Method for manufacturing a battery for a motor vehicle

Abstract

In a first process step, a first housing part is provided. In a second process step, a second housing part is provided, which is positioned opposite the first housing part. In a third process step, at least one battery cell is supplied and arranged between the first and second housing parts. In a fourth process step, a first ultrasound generation unit is attached to the first housing part and a second ultrasound generation unit is attached to the second housing part. In a fifth process step, the first and second housing parts are simultaneously formed on opposite sides of the at least one battery cell, with the first housing part being supplied by unwinding from a first roll and the second housing part from a second roll.In this process, the first ultrasound generation unit introduces ultrasonic vibrations into the first housing part, and the second ultrasound generation unit introduces ultrasonic vibrations into the second housing part. In a sixth process step, the remaining four housing covers are attached to the battery.

Description

The present invention relates to a method for manufacturing a battery for an automobile.In modern-day electric vehicles, the battery plays a central role as an energy store and drive unit. As electric and hybrid vehicles continue to grow in size, the need for powerful, long-lived, and safe batteries is continually increasing. Traditional battery technologies are limited in energy density, charging speed, and lifetime. In addition, possible material stress during production is to be avoided.It is necessary to develop new production methods for improving the automated production of batteries for electric vehicles. These advances help to significantly increase both the efficiency and safety of vehicle batteries.US5601942A discloses a battery having a plurality of battery cells and a battery housing in which the battery cells are arranged, wherein the battery cells are connected to the battery housing in a form-fitting manner in such a way that the battery cells are wound around by the battery housing.EP 4 471 957 A1 relates to a battery assembly and, in particular, to a battery assembly in which a single cross member can improve the structural rigidity and space utilization of the battery housing, facilitate the assembly of a battery cell assembly within the assembly and ensure the secure, fixed state thereof.The invention improves the prior art in that an innovative method for manufacturing such a modular battery for a motor vehicle.To this end, according to the present invention, there is provided a method of manufacturing a battery for an automobile according to claim 1. Advantageous embodiments can be taken from the dependent claims and the description.The invention relates to a method for producing a battery for a motor vehicle, comprising the following method steps:providing a first housing part;providing a second housing part opposite the first housing part,supplying at least one battery cell, wherein the battery cell is arranged between the first housing part and the second housing part;arranging a first ultrasonic generating unit on the first housing part and arranging a second ultrasonic generating unit on the second housing part;simultaneously forming the first housing part and the second housing part on different sides of the at least one battery cell, wherein the first housing part is supplied from a first roller and the second housing part is supplied from a second roller by rolling, wherein ultrasonic vibrations are introduced into the first housing part by the first ultrasonic generating unit and ultrasonic vibrations are introduced into the second housing part by the second ultrasonic generating unit;joining remaining housing covers to the battery.The method takes advantage of the blaha effect. In ultrasonic welding, two or more materials are welded together using pressure and high frequency ultrasonic vibrations (typically in the range of 15-40 kHz). The blaha effect describes the phenomenon in which the required welding pressure force (the force with which the sonotrode or the ultrasonic generating unit presses on the parts to be welded) for achieving a successful welded connection can be significantly reduced when the ultrasonic vibrations are applied in a specific phase for moving the parts with respect to one another. In addition, by introducing the ultrasonic vibrations, the bending stress of the first housing part and of the second housing part can be reduced.In a development, the method comprises the following method step. The first housing part and the second housing part execute a simultaneous bending movement when the first housing part and the second housing part are molded onto the at least one battery cell, wherein a pocket on the respective inner side of the first housing part and of the second housing part is opened, wherein, when the at least one battery cell is supplied, an armature on opposite sides of the at least one battery cell engages in the respective pocket of the first housing part and of the second housing part, wherein the pocket is closed again by a further bending movement of the first housing part and of the second housing part, whereby the at least one battery cell is mechanically fastened to the first housing part and the second housing part.In an advantageous development, the ultrasonic vibrations are introduced into the first housing part and the second housing part at the location of the pocket of the first housing part and of the second housing part.The first housing part and the second housing part are each arranged along a plane in the form ready for use. The respective planes can extend parallel. During the production process, the first housing part and the second housing part can be deformed with respect to the respective plane.In a further development, after the end of the molding of the first housing part and the second housing part on different sides of the at least one battery cell, ultrasonic oscillations are again introduced into the first housing part and the second housing part, so that the respective anchor is welded to the respective pocket of the first and / or second housing part.In an advantageous development, the ultrasound oscillations are introduced once again by the respective first ultrasound generating unit or second ultrasound generating unit.In an advantageous development, the first ultrasonic generating unit on the first housing part is designed as a sonotrode for introducing the ultrasonic vibrations, and the second ultrasonic generating unit on the second housing part is designed as a sonotrode for introducing the ultrasonic vibrations.A sonotrode is a component in ultrasonic technology, in particular in ultrasonic welding, cutting and cleaning applications. The term "sonotrode" is composed of the words "sono" (latent for "sound" or "sound") and "electrode". A sonotrode essentially comprises an acoustic tool head or a converter tip, which converts the mechanical oscillations, generated by an ultrasonic converter, into a defined movement or vibration matched to the application, which can then be introduced into the first housing part and / or the second housing part.In an advantageous development, the tool head or the converter tip is designed as a piezoelectric element.In a development, a battery for a motor vehicle, which is produced according to the method according to a preceding development, is also disclosed, comprising a first housing part and an opposite second housing part, wherein at least one battery cell is arranged between the first housing part and the second housing part, wherein the battery cell has a first armature in the direction of the first housing part and has a second armature in the direction of the second housing part, wherein the first armature is arranged in a pocket of the first housing part and the second armature is arranged in a pocket of the second housing part, as a result of which the at least one battery cell is fixed to the first housing part and to the second housing part.In a development, the first anchor is welded to the pocket of the first housing part and / or the second anchor is welded to the pocket of the second housing part.In an advantageous development, the first armature and / or the second armature comprises a plastic coating or consists of a plastic.In a development, the first housing part and / or the second housing part is an aluminum extruded profile or a plastic extruded profile.In an advantageous development, the respective pocket of the first housing part and / or second housing part can comprise a plastic inlay.In an advantageous development, the plastic extruded profile is designed as a fiber-reinforced plastic extruded profile. The extruded plastic profile can also be designed as a pultrusion profile.A pultrusion profile is a profile that can be produced by the pultrusion process. Pultrusion is a continuous production method for producing profiles from fiber-reinforced plastics. In this case, fibers, such as glass or carbon fibers, are drawn through a mold impregnated with resin and then passed through a heated die in which the resin cures. The result is extremely stable and at the same time light profiles, which are available in different shapes and sizes.In an advantageous development, the first housing part and / or the second housing part can have pockets at an equidistant distance.In an advantageous development, the aluminum extruded profile or the plastic extruded profile can be produced by extrusion. Extrusion offers the advantage of a fast and efficient production of identical parts.The first housing part and / or the second housing part can be produced as raw material on rollers for further processing.In a development, at least one spacer element is arranged between the first housing part and / or the second housing part and the at least one battery cell.In an advantageous development, the at least one spacer element can consist of foam or comprise such a foam.In an advantageous development, at least one first cooling plate and one second cooling plate are arranged between the at least one battery cell and a further battery cell, said cooling plates forming a plate cooler. The first cooling plate and the second cooling plate may comprise cooling channels, wherein the cooling channels may be configured to pass a fluid for cooling.In an advantageous development, the at least one battery cell can comprise the plate cooler. The plate cooler with the at least one battery cell can be formed in one piece or be mechanically connected to it. The connection can be produced by welding. This makes it possible to produce an alternating sequence of battery cell, plate cooler, battery cell, plate cooler. The series with the change from battery cell and plate cooler can be continued as desired.In a development, the first armature and / or the second armature is designed as a clamp, wherein the first armature and / or the second armature is designed to clamp the first cooling plate and the second cooling plate against one another. The first anchor and / or the second anchor may be bonded to the first cooling plate and the second cooling plate by bonding or welding. Alternatively or additionally, the first armature and / or the second armature can be arranged directly on the at least one battery cell.The anchor can be T-shaped in the direction of the plate cooler or comprise such a clamping element, wherein the clamping element comprises a first arm and a second arm opposite the first arm. On the first arm and the second arm of the clamping element, a spacer element stands perpendicular. In an advantageous development, an undercut is formed between the spacer element and the first arm and the second arm. The first cooling plate and the second cooling plate each comprise a guide groove, wherein the respective guide groove of the first cooling plate and / or of the second cooling plate can be inserted.In a development, the first anchor and / or the second anchor is designed asymmetrically, wherein the first anchor and / or the second anchor comprises at least one latching nose for threading into the pocket of the first housing part and of the second housing part. Due to the position of the first armature and / or the second armature in the pocket of the first housing part and / or the second housing part, whereby the at least one battery cell is fixed to the first housing part and to the second housing partThe invention also relates to a motor vehicle, wherein the motor vehicle comprises a battery according to one of the above developments.In an advantageous development, the joining can be effected by welding on.The first housing part and the second housing part cover preferably 2 sides of a 6-sided cuboid. In the last method step, the remaining 4 sides can be sealed.In an advantageous development, the first armature and the second armature can correspond to a geometry of the respective pocket, wherein the pocket of the first housing part corresponds to a geometry of the first armature and the pocket of the second housing part corresponds to a geometry of the second armature. Corresponding means that the geometry, in particular the outer contours of the first armature for the part of the armature which lies in the pocket, corresponds alternatively or additionally to the inner contour of the pocket of the first housing part, the outer contours of the second armature for the part of the armature which lies in the pocket corresponds to the inner contour of the pocket of the second housing part.The first housing part and the second housing part are each arranged along a plane. The respective planes can extend parallel.The invention is described below purely by way of example with reference to the drawings. The following are shown: FIG. 1 shows a method for manufacturing a battery for a motor vehicle; and FIG. 2 shows a battery for a motor vehicle in plan view according to one embodiment of the invention; and FIG. 3 shows a battery for a motor vehicle in section according to one embodiment of the invention; and FIG. 4 shows a battery for a motor vehicle in section according to one embodiment of the invention.FIG. 1 shows a method for producing a battery 100 for a motor vehicle, comprising the following method steps. In a first method step, a first housing part 110, S 1 is provided. In a second method step, a second housing part 120, S 2 is provided opposite the first housing part 110. In a third method step, at least one battery cell 130 is supplied, wherein the battery cell 130 is arranged between the first housing part 110 and the second housing part 120, S 3. In a fourth method step, a first ultrasound generation unit 200 is arranged on the first housing part 110 and a second ultrasound generation unit 300 is arranged on the second housing part 120, S 4. In a fifth method step, the first housing part 110 and the second housing part 120 are simultaneously molded on different sides of the at least one battery cell 130, wherein the first housing part 110 is supplied from a first roller and the second housing part 120 is supplied from a second roller by rolling, wherein ultrasonic vibrations are introduced into the first housing part 110 by the first ultrasonic generating unit 200 and ultrasonic vibrations are introduced into the second housing part 120 by the second ultrasonic generating unit 200, S 5. In a sixth method step, a joining of remaining four housing covers onto the battery takes place, S 6.FIG. 2 shows a battery 100 for a motor vehicle comprising a first housing part 110 and an opposite second housing part 120, wherein at least one battery cell 130 is arranged between the first housing part 110 and the second housing part 120, wherein the battery cell 130 has a first armature 131 in the direction of the first housing part 110 and has a second armature 132 in the direction of the second housing part, wherein the first armature 131 is arranged in a pocket 111 of the first housing part 110 and the second armature 132 is arranged in a pocket 121 of the second housing part 120, whereby the at least one battery cell 130 is fixed to the first housing part 110 and to the second housing part 120. The anchor 131, 132 comprises a plastic coating. The anchor 131, 132 has a T-shaped outer contour.At least one spacer element 140 is arranged between the first housing part 110 and / or the second housing part 120 and the at least one battery cell 130.Between the at least one battery cell 130 and a further battery cell 130, a first cooling plate 151 and a second cooling plate 152 are arranged, which form a plate cooler 150.The anchor is configured as a clip, wherein the anchor is configured to clamp the first cooling plate 151 and the second cooling plate 152 against each other.The first anchor 131 and / or the second anchor 132 are designed asymmetrically, wherein the first anchor 131 and / or the second anchor 132 each comprise at least one latching nose 133 for threading into the pocket 111, 121 of the first housing part 110 and of the second housing part 120.FIG. 3 shows a battery 100 for a motor vehicle comprising a first housing part, wherein at least one battery cell 130 is arranged on the first housing part 110, wherein the battery cell 130 has a first armature 131 in the direction of the first housing part 110, wherein the first armature 131 is arranged in a pocket 111 of the first housing part 110, as a result of which the at least one battery cell 130 is fixed to the first housing part 110. The anchor 131 comprises a plastic coating and has a T-shaped outer contour.At least one spacer element 140 is arranged between the first housing part 110 of the at least one battery cell 130.Between the at least one battery cell 130 and a further battery cell 130, a first cooling plate 151 and a second cooling plate 152 are arranged, which form a plate cooler 150.The anchor is configured as a clip, wherein the anchor is configured to clamp the first cooling plate 151 and the second cooling plate 152 against each other.FIG. 4 shows a battery 100 for a motor vehicle comprising a first housing part, wherein at least one battery cell 130 is arranged on the first housing part 110, wherein the battery cell 130 has a first armature 131 in the direction of the first housing part 110, wherein the first armature 131 is arranged in a pocket 111 of the first housing part 110, as a result of which the at least one battery cell 130 is fixed to the first housing part 110.The anchor 131 comprises a plastic coating and has a T-shaped outer contour.Between the at least one battery cell 130 and a further battery cell 130, a first cooling plate 151 and a second cooling plate 152 are arranged, which form a plate cooler 150.The anchor is configured as a clip, wherein the anchor is configured to clamp the first cooling plate 151 and the second cooling plate 152 against each other.At least one spacer element 140 is arranged between the first housing part 110 of the at least one battery cell 130.The invention is not limited to the described exemplary embodiments. Within the scope of the invention, all features described and / or shown can be combined with one another as desired, unless stated otherwise.Reference numerals denote reference numeralsS 1-S 6 Method steps 100 Battery 110 First housing part 111 Pocket 120 Second housing part 121 Pocket 130 Battery cell 131 First armature 132 Second armature 133 Latching lug 140 Spacer element 150 Plate cooler 151 First cooling plate 152 Second cooling plate 200 Ultrasonic generating unit

Claims

Method for producing a battery (100) for a motor vehicle, comprising the following method steps: - providing a first housing part (110), (S1); - providing a second housing part (120), (S2) opposite the first housing part (110); - supplying at least one battery cell (130), wherein the battery cell (130) is arranged between the first housing part (110) and the second housing part (120), (S3); - arranging a first ultrasound generating unit (200) on the first housing part (110) and arranging a second ultrasound generating unit (300) on the second housing part (120), (S4); - simultaneously forming the first housing part (110) and the second housing part (120) on different sides of the at least one battery cell (130), wherein the first housing part (110) is supplied from a first roller and the second housing part (120) is supplied from a second roller by rolling, wherein ultrasonic vibrations are introduced into the first housing part (110) by the first ultrasonic generating unit (200) and ultrasonic vibrations are introduced into the second housing part (120) by the second ultrasonic generating unit (200) (S5); - joining remaining four housing covers to the battery (S6).Method for producing a battery (100) for a motor vehicle according to claim 1, comprising the following method step, wherein the first housing part (110) and the second housing part (120) perform a simultaneous bending movement when the first housing part (110) and the second housing part (120) are molded onto the at least one battery cell (130), wherein a pocket (111, 121) is opened on a respective inner side of the first housing part (110) and the second housing part (120), wherein, when the at least one battery cell (130) is supplied, an armature (131, 132) on opposite sides of the at least one battery cell (130) engages in the respective pocket of the first housing part (110) and the second housing part (120), wherein the pocket (111, 121) is closed again by a further bending movement of the first housing part (110) and the second housing part (120), whereby the at least one battery cell (130) is mechanically fastened to the first housing part (110) and the second housing part (120).Method for producing a battery (100) for a motor vehicle according to one of the preceding claims, comprising the following method step, wherein after the end of the molding of the first housing part (110) and the second housing part (120) on different sides of the at least one battery cell (130), ultrasonic oscillations are once again introduced into the first housing part (110) and the second housing part (120), such that the respective anchor is welded to the respective pocket of the first and / or second housing part (110, 120).Method for producing a battery (100) for a motor vehicle according to one of the preceding claims, characterized in that the first ultrasonic generation unit (200) is formed on the first housing part (110) as a sonotrode for introducing the ultrasonic vibrations, and the second ultrasonic generation unit (200) is formed on the second housing part (120) as a sonotrode for introducing the ultrasonic vibrations.

Images