Method for manufacturing a battery module

Abstract

The present invention relates to a method (10) for manufacturing a battery module (100). The invention further relates to a battery module (100) and a high-voltage battery (200), comprising several such battery modules (100), as well as a motor vehicle (300).

Description

[0001] The present invention relates to a method for manufacturing a battery module. The invention further relates to a battery module and a high-voltage battery, comprising several such battery modules, as well as a motor vehicle.

[0002] It is generally known that hybrid or purely electric vehicles have at least one propulsion-generating electric motor which is supplied with electrical energy by an electrical storage device, in particular a high-voltage battery.

[0003] Such a high-voltage battery typically consists of several battery modules, each of which in turn comprises several battery packs, in particular a multitude of spatially spaced battery cells. The individual battery cells or battery packs are electrically connected to each other by a cell contacting system.

[0004] The numerous individual battery cells are typically stabilized and fixed within the battery module. This stabilization and fixing can be achieved in various ways, for example, by welding the battery cells together, by using adhesive to bond them, by attaching a cooling system to connect the battery cells, or by attaching a foam core, particularly to fix the positions of the battery cells.

[0005] In the prior art, the foam body is produced in a potting process using a single homogeneous potting compound, in particular a single homogeneous flowable foam-like material, which fills the empty spaces between the spaced-apart battery cells and hardens upon contact with oxygen and / or ambient air, so that the multitude of individual battery cells are permanently stabilized and fixed by the hardened homogeneous foam body.

[0006] A disadvantage of this method is that the individual battery cells are completely embedded in the potting compound during the potting process, so that after hardening the individual battery cells are completely encased by the homogeneous foam body, and in particular the degassing openings of the individual battery cells are blocked.

[0007] By blocking the degassing openings, in the event of a defect in a battery cell or battery pack, degassing or pressure relief is no longer possible, which in turn can lead to a significant heat development of the battery module, especially to catastrophic explosions and fires.

[0008] In other words, the battery modules known from the prior art exhibit very low fire protection safety due to the unfavorable potting processes.

[0009] It is therefore an object of the present invention to at least partially overcome the disadvantages of a battery module described above. In particular, it is an object of the present invention to provide an improved method for manufacturing a battery module with a high level of fire safety. Furthermore, it is an object of the present invention to provide a fire-resistant high-voltage battery and a fire-resistant motor vehicle.

[0010] The foregoing problem is solved by a method having the features of claim 1 or by a method having the features of claim 2. With regard to the battery module, the problem is solved by the subject matter of dependent claim 7, with regard to the high-voltage battery by the subject matter of dependent claim 8, and with regard to the motor vehicle by the subject matter of dependent claim 9.

[0011] Further features and details of the invention will become apparent from the dependent claims, the description, and the drawings. Features and details described in connection with the method naturally also apply in connection with the battery module, the high-voltage battery, and the motor vehicle according to the invention, and vice versa, so that the disclosure regarding the individual aspects of the invention always refers, or can refer, to each other.

[0012] According to the first aspect of the invention, the problem is solved by a method for manufacturing a battery module. The method according to the invention comprises the following process steps: - Spatially spaced arrangement of a plurality of battery cells, each battery cell having a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening is provided on the first cell contact and / or on the second cell contact in order to be able to dissipate any overpressure inside the battery cell to the outside, - Covering the degassing openings of the numerous battery cells with cover elements, - Encasing the multitude of battery cells with a first flowable foam-like material in such a way that the first flowable foam-like material at least partially encases the multitude of battery cells and the cover elements, but does not encase the degassing openings, - Releasing the degassing openings of the multitude of battery cells by removing the cover elements, whereby a cavity forms above each degassing opening, - partial or complete filling of a second flowable foam-like material into the respective cavities above the degassing openings to cover the respective degassing openings of the multitude of battery cells with the second flowable foam-like material and - Curing of the first flowable foam-like material and the second flowable foam-like material upon contact with oxygen and / or ambient air to form a hybrid foam body for the production of a battery module.

[0013] The core idea according to the first aspect of the invention is therefore not to produce the foam body from a single homogeneous casting compound, in particular from a single homogeneous flowable foam-like material, as in the prior art, but from a first flowable foam-like material and from a second flowable foam-like material, which differ in their material and functional properties.

[0014] In other words, a hybrid foam body, consisting of a first flowable foam-like material and a second flowable foam-like material, is produced instead of a homogeneous foam body.

[0015] According to the first aspect of the invention, the degassing openings of the plurality of battery cells are initially covered by cover elements after arrangement, before the plurality of battery cells are encased in foam or the first flowable foam-like material is poured in. Preferably, the cover elements are larger than the diameter of the degassing openings. For example, the cover elements can be hemispherical, cone-shaped, or pyramidal. The cover elements can be made of a thermosetting plastic material and preferably have a higher melting point than the first flowable foam-like material. This allows the cover elements to be easily removed during or after the curing of the first flowable foam-like material without adhering to it.

[0016] According to the first aspect of the invention, it is explicitly provided that the plurality of battery cells are not completely embedded in the first flowable foam-like material as in the prior art, but are surrounded by the first flowable foam-like material in such a way that the first flowable foam-like material partially encloses the plurality of battery cells and the cover elements, preferably completely encloses them laterally, but does not surround the degassing openings.

[0017] Subsequently, the degassing openings of the numerous battery cells are released by removing the cover elements, creating a cavity above each degassing opening.

[0018] To cover the respective degassing openings of the multitude of battery cells, the respective cavities above the degassing openings are partially or completely filled with the second flowable foam-like material.

[0019] The first and second flowable foam-like materials then harden upon contact with oxygen and / or ambient air to form the hybrid foam body, so that the numerous individual battery cells are permanently stabilized by the hardened hybrid foam body and protected from external influences. It is conceivable that the first and second flowable foam-like materials harden together upon contact with oxygen and / or ambient air to form the hybrid foam body. It is also conceivable that the first and second flowable foam-like materials harden sequentially upon contact with oxygen and / or ambient air to form the hybrid foam body.The first flowable, foam-like material swells during the encapsulation process, particularly during curing, so that after swelling, especially after curing, the cover elements can be removed. After removing the cover elements, the respective cavities above the degassing openings of the numerous battery cells can then be partially or completely filled with the second flowable, foam-like material to cover them.

[0020] The provision of the hybrid foam body according to the invention, instead of a homogeneous foam body, offers the significant technical advantage that the degassing openings of the multitude of individual battery cells are no longer blocked by the first flowable foam-like material after curing. In the event of a defect in a battery cell or battery pack, degassing or pressure relief can be ensured by the cured second flowable foam-like material, so that no significant heat generation occurs, and in particular, no catastrophic explosions or fires.

[0021] In other words, the battery module exhibits a very high level of fire safety due to the hybrid foam body according to the invention.

[0022] According to the second aspect of the invention, the problem is also solved by a method for manufacturing a battery module. The method according to the second aspect of the invention comprises the following process steps: - Spatially spaced arrangement of a plurality of battery cells, each battery cell having a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening is provided on the first cell contact and / or on the second cell contact in order to be able to dissipate any overpressure inside the battery cell to the outside, - Covering the respective degassing openings of the multitude of battery cells with a second flowable foam-like material to form caps from the second flowable foam-like material above the respective degassing openings of the multitude of battery cells, - Encasing the multitude of battery cells with a first flowable foam-like material such that the first flowable foam-like material at least partially encases the multitude of battery cells and the cover caps, but does not encase the degassing openings, and - Curing of the first flowable foam-like material and the second flowable foam-like material upon contact with oxygen and / or ambient air to form a hybrid foam body for the production of a battery module.

[0023] The core idea according to the second aspect of the invention is therefore again to produce the foam body not from a single homogeneous casting compound, in particular from a single homogeneous flowable foam-like material, as in the prior art, but from a first flowable foam-like material and from a second flowable foam-like material.

[0024] In other words, a hybrid foam body, consisting of a first flowable foam-like material and a second flowable foam-like material, is produced instead of a homogeneous foam body.

[0025] According to the second aspect of the invention, it is provided that the respective degassing openings of the plurality of battery cells are first covered by cover caps consisting of the second flowable foam-like material after arrangement, before the plurality of battery cells are foamed over or the first flowable foam-like material is filled in.

[0026] According to the second aspect of the invention, it is again explicitly provided that the plurality of battery cells are not completely embedded in the first flowable foam-like material as in the prior art, but are surrounded by the first flowable foam-like material in such a way that the first flowable foam-like material partially encloses the plurality of battery cells and the cover caps, preferably completely encloses them laterally, but does not enclose the degassing openings.

[0027] According to the second aspect of the invention, the cover caps, consisting of the second flowable foam-like material, are not removed, so that the cover caps remain above the respective degassing openings of the plurality of battery cells to cover the respective degassing openings of the plurality of battery cells.

[0028] The first flowable foam-like material and the second flowable foam-like material then harden again upon contact with oxygen and / or ambient air to form the hybrid foam body, so that the multitude of individual battery cells are permanently stabilized by the hardened hybrid foam body and protected from external influences.

[0029] The hybrid foam body according to the invention, consisting of the first flowable foam-like material and the second flowable foam-like material, essentially fulfills two technical functions.

[0030] The first component of the hybrid foam body according to the invention, i.e. the first flowable foam-like material, serves as a kind of fixation and absorption structure and is designed to provide fixation or mechanical stabilization in order to optimally protect the multitude of individual battery cells or battery packs from mechanical influences such as shocks and vibrations.

[0031] The first flowable, foam-like material serves to bond the numerous individual battery cells to one another, particularly in a metallurgical manner. The numerous individual battery cells, in this case, for example, cylindrical cells, are preferably arranged vertically and spaced apart from each other. This results in gaps between the individual battery cells. In the event of an exothermic cell reaction, there is a risk that conductive particles, such as copper and carbon black particles, which escape from a damaged cell, will enter these intercellular spaces. This can lead to short-circuit reactions, which can have devastating consequences.

[0032] Filling these cell spaces with the first flowable, foam-like material can prevent this, while simultaneously achieving excellent crash performance properties. Furthermore, the weight can be kept low.

[0033] The second component of the hybrid foam body according to the invention, i.e., the second flowable foam-like material, serves as a kind of throttle and breakthrough structure, in particular as a kind of pressure relief valve, and is designed to provide a shielding or protective effect towards the top of the individual battery cells, i.e., outwards, in order to optimally protect the multitude of individual battery cells or the battery packs from external environmental influences such as moisture and dust, while simultaneously ensuring degassing or pressure relief to the outside.

[0034] During operation, the volume or thickness of individual battery cells increases with their lifespan. In electrical engineering, this gradual increase is referred to as "swelling" of a battery cell and is further characterized by fluctuating intervals. Each fluctuating interval typically corresponds to an electrical charging of the battery cell, while each fluctuating interval corresponds to an electrical discharging of the battery cell. This fluctuating volume, along with the overall increase in the battery cell's size, leads to mechanical stress on the battery cell and, consequently, on the battery as a whole.

[0035] In particular, damage can occur within the battery cell. Due to a subsequent chemical reaction, especially thermal runaway, a gas mixture, dependent on the cell chemistry, can form and accumulate inside the battery cell. This gas evolution can cause overpressure to build up within the damaged battery cell, leading to the gas mixture escaping from the cell at very high speed as a jet of gas and / or fire. This chemical reaction caused by the damage typically results in intense heating of the affected battery cell and its immediate surroundings, as well as a catastrophic explosion and fire.

[0036] In other words, thermal runaway occurs in a battery module when a single battery cell, or a region within a battery cell, reaches excessively high temperatures due to thermal failure, mechanical failure, internal / external short circuit, swelling and cooling, over-discharging, over-charging, or electrochemical malfunction. When the battery cell reaches such a high internal temperature that the electrolyte, being an organic liquid, ignites, the oxide material in the cathode breaks down and releases oxygen. The damaged battery cell then contains fuel (liquid organic electrolyte) and oxygen (from the oxides in the cathode) for a fire that can itself generate oxygen, making it extremely difficult to extinguish. At elevated temperatures prior to thermal runaway, exothermic decomposition of the cell materials begins.As a result, internal pressure builds up in the battery cell, which must be released to the outside.

[0037] The second flowable, foam-like material ensures such degassing and pressure reduction to the outside. This second flowable, foam-like material can contain or retain the gas mixture in the form of the gas and / or fire jet towards the top of the battery cells, particularly towards the degassing openings of the numerous battery cells, and in particular significantly reduce the exit velocity of the gas and / or fire jet, thus ensuring targeted and controlled escape.

[0038] According to a preferred further development of the invention, in a method for manufacturing a battery module according to the first or second aspect of the invention, it may be provided that the first flowable foam-like material and the second flowable foam-like material have different melting points, wherein the melting point of the first flowable foam-like material is higher than the melting point of the second flowable foam-like material.

[0039] Thermal runaway is known to begin at approximately 165 °C. To prevent the permanent stabilization and fixation, in particular the material bonding of the multitude of individual battery cells to one another, from being affected by thermal runaway, especially from being melted, a preferred further development of the invention provides that, in a method for manufacturing a battery module according to the first or second aspect of the invention, the melting point of the first flowable foam-like material is above 165 °C.

[0040] The faster the degassing or pressure reduction to the outside occurs, the lower the risk of a catastrophic explosion and fire. In other words, a low melting point is highly advantageous for degassing or pressure reduction. However, the melting point must not be too low, so that a controlled and directed escape of the gas and / or fire jet can still be ensured while simultaneously providing a shielding or protective effect to the outside.

[0041] Therefore, according to a preferred further development of the invention, in a method for manufacturing a battery module according to the first or second aspect of the invention, it can be provided that the melting point of the second flowable foam-like material is below 165 °C, preferably between 90 °C and 150 °C.

[0042] According to a preferred further development of the invention, in a method for manufacturing a battery module according to the first or second aspect of the invention, it may be provided that the first flowable foam-like material and the second flowable foam-like material have different porosities, wherein the porosity of the first flowable foam-like material is denser than the porosity of the second flowable foam-like material.

[0043] The first flowable foam-like material can be, for example, a rigid or flexible foam, polyurethane foam, polypropylene foam, epoxy resin, silicone foam and / or another suitable, in particular expanding, plastic foam, which can be introduced into the intercellular spaces in liquid or paste form and, upon contact with oxygen and / or ambient air, can harden together with the second flowable foam-like material to form the hybrid foam body according to the invention, in order to optimally protect the multitude of individual battery cells or the battery packs from mechanical influences such as shocks and vibrations.

[0044] The second flowable foam-like material can be, for example, a polyethylene foam, organic foam, non-woven foam, textile foam or a thermosetting plastic foam with a fiber material or fiber matrix, such as a glass fiber matrix.

[0045] The use of such a flowable, foam-like material offers the particular advantage of providing the desired protective effect, especially since the second flowable, foam-like material can act as a predetermined breaking point. After curing, the second flowable, foam-like material is open-pored and has holes, particularly perforations, through which degassing can occur and excess pressure can escape. These holes, particularly perforations, expediently act as throttles or as a multitude of small pressure relief valves, so that targeted and controlled pressure reduction can be achieved simply and cost-effectively via this throttling function.

[0046] According to a third aspect of the invention, a battery module for integration into a high-voltage battery is provided, which is manufactured by a method according to at least one of the preceding claims.

[0047] The battery module includes: - a battery pack, in particular a plurality of spatially spaced battery cells, wherein each battery cell has a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening is provided on the first cell contact and / or on the second cell contact in order to be able to dissipate any overpressure inside the battery cell to the outside, - a housing for receiving the battery pack, wherein the housing has a safety valve for degassing the battery pack, - a cell contacting system with a multitude of cell connection elements for serial and / or parallel electrical contacting of the multitude of battery cells with each other and - a hybrid foam body for stabilizing and permanently positioning the plurality of battery cells, wherein the hybrid foam body at least partially encloses the plurality of battery cells, preferably completely encloses them laterally, but does not enclose the degassing openings, - wherein the hybrid foam body is formed from a first flowable foam-like material and a second flowable foam-like material, wherein the first flowable foam-like material and the second flowable foam-like material harden upon contact with oxygen and / or ambient air to form the hybrid foam body, - wherein the first flowable foam-like material and the second flowable foam-like material have different melting points, the melting point of the first flowable foam-like material being higher than the melting point of the second flowable foam-like material.

[0048] According to a fourth aspect of the invention, a high-voltage battery for a motor vehicle, comprising several such battery modules, is proposed, wherein the battery modules are electrically connected in series and / or parallel.

[0049] According to a fifth aspect of the invention, a motor vehicle with such a high-voltage battery is proposed.

[0050] A method according to the invention for manufacturing a battery module is explained in more detail below with reference to the drawings. The drawings schematically show: Fig. 1 a schematic illustration of the process steps for manufacturing a battery module according to the first aspect of the present invention, Fig. 2 a schematic illustration of the process steps for manufacturing a battery module according to the second aspect of the present invention and Fig. 3 a motor vehicle with a high-voltage battery according to an embodiment of the present invention.

[0051] As in the Fig. As can be clearly seen, according to the first aspect of the invention, in a first step S1 a plurality of battery cells 20 are arranged standing upright and spatially spaced apart from each other, so that cell gaps are formed between the individual battery cells 20.

[0052] In the depicted Fig. 1, Fig. 2 to Fig. 3. The battery cells 20 are designed as cylindrical lithium-ion battery cells 20, in particular as round cells. It is conceivable that the battery cells 20 also have a different geometry and are designed, for example, as cuboid storage cells or so-called "pouch cells". It is conceivable that the battery cells 20 are designed, for example, as alkaline, lithium, NiMH, NiCd or zinc-air battery cells.

[0053] Battery cells 20 with different cell chemistries can also be used.

[0054] Each battery cell 20 has a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening 25 is provided on the first cell contact and / or on the second cell contact in order to be able to dissipate an overpressure inside the battery cell 20 to the outside.

[0055] In a second step S2, the degassing openings 25 of the multitude of battery cells 20 are covered by cover elements 30.

[0056] In a third step S3, the plurality of battery cells 20 are foamed over with the first flowable foam-like material 41 in such a way that the first flowable foam-like material 41 at least partially encloses the plurality of battery cells 20 and the cover elements 30, preferably completely encloses them laterally, but does not foam over the degassing openings 25.

[0057] In a fourth step S4, the degassing openings 25 of the plurality of battery cells 20 are released by removing the cover elements 30, whereby a cavity 26 is formed above each of the degassing openings 25.

[0058] In a fifth step S5, the second flowable foam-like material 42 is partially or completely filled into the respective cavities 26 above the degassing openings 25 to cover the respective degassing openings 25 of the plurality of battery cells 20.

[0059] In a sixth step S6, the first flowable foam-like material 41 and the second flowable foam-like material 42 harden upon contact with oxygen and / or ambient air to form the hybrid foam body 45 for the production of a battery module 100.

[0060] As in the Fig. As can be clearly seen in Figure 2, according to the second aspect of the invention, in a first step E1 a plurality of battery cells 20 are arranged standing upright and spatially spaced apart from each other, so that cell gaps are formed between the individual battery cells 20.

[0061] Each battery cell 20 has a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening 25 is provided on the first cell contact and / or on the second cell contact in order to be able to dissipate an overpressure inside the battery cell 20 to the outside.

[0062] In a second step E2, the respective degassing openings 25 of the plurality of battery cells 20 are covered with the second flowable foam-like material 42 to form cover caps 40 made of the second flowable foam-like material 42 above the respective degassing openings 25 of the plurality of battery cells 20.

[0063] In a third step E3, the plurality of battery cells 20 are foamed over with the first flowable foam-like material 41 in such a way that the first flowable foam-like material 41 at least partially encloses the plurality of battery cells 20 and the cover caps 40, preferably completely encloses them laterally, but does not foam over the degassing openings 25.

[0064] In a fourth step E4, the first flowable foam-like material 41 and the second flowable foam-like material 42 harden upon contact with oxygen and / or ambient air to form the hybrid foam body 45 for the production of a battery module 100.

[0065] The battery module 100 is designed for integration into a high-voltage battery 200. The battery module 100 comprises a battery pack 50, in particular a plurality of spatially spaced battery cells 20, each battery cell 20 having a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening 25 is provided at the first cell contact and / or at the second cell contact in order to be able to dissipate any overpressure inside the battery cell 20 to the outside.

[0066] The battery module 100 further comprises a housing 60 for receiving the battery pack 50, wherein the housing 60 has a safety valve 65 for degassing the battery pack 50.

[0067] The battery module 100 further comprises a cell contacting system (not shown) with a plurality of cell connection elements for serial and / or parallel electrical contacting of the plurality of battery cells 20 with each other.

[0068] The battery module 100 further comprises a hybrid foam body 45 for stabilizing and permanently positioning the plurality of battery cells 20, wherein the hybrid foam body 45 at least partially encloses the plurality of battery cells 20, preferably completely encloses them laterally, but does not enclose the degassing openings 25.

[0069] The hybrid foam body 45 is formed from a first flowable foam-like material 41 and from a second flowable foam-like material 42, wherein the first flowable foam-like material 41 and the second flowable foam-like material 42 cure upon contact with oxygen and / or ambient air to form the hybrid foam body 45, and wherein the first flowable foam-like material 41 and the second flowable foam-like material 42 have different melting points, the melting point of the first flowable foam-like material 41 being higher than the melting point of the second flowable foam-like material 42.

[0070] Fig. Figure 3 shows a motor vehicle 300 with a high-voltage battery 200 according to an embodiment of the present invention.

[0071] The high-voltage battery 200 comprises several battery modules 100 according to the invention, wherein the battery modules 100 are electrically connected in series and / or parallel. The high-voltage battery 200 is characterized, among other things, by its high energy density, thermal stability, and extremely low self-discharge.

[0072] The high-voltage battery 200 can, for example, provide an output or nominal voltage of at least 48 V, 100 V, 200 V, 400 V, 600 V, 800 V or more, so that the high-voltage battery 200 can be used in particular as a traction battery for the motor vehicle 300.

[0073] The vehicle 300 can be a pure electric vehicle (EV), a hybrid vehicle (HEV), or a plug-in hybrid vehicle (PHEV). It is conceivable that the high-voltage battery 200 could also be used for other purposes, such as a home or building battery, a buffer or stabilization battery for a power grid, for supplying stationary equipment or systems, and / or the like. Reference symbol list 10 procedures 20 battery cells 25 Degassing opening 26 cavity 30 cover elements 40 cover caps 41 first flowable foam-like material 42 second flowable foam-like material 45 hybrid foam body 50 battery pack 100 battery modules 200 high-voltage battery 300 motor vehicles

Claims

Method (10) for manufacturing a battery module (100), wherein the method (10) comprises the following process steps: - (S1) Spatially spaced arrangement of a plurality of battery cells (20), each battery cell (20) having a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening (25) is provided at the first cell contact and / or at the second cell contact in order to be able to dissipate any overpressure inside the battery cell (20) to the outside, - (S2) Covering the degassing openings (25) of the plurality of battery cells (20) by cover elements (30), - (S3) Encasing the plurality of battery cells (20) with a first flowable foam-like material (41) such that the first flowable foam-like material (41) at least partially encloses the plurality of battery cells (20) and the cover elements (30), but does not enclose the degassing openings (25). foamed over,- (S4) Releasing the degassing openings (25) of the plurality of battery cells (20) by removing the cover elements (30), whereby a cavity (26) is formed above each of the degassing openings (25), - (S5) partially or completely filling a second flowable foam-like material (42) into the respective cavities (26) above the degassing openings (25) to cover the respective degassing openings (25) of the plurality of battery cells (20) with the second flowable foam-like material (42), and - (S6) curing of the first flowable foam-like material (41) and the second flowable foam-like material (42) upon contact with oxygen and / or ambient air to form a hybrid foam body (45) for the production of a battery module (100). Method (10) for manufacturing a battery module (100), wherein the method (10) comprises the following process steps: - (E1) Spatially spaced arrangement of a plurality of battery cells (20), each battery cell (20) having a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening (25) is provided at the first cell contact and / or at the second cell contact in order to dissipate any overpressure inside the battery cell (20) to the outside, - (E2) Covering the respective degassing openings (25) of the plurality of battery cells (20) with a second flowable foam-like material (42) to form caps (40) made of the second flowable foam-like material (42) above the respective degassing openings (25) of the plurality of battery cells (20), - (E3) Foaming around the plurality of battery cells (20) with a first flowable foam-like material (41) such,that the first flowable foam-like material (41) at least partially envelops the plurality of battery cells (20) and the cover caps (40), but does not envelop the degassing openings (25), and- (E4) curing of the first flowable foam-like material (41) and the second flowable foam-like material (42) upon contact with oxygen and / or ambient air to form a hybrid foam body (45) for the manufacture of a battery module (100). Method (10) according to at least one of the preceding claims, characterized in that the first flowable foam-like material (41) and the second flowable foam-like material (42) have different melting points, wherein the melting point of the first flowable foam-like material (41) is higher than the melting point of the second flowable foam-like material (42). Method (10) according to at least one of the preceding claims, characterized in that the melting point of the first flowable foam-like material (41) is above 165 °C. Method (10) according to at least one of the preceding claims, characterized in that the melting point of the second flowable foam-like material (42) is below 165 °C, preferably between 90 °C and 150 °C. Method (10) according to at least one of the preceding claims, characterized in that the first flowable foam-like material (41) and the second flowable foam-like material (42) have different porosities, wherein the porosity of the first flowable foam-like material (41) is denser than the porosity of the second flowable foam-like material (42). Battery module (100) for integration into a high-voltage battery (200), manufactured by a method according to at least one of the preceding claims, the battery module (100) comprising: - a battery pack (50), in particular a plurality of spatially spaced battery cells (20), wherein each battery cell (20) has a first cell contact with a first polarity and a second cell contact with a second polarity, wherein a degassing opening (25) is provided at the first cell contact and / or at the second cell contact in order to be able to dissipate any overpressure inside the battery cell (20) to the outside, - a housing (60) for receiving the battery pack (50),wherein the housing (60) comprises a safety valve (65) for degassing the battery pack (50), a cell contacting system with a plurality of cell connection elements for series and / or parallel electrical contacting of the plurality of battery cells (20) with each other, and a hybrid foam body (45) for stabilizing and permanently positioning the plurality of battery cells (20), wherein the hybrid foam body (45) at least partially encloses the plurality of battery cells (20), preferably completely enclosing them laterally, but not enclosing the degassing openings (25), and wherein the hybrid foam body (45) is formed from a first flowable foam-like material (41) and from a second flowable foam-like material (42).wherein the first flowable foam-like material (41) and the second flowable foam-like material (42) harden upon contact with oxygen and / or ambient air to form the hybrid foam body (45), wherein the first flowable foam-like material (41) and the second flowable foam-like material (42) have different melting points, the melting point of the first flowable foam-like material (41) being higher than the melting point of the second flowable foam-like material (42). High-voltage battery (200) for a motor vehicle (300) comprising several battery modules (100) according to at least one of the preceding claims, wherein the battery modules (100) are electrically connected in series and / or parallel with each other. Motor vehicle (300), with a high-voltage battery (200) according to the preceding claim.

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