Method for manufacturing battery cells for a motor vehicle

Abstract

The invention relates to a method for manufacturing battery cells for a motor vehicle, comprising the following process steps. In a first process step, a first horizontal workpiece carrier is provided. In a second process step, an adhesive is applied to the surface of the workpiece carrier. In a third process step, at least two cells for a battery are provided in at least a first layer. In a fourth process step, steps two and three are repeated in each subsequent layer up to a predetermined number of layers. In a fifth process step, a second horizontal workpiece carrier with a layer of adhesive is applied for fixing the cells.

Description

[0001] The present invention relates to a method for manufacturing battery cells for a motor vehicle.

[0002] Battery cell manufacturing for motor vehicles is a crucial step in the development of electric and hybrid vehicles. However, these battery cells must meet specific requirements, such as high energy density, a long lifespan, and safe and reliable operation.

[0003] The production of battery cells is a complex process encompassing various steps, from material preparation to final assembly. Therefore, the development of new methods and technologies for battery cell manufacturing is crucial for improving battery cell performance and reliability.

[0004] The present invention relates to a method for manufacturing battery cells for motor vehicles, which enables improved power density, a longer service life, and safe and reliable operation of the battery cells. The method is particularly advantageous because it allows for the simple and efficient production of battery cells that meet the requirements of motor vehicles.

[0005] The production of battery cells that meet the requirements of motor vehicles is a complex process that requires careful planning and execution. The present invention therefore aims to contribute to solving these problems by presenting a simple and efficient method for manufacturing battery cells that meets the requirements of motor vehicles.

[0006] According to the invention, a method for manufacturing battery cells for a motor vehicle according to claim 1, as well as a motor vehicle with a battery cell according to claim 10, which was manufactured according to the method, is provided.

[0007] Advantageous embodiments can be found in the dependent claims and the description.

[0008] The invention relates to a method for manufacturing battery cells for a motor vehicle, comprising the following process steps. In a first process step, a first horizontal workpiece carrier is provided. In a second process step, an adhesive is applied to a surface of the first workpiece carrier. In a third process step, at least two cells for a battery cell are provided in at least a first layer, wherein the at least two cells are applied to the workpiece carrier, and wherein the at least two cells are arranged on the adhesive side of the first workpiece carrier.In a fourth process step, the preceding steps are repeated at least once in each further layer up to a predetermined number of layers, wherein the layer thickness of the battery cell increases vertically, wherein the adhesive for the at least two cells of the further layer is applied to the cells of the first layer, and wherein the cells of the further layer are applied into the adhesive on the cells of the preceding layer.In a fifth process step, a second horizontal workpiece carrier is applied, wherein the second horizontal workpiece carrier is arranged opposite the first horizontal workpiece carrier, wherein at least one first layer and at least one further layer of cells are arranged between the first horizontal workpiece carrier and the second horizontal workpiece carrier, and wherein a layer of adhesive for attaching the cells of the at least one further layer to the second horizontal workpiece carrier is arranged between the at least one further layer of cells and the second horizontal tool carrier.

[0009] The above method is advantageous because the cells of the battery cell are accessible from both sides during the manufacturing process. This allows the battery cell to be built up layer by layer. Alternatively or additionally, simple contacting of the individual cells of the battery cell is possible without rearranging the battery cell.

[0010] The respective workpiece carrier can be designed as a side part of the battery, in other words as a cover or base. The first workpiece carrier and / or the second workpiece carrier can include connections for cooling channels for conveying a fluid, in particular a liquid.

[0011] In an advantageous further development, the first workpiece carrier and / or the second workpiece carrier can be shaped perpendicular to the at least two cells, or the workpiece carrier can be additively manufactured.

[0012] In an advantageous further development, the cells of the battery cell or the respective layer of cells are arranged parallel to the first workpiece carrier and / or the second workpiece carrier.

[0013] In a further advantageous embodiment, the first workpiece carrier and / or the second workpiece carrier can be formed from or comprise webs or ribs. In a further advantageous embodiment, adhesive can be applied to the webs for attaching the cells. The first workpiece carrier and / or the second workpiece carrier can each comprise a closed base. Webs or ribs can be arranged on the base of the respective workpiece carrier.

[0014] In an advantageous further development, a structural element can be arranged between the respective layers, or in a further process step, a structural element can be inserted between the respective layers, with an adhesive being applied to the respective structural element and / or to the respective cells on which the structural element is placed. Alternatively or additionally, the application of adhesive to the cells can be at least partially omitted.

[0015] In an advantageous further development, the ribs or webs of the first workpiece carrier and / or the second workpiece carrier run transversely to the cells and / or to the structural elements. This allows gaps to be formed between the cells.

[0016] In an advantageous further development, a waiting period is observed between the application of the first layer of cells and the next layer of cells, or between the application of each subsequent layer of cells. This may be necessary to allow the adhesive of the first layer, into which the at least two cells of the next layer and / or the structural element are applied, or the cells of each subsequent layer to reach sufficient strength for assembly before a new layer of cells and / or a structural element is applied.

[0017] The assembly strength of adhesives refers to the ability of an adhesive to maintain a bond between two surfaces without them breaking apart under stress or strain.

[0018] In a further training, each of the at least two cells in a layer is arranged antiparallel to its neighboring cell in the same layer, or each of the at least two cells in a layer is arranged parallel to its neighboring cell in the same layer.

[0019] The at least two cells of each layer each comprise a first end face with a first contact area and a second end face with a second contact area.

[0020] The at least two cells of each layer can be arranged in the same orientation, i.e., parallel to each other, so that the poles of the at least two cells with the same polarity point in the same direction. The at least two cells can also be arranged in inverted orientation, so that the poles of the at least two cells with opposite polarities point in the same direction.

[0021] With more than two cells, parallel or serially connected groups of cells can be interconnected via a cell contacting system between the cells and / or between the layers.

[0022] The first contact area or the second contact area of ​​one of the at least two cells is the area in which a positive pole or a negative pole of the respective cell is located.

[0023] In a further process step, at least two cells are contacted in a respective end area of ​​the respective cell.

[0024] In a further process step, a structural element is inserted between each layer of cells.

[0025] In an advantageous further development, the structural element is designed as a heat-conducting plate and / or as a positioning means of the cells in relation to each other and / or to the first workpiece carrier and / or the second workpiece carrier, or comprises such a means.

[0026] The adhesive to be applied can be applied to the cells of the respective layer and / or the structural element.

[0027] In a further process step, the spaces between the cells are filled with a flame-retardant material.

[0028] In a training course, the flame-retardant material is injected into the spaces between the cells.

[0029] These gaps can be filled by polyurethane, especially polyurethane foam.

[0030] The gaps can occur between the cells and the adhesive or the adhesive layer formed by the adhesive. Alternatively or additionally, the gaps can occur between the cells themselves. Alternatively or additionally, the gaps can occur between the cells, the adhesive, and / or the first and / or second workpiece carriers. Alternatively or additionally, the gaps between the webs of the first and / or second workpiece carriers, the adhesive, and / or the cells can be filled with the flame-retardant material. The first and / or second workpiece carrier can include a recess for this purpose.

[0031] The trend towards larger battery cells carries certain risks, as the lithium they contain is highly reactive and flammable. Rapid charging, overcharging, undercharging, or charging at excessively low temperatures can damage the battery cell. Lithium-ion batteries are designed for a specific energy capacity. Exceeding this capacity can alter the cell's chemical composition. An unstable battery cell often leads to overheating. Once thermal runaway has begun, it is irreversible and can result in short circuits or fires.

[0032] In an advantageous further development, the flame-retardant material is made of or comprises a polyurethane.

[0033] In an advantageous further development, the polyurethane is formed as polyurethane foam.

[0034] The polyurethane foam is placed directly between the cells of the battery cell. There, it prevents a burning cell from igniting neighboring cells. In this way, overheating of the battery cell cannot occur in the first place. The foam also minimizes the weight load on the battery cells, absorbs external environmental influences, and reduces shocks, noise, and vibrations.

[0035] In a further process step, the respective layer of cells is supplied via a conveyor device, whereby a continuous material flow to cells is provided via the conveyor device, whereby the respective workpiece carrier and / or the conveyor device can be positioned relative to each other for positioning the respective cell on the respective workpiece carrier.

[0036] In an advantageous further development, 1 cell per second is fed via the conveying device. In an advantageous further development, the conveying speed of the conveying device can be varied between one cell per second and 5 cells per second.

[0037] In a training course, the cells of a layer are supplied continuously via the conveying device.

[0038] In a further process step, after the adhesive has been applied to the respective workpiece carrier and / or the respective layer of cells and / or the respective structural element, the adhesive is activated with a plasma jet or UV light or heat.

[0039] The invention also relates to a motor vehicle with a battery which was manufactured according to a method of the preceding method.

[0040] In an advantageous embodiment, the battery cell comprises a first workpiece carrier, wherein an adhesive is arranged on the first workpiece carrier, wherein a first layer of at least two cells is fixed to the first workpiece carrier with the adhesive, wherein a further adhesive layer is arranged on the at least two cells of the first layer, wherein a further layer of cells is arranged and fixed in the second adhesive layer, wherein a further layer of adhesive is arranged on the further layer of cells, wherein a second workpiece carrier is attached with the layer of adhesive on the second layer of cells.

[0041] In a further education course, a structural element is inserted between each layer of cells.

[0042] In an advantageous further development, the structural element is designed as a heat-conducting plate and / or as a positioning means of the cells in relation to each other and / or to the first workpiece carrier and / or the second workpiece carrier, or comprises such a means.

[0043] In a beneficial advanced training, the layering of cells can be repeated as often as desired.

[0044] In an advantageous further development, the structural element and / or the first workpiece carrier and / or the second workpiece carrier and / or the adhesive layer can be designed in such a way that they allow for individual and complex geometric shapes. In an advantageous further development, this can enable, for example, the creation of cooling channels using 3D printing.

[0045] The invention is described below by way of example only, with reference to the drawings. The drawings show: Fig. Figure 1 shows a method for manufacturing battery cells for a motor vehicle according to an embodiment of the invention, and Fig. Figure 2 shows a battery cell manufactured according to a method for manufacturing battery cells according to an embodiment of the invention.

[0046] Fig. Figure 1 shows a method for manufacturing battery cells 100 for a motor vehicle, comprising the following process steps. In a first process step, a first horizontal workpiece carrier 140 is provided, S1. In a second process step, an adhesive 160 is applied to a surface of the first workpiece carrier 140, S2. In a third process step, at least two cells 110 for a battery cell 100 are provided in at least a first layer 120, wherein the at least two cells 110 are applied to the first workpiece carrier 140, the at least two cells 110 being arranged on the side of the adhesive 160 on the first workpiece carrier 140, S3.In a fourth process step, the preceding steps are repeated at least once in each further layer 130 up to a predetermined number of layers, wherein the layer thickness of the battery cell 100 increases vertically, wherein the adhesive 160 for the at least two cells 110 of the further layer 130 is applied to the cells 110 of the first layer 120, wherein the cells 110 of the second layer 130 are applied into the adhesive 160 on the cells 110 of the first layer 120, S4.In a fifth process step, a second horizontal workpiece carrier 150 is applied, wherein the second horizontal workpiece carrier 150 is arranged opposite the first horizontal workpiece carrier 140, wherein at least one first layer 120 and at least one further layer 130 are arranged on cells 110 between the first horizontal workpiece carrier 140 and the second horizontal workpiece carrier 150, wherein a layer of adhesive 160 is arranged between the at least one further layer 130 on cells 110 and the second horizontal tool carrier 150 for attaching the at least one further layer on cells 110 to the second horizontal workpiece carrier 150, S5.

[0047] Fig.Figure 2 shows a side view of a battery cell 100. The battery cell 100 comprises a first workpiece carrier 140, on which an adhesive 160 is arranged. A first layer 120, consisting of at least two cells 110, is fixed to the first workpiece carrier 140 by the adhesive 160. A further adhesive layer 160 is arranged on the at least two cells 110 of the first layer 140. A second layer 130, consisting of cells 110, is arranged and fixed within the second adhesive layer 160. A further layer of adhesive 160 is arranged on the second layer 130 of cells 110. A second workpiece carrier 150, with the layer of adhesive 160, is attached to the second layer 130 of cells 110. Structural elements 170, designed as heat-conducting plates, are arranged between the cells 110 and dissipate heat from the battery cell 100.Additionally, structural elements 170 are arranged between the cells 110 of the first layer 120 and the second layer 130, on which the cells 110 of the first layer 120 and the second layer 130 are mounted, or rather, mounted against each other. Structural elements 170 are also arranged between the cells 110 of the first layer 120 and the second layer 130 and the first workpiece carrier 140 and the second workpiece carrier 150.

[0048] Adhesive 160 is applied between the cells 110 and the structural elements 170 in order to attach the cells 110 to the structural elements 170.

[0049] In a top view of the battery cell (not shown), the first workpiece carrier 140 and the second workpiece carrier comprise ribs or webs that run transversely to the cells 110 or to the structural elements 170. This allows gaps to be formed. These gaps can be filled with polyurethane, in particular polyurethane foam.

[0050] The invention is not limited to the described embodiments. Within the scope of the invention, all described and / or drawn features can be combined with one another as desired, unless otherwise stated. Reference sign S1 - S5 Procedure steps 100 battery cells 110 cells 120 First shift 130 Second shift 140 First workpiece carrier 150 Second workpiece carrier 160 adhesive 170 structural element

Claims

[1] Method for manufacturing battery cells (100) for a motor vehicle, comprising the following process steps: - Providing a first horizontal workpiece carrier (140), (S1) - Applying an adhesive (160) to a surface of the first workpiece carrier (140), (S2) - Providing at least two cells (110) for the battery cell (100) in at least a first layer (120), wherein the at least two cells (110) are applied to the first workpiece carrier (140), wherein the at least two cells (110) are arranged on the adhesive side (160) of the first workpiece carrier (140), (S3) - At least one repetition of the preceding steps in each further layer (130) up to a predetermined number of layers, wherein the layer thickness of the battery cell (100) increases vertically, wherein the adhesive (160) is applied to the cells of the preceding layer (120) for at least two cells (110) of the further layer (130), wherein the cells of the next layer (130) are applied to the adhesive (160) on the cells (110) of the first layer (120), (S4) - Applying a second horizontal workpiece carrier (150), wherein the second horizontal workpiece carrier (150) is arranged opposite the first horizontal workpiece carrier (140), wherein at least one first layer (120) and at least one further layer (130) of cells (110) are arranged between the first horizontal workpiece carrier (140) and the second horizontal workpiece carrier (150), wherein a layer of adhesive (160) is arranged between the at least one further layer (130) of cells (110) and the second horizontal tool carrier (150) for attaching the at least one further layer (130) of cells (110) to the second horizontal workpiece carrier (150), (S5). [2] Method for manufacturing battery cells (100) for a motor vehicle according to claim 1, characterized by , that each of the at least two cells (110) in a layer (120, 130) is arranged antiparallel to its neighboring cell (110) in the same layer (120, 130) or that each of the at least two cells (120, 130) in a layer (120, 130) is arranged parallel to its neighboring cell (110) in the same layer (120, 130). [3] Method for manufacturing battery cells (100) for a motor vehicle, according to one of the preceding claims, characterized by, that at least two cells (110) are contacted in a respective end region of the respective cell (110). [4] Method for manufacturing battery cells (100) for a motor vehicle, according to one of the preceding claims, characterized by , that a structural element (170) is inserted between each of the respective layers (120, 130) of cells (110), wherein an adhesive (160) is applied to the respective structural element (170). [5] Method for manufacturing battery cells (100) for a motor vehicle, according to one of the preceding claims, characterized by , that the spaces between the cells (110) are filled with a flame-retardant material. [6] Method for manufacturing battery cells (100) for a motor vehicle, according to claim 5, characterized by , that the flame-retardant material is injected into the spaces between the cells (110). [7] Method for manufacturing battery cells (100) for a motor vehicle according to one of the preceding claims, characterized by , that the respective layer (120, 130) is supplied to cells (110) via a conveying device, wherein a continuous material flow to cells (110) is provided via the conveying device, wherein the respective workpiece carrier (140, 150) and / or the conveying device for positioning the respective cell (110) on the respective workpiece carrier (140, 150) can be positioned relative to each other. [8] Method for manufacturing battery cells (100) for a motor vehicle, according to one of the preceding claims, characterized by , wherein the cells (110) are supplied continuously via the conveying device. [9] Method for manufacturing battery cells (100) for a motor vehicle, according to one of the preceding claims, characterized by, that after applying the adhesive (160) to the respective workpiece carrier (140, 150) and / or the respective layer (120, 130) of cells (110) and / or the respective structural element (170), the adhesive is activated with a plasma jet or UV light or heat. [10] Motor vehicle comprising a battery cell (100) manufactured according to the above method.

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