aid 32 are designed such that the respective sealing plate 33, 34, in the area of ​​an outer edge of the respective sealing plate 33, 34, bears in a sealing manner with its front side against an inner side of the upper housing wall 11 of the base body 10 facing the receiving chamber 15, as schematically shown in the Fig. 2 shown. This prevents leakage of filling material 41 between the upper housing wall 11 and the respective sealing plate 33, 34.

[0060] To prevent leakage of filling material 41 between the respective sealing plate 33, 34 and the top of the battery cell stack 33, a sealant 50 is introduced between the back of the respective sealing plate 33, 34 and the top of the battery cell stack 3, which seals against the top of the battery cell stack 3 and seals against the back of the respective sealing plate 33, 34.

[0061] The sealant 50 is an elastically compressible foam material, which is bonded to both the respective sealing plates 33, 34 and the top surface of the battery cell stack 3. Due to its elastic compressibility, a spring / damper system is formed. The sealant 50 is designed as a FIPFG seal.

[0062] To ensure particularly effective cooling of the battery cells 4, a cooling plate 60 is attached to an outer surface of the housing wall 11 opposite the inner surface. The cooling plate 60 has several cooling channels 61 through which a coolant flows when the battery module 1 is in operation. The thermal paste applied to the space 40 ensures particularly good thermal contact between each battery cell 4 and the upper housing wall 11, which in turn is cooled by the cooling plate 60.

[0063] The Fig. 3, Fig. 4 to Fig. Figure 5 shows another embodiment of the battery module 1. The compression pads 5 arranged between the individual battery cells 4 of the battery cell stack 3 are also shown.

[0064] The battery cell stack 3 comprises a carrier housing, the carrier housing having a left support wall, a right support wall 35 opposite the left support wall in the transverse direction Y, and a first end wall 36 connecting the left support wall to the right support wall 35, wherein the first sealing plate 33 is hingedly connected to the first end wall 36. The carrier housing further comprises a second end wall connecting the left support wall to the right support wall and opposite the first end wall 36 in the longitudinal direction X, wherein the second sealing plate is hingedly connected to the second end wall.

[0065] The Fig. Figure 3 shows the housing base 10 and the battery cell stack 3 during the process of inserting the battery cell stack 3 into the receiving space 15 of the housing base 10. The right side wall 14 of the housing base 10 is formed by an intermediate wall. Fig. Figure 4 shows the battery cell stack 3 according to Fig. 3 in the area of ​​the first insertion aid 31 and thus in the area of ​​the first end section in a top view of the top of the battery cell stack 3. The Fig. Figure 5 shows the battery cell stack 3 according to Fig. 3 in the area of ​​the first insertion aid 31, whereby the first sealing plate 33 is not shown for better understanding. The applied sealant 50 is the one in the Fig. 3, Fig. 4 to Fig. 5 illustrated embodiment of a FIPFG seal, namely a polyurethane adhesive foam, wherein the polyurethane adhesive foam is applied in the form of an adhesive bead.

[0066] During the insertion process, the space 40 between the first insertion aid 31 and the second insertion aid 32 is not yet filled with the filling material 41. The process of filling the space 40 only takes place after the battery cell stack 3 has been inserted into the receiving chamber 15. The procedure is described below with reference to the flowchart according to Fig. 6 described in more detail.

[0067] The Fig. Figure 6 shows a flowchart for a method for injecting the fluid filling material 41 into the space 40 between the battery cell stack 3 and the housing base body 10 using an injection device.

[0068] In a first process step S1, the battery cell stack 3 with the attached first and second insertion aids 31, 32 is provided. The sealant 50 is in the form of an adhesive foam, which is bonded to both the top surface of the battery cell stack 3 and the back surface of the respective sealing plate 33, 34. The sealant 50 in the form of the adhesive foam is already cured.

[0069] In a second process step S2, the housing base body 10 is provided.

[0070] In a third process step S3, the injection device is provided.

[0071] In the fourth process step S4, the battery cell stack 3 with the attached first insertion aid 31 and the attached second insertion aid 32 is inserted into the receiving space 15 via the insertion opening 16, such that the space 40 between the top of the battery cell stack 3 and the upper housing wall 11 is formed between the first insertion aid 31 and the second insertion aid 32.

[0072] In a fifth process step S5, the thermally conductive filling material 41 is injected into the space 40 using the injection device, wherein the fifth process step S5 is carried out after the fourth process step S4. Reference symbol list 1 battery module 3 battery cell stacks 4 battery cells 10 Housing base bodies 11 upper case wall 12 lower case wall 13 left case wall 14 right side of case 15 Recording room 16 Insertion opening 31 First introduction aid 32 second insertion aid 33 first sealing plate 34 second sealing plate 35 right support wall 36 first front wall 40 space 41 Filling material 50 sealant 60 Cooling plate 61 Cooling channel 111 Filling opening X Longitudinal direction Y transverse direction Z Upward direction

Claims

[1] Battery module (1) for a traction battery of an electrically or partially electrically powered motor vehicle, wherein the battery module (1) comprises a housing base body (10) and a battery cell stack (3) with several battery cells (4), wherein the housing base body (10) comprises an upper housing wall (11), a lower housing wall (12) opposite the upper housing wall (11) in a vertical direction (Z), a left housing wall (13) and a right housing wall (14) opposite the left housing wall (13) in a transverse direction (Y), wherein the housing walls (11, 12, 13, 14) circumferentially define a receiving space (15) for the battery cell stack (3), wherein the housing base body (10) has an end-face insertion opening (16) for inserting the battery cell stack (3) into the receiving space (15) along a longitudinal direction (X), wherein the battery cell stack (3) is arranged in the receiving space (15),wherein a first insertion aid (31) is attached to the battery cell stack (3), wherein the first insertion aid (31) has a first sealing plate (33), wherein the first sealing plate (33) covers a top surface of the battery cell stack (3) facing the upper housing wall (11) in the region of a first end section, wherein the first sealing plate (33) has a front surface facing away from the top surface and a back surface opposite the front surface and facing the top surface, wherein a space (40) adjoining the first insertion aid (31) in the longitudinal direction (X) and formed between the top surface of the battery cell stack (3) and the upper housing wall (11) is filled with a thermally conductive filling material (41), wherein the first sealing plate (33) abuts with its front surface a sealingly against an inner surface of the upper housing wall (11) of the housing base body (10) facing the receiving space (15),wherein a sealant (50) is introduced between the back of the first sealing plate (33) and the top of the battery cell stack (3), the sealant (50) acting in a sealing manner with the top of the battery cell stack (3) and in a sealing manner with the back of the first sealing plate (33) to seal the gap against an escape of the thermally conductive filler material (41) between the top of the battery cell stack (3) and the upper housing wall (11) in the region of the first end section, , characterized by , that the battery cell stack (3) has a carrier housing, wherein the carrier housing has a left support wall, a right support wall (35) opposite the left support wall in the transverse direction (Y) and a first end wall (36) connecting the left support wall with the right support wall (35), wherein the first sealing plate (33) is hingedly connected to the first end wall (36). [2] Battery module (1) according to claim 1, wherein a second insertion aid (32) is attached to the battery cell stack (3), the second insertion aid (32) comprising a second sealing plate (34), the second sealing plate (34) covering the top of the battery cell stack (3) in the region of a second end section opposite the first end section in the longitudinal direction (X), the second sealing plate (34) having a front side facing away from the top and a back side opposite the front side and facing the top, the space (40) filled with the thermally conductive filler material (41) extending to the second insertion aid (32), the front side of the second sealing plate (34) sealingly abutting the inside of the upper housing wall (11) of the housing base body (10) facing the receiving space (15).wherein a sealant (50) is introduced between the back of the second sealing plate (34) and the top of the battery cell stack (10), wherein the sealant (50) acts sealingly with the top of the battery cell stack (3) and sealingly with the back of the second sealing plate (34) to seal the gap (40) against leakage of the thermally conductive filler material (41) between the top of the battery cell stack (3) and the upper housing wall (11) in the region of the second end section. [3] Battery module (1) according to claim 1 or claim 2, wherein the thermally conductive filling material (41) is a material introduced into the space (40) in a flowable form. [4] Battery module (1) according to one of claims 1 to 3, wherein the housing base body (10) is an extrusion profile. [5] Battery module (1) according to one of claims 1 to 4, wherein the upper housing wall (11) is a cooling wall, the cooling wall having a cooling channel structure for a cooling fluid and / or wherein a cooling plate (60) is attached to an outer surface of the cooling wall opposite the inner surface. [6] Battery module (1) according to any one of claims 1 to 5, wherein the sealant (50) is compressible at least in the vertical direction (Z). [7] Battery module (1) according to any one of claims 1 to 6, wherein the sealant (50) is a Formed In Place Foam Gasket (FIPFG) gasket. [8] Battery module (1) according to any one of claims 1 to 7, wherein the sealant (50) is bonded to the top of the battery cell stack (3) and the back of the first sealing plate (33) and / or wherein the sealant (50) is bonded to the top of the battery cell stack (3) and the back of the second sealing plate (34). [9] Battery module (1) according to any one of claims 1 to 8, wherein the first sealing plate (33) and / or the second sealing plate (34) extend wedge-shaped to the top of the battery cell stack (3) such that the distance of the sealing plate (33; 34) from the top of the battery cell stack (3) increases in the direction of the space (40). [10] Battery module (1) according to any one of claims 1 to 9, wherein the upper housing wall (11) has a filling opening (111) opening into the space (40) for injecting the filling material. [11] Method for injecting a fluid filling material (41) into a space (40) between a battery cell stack (3) and a housing base body (10) by means of an injection device, the method comprising the following process steps: - Providing the battery cell stack (3) with multiple battery cells (4), wherein a first insertion aid (31) is attached to the battery cell stack (3), the first insertion aid (31) comprising a first sealing plate (33), the first sealing plate (33) covering a top surface of the battery cell stack (3) in the region of a first end section, the first sealing plate (31) having a front surface facing away from the top surface and a rear surface opposite the front surface and facing the top surface, a sealant (50) being introduced between the rear surface of the first sealing plate (33) and the top surface of the battery cell stack (3), the battery cell stack (3) comprising a support housing, the support housing comprising a left support wall, a right support wall (35) opposite the left support wall in the transverse direction (Y), and a first end wall (36) connecting the left support wall to the right support wall (35).wherein the first sealing plate (33) is articulated to the first end wall (36), - Providing the housing base body (10), wherein the housing base body (10) has an upper housing wall, a lower housing wall (12) opposite the upper housing wall (11) in a vertical direction (Z), a left housing wall (13) and a right housing wall (14) opposite the left housing wall (13) in a transverse direction (Y), wherein the housing walls (11, 12, 13, 14) circumferentially delimit a receiving space (15) for the battery cell stack (3), wherein the housing base body (10) has an end-face insertion opening (16) for inserting the battery cell stack (3) into the receiving space (15) along a longitudinal direction (X), - Providing the injection device, - Inserting the battery cell stack (3) with the first insertion aid (31) attached to it through the insertion opening (16) along the longitudinal direction (X) into the receiving space (15) such that an intermediate space (40) adjoining the first insertion aid (31) in the longitudinal direction (X) is formed between the top of the battery cell stack (3) and the upper housing wall (11), wherein the first sealing plate (33) comes into contact with an inner surface of the upper housing wall (11) of the housing body (10) facing the receiving space (15) in a sealing manner, and the sealant (50) acts in a sealing manner with the top of the battery cell stack (3) and in a sealing manner with the rear side to seal the intermediate space (40) against escape of the thermally conductive filler material (41) to be injected into the intermediate space (40) between the top of the battery cell stack (3) and the upper housing wall (11) in the area of ​​the first final section, - Injecting the thermally conductive filling material (41) into the space (40) using the injection device, wherein the injection takes place after the battery cell stack (3) has been inserted into the receiving space (15). [12] The method of claim 11, wherein the method additionally comprises the following process steps: - Detection of an injection pressure of the filling material (41) during the injection process, wherein the injection is terminated based on a shutdown criterion, wherein the shutdown criterion is present when a predefined limit for the injection pressure is exceeded and / or when a predefined limit for the gradient of the injection pressure is exceeded.

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