Battery, in particular for a vehicle, and methods for manufacturing such a battery

Abstract

The invention relates to a battery, in particular for a vehicle, with a battery housing into which at least one battery module (13, 14) is inserted in a module insertion process in a insertion direction (S) and with a insertion force (F). S1 , F S2 ) is retractable. According to the invention, at least one force redirection unit (27) is provided between the battery module (13, 14) and at least one side wall (5, 7) of the battery housing. This unit converts a portion of the insertion force (F) when the battery module (13, 14) is retracted. S1 , F S2 ) into a shear force (F y , F x ) which acts on the base of the housing (1) to at least partially reduce unevenness of the base (10).

Description

[0001] The invention relates to a battery, in particular for a vehicle, according to the preamble of claim 1, and to a method for manufacturing such a battery according to the preamble of claim 10.

[0002] Such a battery is preferably designed as a traction battery and comprises a battery housing into which a plurality of battery modules are inserted in a module insertion process, in the insertion direction and with a insertion force, until a mounting position is reached in which the battery modules are in thermal contact with a housing base of the battery housing. The housing base can be a double-layer sheet metal structure in which coolant channels are incorporated. Side walls typically extend from the housing base, dividing the interior of the housing into compartments, each of which can accommodate one battery module. Each battery module is mounted in the battery housing via screw connections.

[0003] One problem with such traction batteries is that the base of the casing is often uneven before the module installation process. This unevenness is due to manufacturing tolerances and mechanical stresses, for example, from welding or assembly distortion. These irregularities make it difficult for the battery modules to make full contact with the casing base. Consistent thermal contact between the battery module and the casing base cannot be reliably ensured throughout the entire manufacturing process.

[0004] To compensate for these uneven surfaces, a thermally conductive paste is conventionally required. While this increases the contact area between the battery module and the housing base, the thermal paste also has thermal insulation properties that impair heat transfer between the battery module and the housing base. This negatively affects the temperature distribution within the battery and can lead to efficiency losses during operation. Furthermore, the use of thermally conductive paste is associated with high costs.

[0005] From DE 10 2017 120 544 B4, a battery carrier for an electric motor vehicle is known. This carrier has a laterally outwardly oriented bulge in a bending area between the base and the side wall.

[0006] From DE 10 2017 119 467 B4 a battery device is known which has a pre-tensioning device with wedge elements.

[0007] US Patent 9,853,257 B2 discloses a one-piece molded battery carrier system for holding and safely transporting cylindrical batteries. The system uses elastic side surfaces and ribs to secure the batteries without direct contact with the base.

[0008] The object of the invention is to provide a battery in which the use of thermal paste can be easily reduced compared to the prior art and / or improved thermal contact between the battery module and the base of the battery housing is enabled.

[0009] The problem is solved by the features of claim 1 or 10. Preferred embodiments of the invention are disclosed in the dependent claims.

[0010] The invention relates to a battery, preferably for a vehicle, in which a battery module is inserted into a battery housing during a module insertion process, the module being in thermal contact with a housing base in its mounting position. This measure enables reliable positioning of the module and a controlled thermal transfer from the module to the base structure. The housing base has a raised side wall, which allows for edge support of the modules. This creates a defined geometry for the load transfer from the module to the housing and enables a modular battery design. Before the module insertion process, the housing base has unevenness, which corresponds to the reality of large-area formed parts.According to the characterizing part of claim 1, the following measure is taken to reduce base irregularities: A force redirection unit is provided between the battery module and the side wall, which converts a portion of the insertion force into a transverse force when the module is inserted. This measure enables targeted mechanical manipulation of the housing structure during the assembly process, thereby eliminating or reducing the need for purely passive tolerance compensation. The transverse force is suitable for placing the housing base under tensile stress and thereby at least partially reducing existing base irregularities. This creates a flatter contact surface between the module and the base, which improves thermal contact and significantly reduces the thickness of thermal pastes or gap fillers.

[0011] In one technical implementation, the battery module features a mounting section that, in its installed position, is supported on a side-wall support flange and bolted to it. This design enables a secure, yet releasable connection with a clearly defined force direction and contributes to assembly reproducibility. The bolted connection includes a bolt that passes through a bolt hole in the mounting section and engages with the threads of the support flange. This allows for cost-effective manufacturing using standard components and enables easy tightening or loosening during servicing. The mounting section is clamped between the bolt head and the support flange. This clamping action provides a stable, vibration-resistant fix that simultaneously activates the pivoting movement of the support flange in a defined manner.

[0012] In one specific embodiment, the side wall support flange is positioned in a joining plane that is preferably parallel to the housing base. This creates a geometrically unambiguous final position, thereby simplifying assembly and reliably reproducing the geometric position of the modules.

[0013] In another embodiment, the side wall support flange is connected to the side wall at a flange node, thus transmitting the force. In this configuration, the side wall support flange projects – viewed in the transverse direction of the housing – from the side wall into the interior of the housing. This measure allows the resulting transverse force to be directed into the housing structure, with the defined projection length acting as a mechanical lever arm.

[0014] In a specific development, the sidewall support flange forms the force redirection unit, with a section of the flange between the node and the thread engagement acting as a lever arm. This integrates the conversion of the setting force into a laterally acting shear force into the connecting element without requiring additional components. Before the module setting process, the support flange is angled against the setting direction. This geometric pre-setting ensures that a controlled movement is triggered under setting load, activating the force redirection. During the module setting process, the battery module is pressed into the mounting position by the setting force, and the flange section pivots into the joining plane. This defined pivoting movement utilizes the mechanical deformation to actively reduce the floor flatness.The flange section generates a shear force that is transferred to the side wall via the joint, thereby placing the floor under tensile stress. This measure allows for a systematic smoothing of the floor structure during assembly, thus improving the thermal connection without additional assembly effort.

[0015] In one specific embodiment, the battery housing has a cuboid shape with a circumferential side wall. This design allows for a standardized housing structure with easy integration into existing vehicle platforms. Force deflection units are arranged between the circumferential side wall and the adjacent edge modules. This measure enables segment-wise stress distribution in the base area and ensures that the base flatness can be specifically controlled across the entire width and length of the battery.

[0016] An embodiment of the invention is described below with reference to the accompanying figures.

[0017] They show: Fig. Figures 1 to 4 show different views illustrating the structure and function of the deflection unit according to the invention for reducing unevenness in the housing base.

[0018] In the Fig. 1 and Fig. Figure 2 shows a perspective view of a battery housing for a traction battery of a motor vehicle, indicated to the extent necessary for understanding the invention. Accordingly, the battery housing is cuboid in shape and consists of a housing base 1 ( Fig. 2) and a housing cover 3, which are connected to each other via a surrounding housing side wall 5. The interior of the housing is divided into compartments by means of partition walls 7, in which an electronic battery control unit 11 as well as a number of edge battery modules 13 and middle battery modules 14 are installed.

[0019] As from the Fig. As can be seen from Figure 2, the housing partitions 7 divide the housing interior – viewed in the transverse direction y – into a total of three battery module compartments 15, in each of which an edge battery module 13 is inserted laterally and a central battery module 14 is inserted in the middle. Each of the battery modules 13, 14 rests on the housing base 1 in a thermally conductive manner with a thermal paste 16 in between.

[0020] Furthermore, each of the battery modules 13, 14 is fastened in its respective battery module compartment 15 via screw connections 19. For this purpose, the housing side wall 5 and the housing intermediate walls 7 are each formed with support flanges 17 that project horizontally into the battery module compartments 15 in the housing transverse direction y. Each of the battery modules 13, 14 is supported on the support flanges 17 via its mounting sections 20 and with the interposition of a tolerance compensation unit 33 (indicated only by dashed lines) and is firmly connected to the respective support flange 17 by screw connection 19. The gap width between the respective battery module 13, 14 and the housing base 1 can be adjusted by means of the tolerance compensation unit 33. It should be noted that the tolerance compensation units 33 are only available in the Fig. 3 are indicated by dashed lines, while in the Fig. 2 and Fig. 4. The tolerance compensation units 33 have been omitted for the sake of clarity.

[0021] The screw connection 19 has a screw bolt 21 which is guided through a threadless bolt passage 23 of the battery module mounting section 20 and whose bolt tip engages with a press-fit nut 25 of the support flange 17. In the Fig. 2 or Fig. In the mounting position shown in Figure 4, the respective battery module mounting section 20 is therefore firmly clamped between the bolt head of the screw bolt 21 and the support flange 17. The [unclear text] Fig. 2 or Fig. The 4 indicated support flanges 17 lie in a joining plane F that is aligned parallel to the housing base 1.

[0022] As from the Fig. 2 or Fig. As further shown in section 4, each of the support flanges 17 is integrally formed with the material of the same material and in one piece and is force-transmitting on the housing side wall 5 or on the housing intermediate wall 7.

[0023] Below we will use the following as an example. Fig. 3 and Fig. 4 describes an assembly method for mounting the battery modules 13, 14 into the battery housing. According to this method, an application process is first carried out in which the high-viscosity thermal paste 16 is applied to the housing base 1. In the process described in the Fig. In the process state shown in Figure 3, the battery module compartments 15 are still empty. Furthermore, according to the Fig. 3 the case base 1 with base irregularities 10.

[0024] After the thermal paste has been applied, the [device] starts up in the Fig. 3 Indicated module setting process, in which each of the battery modules 13, 14 is set with a setting force F S1 , F S2in a setting direction S into the respective battery module compartment 15 of the battery housing, until the battery module 13, 14 is inserted into the Fig. 2 or Fig. The assembly position shown in Figure 4 is reached, in which the battery module 13, 14 is pressed against the thermal paste 16 with a clamping force. This distributes the thermal paste 16 evenly under compression. Furthermore, the respective battery module mounting section 20 rests on the respective support flange 17. In the next step of the process, the screw connections 19 are tightened to secure the battery module 13, 14 to the support flanges 17.

[0025] A key aspect of the invention is that a force deflection unit 27 is arranged between each of the edge battery modules 13 and the surrounding housing side wall 5. With the aid of the force deflection unit 27, a portion of the setting force F is transferred during the insertion of the edge battery module 13 in the module setting process. S1 , F S2into a shear force F x , F y ( Fig. 2 or Fig. 4) converted. The shear force F x , F y By interposing the housing side wall 7, the housing base 1 is subjected to tensile stress Z, thereby reducing the existing base irregularities 10. The elimination of these base irregularities 10 reduces the amount of thermal paste 16 required.

[0026] In the present embodiment, the support flange 17 integrally formed on the circumferential housing side wall 5 is part of the force redirection unit 27. Accordingly, a support flange section 29 between the flange node K and the thread engagement GE acts as a lever arm, which, during the module setting process, exerts a shear force F on the circumferential housing side wall 5. x , F y imposed.

[0027] The support flange 17 molded onto the side wall 5 of the housing is in the Fig. Figure 3 shows the module setting process before it is carried out. Accordingly, the support flange 17, as a component of the force redirection unit 27, is positioned in an undeformed state at an angle α out of the joining plane F and obliquely upwards against the setting direction S.

[0028] During the module setting process, the battery module mounting section 20 is clamped to the outer lateral support flange 17 and simultaneously the edge battery module 13 is moved into the mounting position with the setting force Fs ( Fig. 4) pressed. This causes the following: The flange section 29, acting as a lever arm, is – by using up the angle of attack α and by pivoting about the flange node K – from its undeformed inclined position ( Fig. 3) pivoted into the joining plane F. As a result of this pivoting movement, the flange section 29, acting as a lever arm, generates the transverse force F. x , F yThis is introduced into the surrounding housing side wall 5 via the flange node K, thereby placing the housing bottom 1 under tensile stress Z, by means of which the existing bottom irregularities 10 are smoothed. REFERENCE MARK LIST: 1 Case base 3 Housing covers 5 Case side panel 7 Housing partition 10 Unevenness of the ground 11 electronic battery control unit 13 Edge battery module 14 medium battery module 15 battery module compartment 16 Thermal paste 17 Support flange 19 Screw connection 20 Assembly section 21 screw bolts 23 Bolt feedthrough 25 Press-fit nuts 27 Force deflection unit 29 Flange section 31 Partition wall screw 33 Tolerance compensation unit 35, 37 Setting stamp α Angle of attack GE thread engagement F joining plane K flange joint S Setting direction Z Tension F S1 , F S2 Setting force F x , F y Shear force

Claims

[1] Battery preferably for a vehicle, with a battery housing into which at least one battery module (13, 14) is inserted in a module insertion process in the insertion direction (S) and with insertion force (F) S1 , F S2 ) is retractable until the battery module (13) reaches a mounting position in which the battery module (13, 14) is in thermal contact with a housing base (1) of the battery housing, wherein at least one side wall (5, 7) is raised from the housing base (1), and wherein in particular the housing base (1) has unevenness (10) before the module insertion process is carried out, characterized by , that between the battery module (13, 14) and the side wall (5, 7) at least one force redirection unit (27) is provided which, when the battery module (13, 14) is inserted, converts part of the insertion force (Fs) into a lateral force (F y , F x ) converts, which acts on the case base (1), and that the shear force (F y , F x) is suitable to put the housing base (1) under tensile stress (Z) and thereby at least partially reduce existing base irregularities (10). [2] Battery according to claim 1, characterized by , that the battery module (13, 14) has a mounting section (20) which in the mounting position - in particular with an intermediate tolerance compensation unit (33) - is supported on a side wall support flange (17) and is screwed (19) to the side wall support flange (17), and that in particular the screw connection (19) has a screw bolt (21) which is guided through a bolt passage (23) of the battery module mounting section (20) and is in thread engagement (GE) with the side wall support flange (17), so that the battery module mounting section (20) is clamped between the bolt head of the screw bolt (21) and the side wall support flange (17). [3] Battery according to claim 2, characterized by, that in the mounting position of the side wall support flange (17), in particular the mutually facing contact surfaces of the battery module mounting section (20) and the side wall support flange (17), lie in a joining plane (F) which is in particular parallel to the housing base (1). [4] Battery according to claim 1, 2 or 3, characterized by , that the side wall support flange (17) is connected to the side wall (5, 7) at a flange node (K) in a force-transmitting manner, and that in particular the side wall support flange (17) - viewed in a transverse direction (y) of the housing - projects with a projection from the side wall (5, 7) into the interior of the housing. [5] Battery according to claim 4, characterized by , that the side wall support flange (17) is a component of the force redirection unit (27), and that in the force redirection unit (27) a flange section (29) between the flange node (K) and the thread engagement (GE) acts as a lever arm, and that the flange section (29) acting as a lever arm in the module setting process exerts a shear force (F) on the side wall (5, 7) x , F y ) is charged, and / or that in particular the side wall support flange (17) is tilted in an undeformed state at an angle of inclination (α) from the joining plane (F) in the opposite direction to the setting direction (S) before the module setting process is carried out. [6] Battery according to claim 5, characterized by , that In the module setting process, the battery module mounting section (20) is clamped to the side wall support flange (17), and the battery module (13, 14) is set with the setting force (F S1 , F S2 ) is pressed into the mounting position, thereby the flange section (29) acting as a lever arm - by using up the angle of attack (α) and by pivoting about the flange node (K) - is pivoted from its undeformed inclined position into the joining plane (F), and as a result of the pivoting movement of the flange section (29) acting as a lever arm, the transverse force (F y , F x ) builds up, which is introduced into the side wall (5, 7) via the flange node (K) so that the housing bottom (1) is placed under tensile stress (Z). [7] Battery according to claim 6, characterized by , that in the module setting process the battery module side to which a force redirection unit (27) is assigned and the battery module side to which no force redirection unit (27) is assigned can each be actuated with their own setting punch (35, 37), and that in particular the setting punch (35) arranged on the side of the force redirection unit (27) can be actuated with a larger setting force (F S1) against the battery module (13) presses as the setting plunger (37) arranged on the side facing away from it, and that the setting force (F S1 ) of the setting die (35) is sufficiently large to bring the side wall support flange (17) from its undeformed inclined position into the joining plane (F). [8] Battery according to any one of the preceding claims, characterized by , that the battery housing is cuboid in shape, with the housing base (1) and a housing cover (3) as large flat surfaces and a surrounding narrow housing side wall (5) that connects the housing base (1) to the housing cover (3), and that a number of battery modules (13, 14) are arranged inside the housing, and in particular the force deflection unit (27) is arranged between the housing side wall (5) and at least one of the adjacent edge battery modules (13), and in particular force deflection units (27) are arranged between the housing side wall (5) and all adjacent edge battery modules (13), and / or in particular the housing side wall (5) is divided into two longitudinal walls extending in the battery longitudinal direction (x) and into two transverse walls extending in the battery transverse direction (y), and in particular either only the two longitudinal walls in the battery transverse direction (y) are subjected to transverse forces (F) in opposite directions to each other. y ) are subjected to shear forces, or only the two transverse walls in the longitudinal direction of the battery (x) are subjected to shear forces in opposite directions to each other (F x) are subjected to shear forces, or in combination both the longitudinal walls in the battery transverse direction (y) are subjected to shear forces in opposite directions (F) y ) are subjected to shear forces (F) as well as the two transverse walls in the longitudinal direction of the battery (x) in opposite directions to each other. x are subject to charges. [9] Battery according to claim 8, characterized by , that at least one partition wall (7) extending inside the housing is floatingly mounted on the housing base (1), thereby enabling a relative movement induced by tensile stress between the housing base (1) and the partition wall (7), and that in particular the floating bearing is realized as an intermediate wall screw connection (31) with screw hole clearance, so that the relative movement is enabled with at least partial use of the screw hole clearance. [10] Method for manufacturing a battery, preferably for a vehicle according to one of the preceding claims, wherein in a module setting process at least one battery module (13) is set in a setting direction (S) and with a setting force (F). S1 , F S2 ) is inserted until the battery module (13) reaches a mounting position in which the battery module (13) is in thermal contact with a housing base (1) of the battery housing, wherein at least one side wall (5, 7) is raised from the housing base (1), and wherein in particular the housing base (1) has base irregularities (10) before the module insertion process is carried out, characterized by , that at least one force deflection unit (27) is provided between the battery module (13) and the side wall (5, 7), which, when the battery module (13) is retracted, distributes part of the insertion force (F) S1 , F S2 ) into a shear force (F y , F x ) converts, which acts on the housing base (1), and that the transverse force (Fy , F x ) is suitable to put the housing base (1) under tensile stress (Z) and thereby at least partially reduce existing base irregularities (10).

Images