Three-dimensional component for use in battery arrangements

Abstract

Three-dimensional component (10) for use in battery arrangements, preferably as part of a battery container, in particular as part of a protective cover component, and / or as part of a gas venting system, wherein the three-dimensional component (10) consists at least partially of a composite material (12) comprising: i) a matrix (14) in a mass fraction of 2% or more, based on the mass of the composite material (12), wherein the matrix (14): ii) is produced or can be produced by condensation of one or more organic condensation resins, or i.ii) is produced or can be produced by drying an aqueous solution of one or more water glasses, ii) one or more reinforcing elements (16) embedded in the matrix (14), which consist at least partially of one or more reinforcing materials selected from the group consisting of ceramic materials and mineral materials, wherein the combined mass fraction of reinforcing materials is 60% or more, based on the mass of the composite material (12).

Description

[0001] The invention relates to a three-dimensional component for use in battery arrangements, and a corresponding battery arrangement comprising such a three-dimensional component, as well as a method for manufacturing such a three-dimensional component.

[0002] As awareness of the need for a more sustainable use of fossil resources and the avoidance of greenhouse gas emissions has grown, the improvement of electric vehicles and the development of new concepts for electromobility have increasingly become the focus of many industries in recent years.

[0003] A key component of electric vehicles, which in many cases is largely responsible for the distances achievable with the vehicle, is the battery system used to store electrical energy, and consequently, a great deal of research and development effort is focused on this area. Furthermore, the transition to renewable energy sources in other sectors, such as solar energy, also requires reliable and, in particular, safe energy storage to ensure a sufficient supply of electricity, for example, during the night or in cloudy weather.

[0004] Modern battery systems, especially for electric vehicles, typically consist of numerous electrically interconnected battery units, for example, in the form of pouch cells, prismatic cells, or cylindrical cells. These battery units contain the components of the respective electrochemical cells, which serve for the electrochemical storage of energy.

[0005] The individual battery units, which can be, for example, lithium-ion batteries, represent chemically complex and comparatively failure-prone systems in which at least partially exothermic reactions occur during cycling. Such battery units are susceptible to malfunctions, especially since they often contain flammable substances, such as electrolytes, and high temperatures can occur during operation. Consequently, in the worst-case scenario, a battery unit can experience thermal runaway. In addition to a possible pressure buildup within the battery unit, such thermal runaway typically results in a significant temperature increase and potentially leads to the battery unit bursting.

[0006] A battery bursting due to thermal runaway is usually, and depending on the battery's state of charge, associated with the release of hot gases and decomposition products. The resulting fluid stream may also contain entrained solids. Such a fluid stream typically contains very hot gas, for example, gas exceeding 1000 °C, as well as corrosive or abrasive particles and the often harmful components of the battery's electrolyte composition or its decomposition products.

[0007] There is a need to prevent such incidents as far as possible and to minimize their impact should they occur. Firstly, the thermal runaway of a battery unit and the resulting pressure relief jet can potentially trigger a chain reaction, in which a malfunctioning battery unit disrupts the fragile equilibrium of neighboring battery units and also causes thermal runaway in them. Secondly, the pressure relief jet from a runaway battery unit is also dangerous for its immediate surroundings, which in electric vehicles can include not only the vehicle itself but also the occupants. Therefore, thermal runaway poses a potentially significant risk of damage to the vehicle and potentially life-threatening injuries to the occupants.Furthermore, a battery unit failing at high temperatures, especially at 1000 °C or more, can quickly lead to the entire vehicle catching fire, and such fires can often only be extinguished with great effort.

[0008] To protect both the vehicle and the occupants from a possible runaway battery unit, protective containers are frequently used in the prior art, which in many cases have a gas venting system whose purpose is to vent the gases produced from the protective container.

[0009] To reinforce such battery containers or for the gas venting system, iron or aluminum alloys are frequently used as the material for the battery container walls. However, this leads to a conflict of objectives, particularly in electric vehicles, between the requirement to build the lightest possible vehicle and fire safety considerations regarding the battery systems, as these materials contribute significantly to the increased weight. Furthermore, vibrations inherent in vehicle operation can cause damage, especially in the form of cracks in battery containers, resulting in a loss of the desired fire protection properties. Moreover, such battery containers, and especially complex gas venting systems, can typically only be manufactured from metallic materials with considerable manufacturing effort and / or energy expenditure.

[0010] In the prior art, it has been proposed to solve the aforementioned weight problems by using polymer materials in the battery housings, which often have a more advantageous weight. However, it is frequently considered a disadvantage that this usually provides only limited protection for the vehicle and its occupants against thermal runaway of the battery units.

[0011] As an alternative, composite materials could potentially be considered, as they offer improved fire resistance compared to pure plastics. However, it is generally found that these composite materials also suffer from either insufficient fire resistance or poor processability, particularly when manufacturing complex geometries. A particular disadvantage of many composite materials is their often very long processing time and / or the need for complex forming processes, such as lengthy pressing under high pressure.

[0012] The primary objective of the present invention was to eliminate or at least mitigate the disadvantages of the prior art.

[0013] In particular, an object of the present invention was to provide a three-dimensional component for use in battery arrangements, the use of which enables battery arrangements to be obtained that meet high fire protection safety requirements, in order to enable particularly safe use of the battery arrangement, especially in electric vehicles and stationary applications. A desirable feature of the present invention was that the three-dimensional components to be provided should have an advantageously low weight, in order to enable designs for battery arrangements with advantageous installation space requirements and low weight.

[0014] It was an object of the present invention that the three-dimensional component to be specified should not only have excellent thermal and chemical resistance, but in particular should also have particularly advantageous manufacturability.

[0015] In particular, an object of the present invention was that the specified three-dimensional components for use in battery assemblies should be producible in a particularly time- and cost-efficient manner. In this context, it was a desirable requirement of the present invention that the specified three-dimensional components should be producible reliably and reproducibly with high quality, even in complex geometries, and so quickly that large-scale production of the three-dimensional components in large quantities could be realized particularly well.

[0016] A further objective of the present invention was to provide an advantageous battery arrangement comprising the three-dimensional component, which advantageously resolves the conflict of objectives between good fire protection properties, low weight and advantageous manufacturability.

[0017] Furthermore, it was another objective of the present invention to provide an advantageous method for manufacturing a three-dimensional component for use in battery arrangements, with which high-performance three-dimensional components can be obtained in a particularly time- and cost-efficient manner, yet reproducibly in high quality, even if these three-dimensional components comprise complex geometries and structures, for example channels and coils.

[0018] The inventor of the present invention has now found that the problems described above can surprisingly be solved by providing a three-dimensional component for use in battery arrangements, which consists at least partially of a specific composite material comprising a relatively large mass fraction of ceramic and / or mineral reinforcing materials embedded in a specific matrix, which can be produced by condensing one or more organic condensation resins or by drying an aqueous solution of water glass.

[0019] Surprisingly, it is possible to achieve excellent fire-resistant properties with appropriate three-dimensional components, particularly for protecting vehicle occupants from escaping hot gases and abrasive particles in the event of thermal runaway of the electric battery. A particular advantage of the present invention is that the composite materials used according to the invention can be manufactured in a particularly time- and cost-efficient manner and, in particular, can be shaped using time- and cost-efficient processes, whereby even complex three-dimensional components can advantageously be obtained with high precision and high reproducibility in a very short time.

[0020] Through the use of specific composite materials, the three-dimensional components exhibit thermal, mechanical, and chemical resistance that is at least comparable to, and in many cases even superior to, solutions known from the prior art. In contrast to solutions known from the prior art, particularly those composite materials that rely on silicone as a substrate matrix, these three-dimensional components can be manufactured in a fraction of the time, eliminating the need for complex hot pressing processes.

[0021] The aforementioned problems are solved accordingly by the subject matter of the invention as defined in the claims. Preferred embodiments of the invention are described in the dependent claims and the following descriptions.

[0022] Such embodiments, which are hereinafter referred to as preferred, are combined in particularly preferred embodiments with features of other embodiments referred to as preferred. Combinations of two or more of the embodiments referred to below as particularly preferred are therefore especially preferred. Also preferred are embodiments in which a feature of one embodiment referred to as preferred to any degree is combined with one or more further features of other embodiments referred to as preferred to any degree. Features of preferred battery arrangements and methods result from the features of preferred three-dimensional components.

[0023] Particularly preferred embodiments of the invention are disclosed in the exemplary embodiments. Particularly preferred embodiments of the invention have two or more, preferably three or more, and most preferably four or more, of the preferred features of the invention disclosed below, which are also implemented in the exemplary embodiments.

[0024] The invention relates to a three-dimensional component for use in battery arrangements, preferably as part of a battery container, in particular as part of a protective cover component, and / or as part of a gas drainage system. the three-dimensional component consists at least partially of a composite material which includes: i) a matrix comprising 2% or more of the mass of the composite material, wherein the matrix: ii) is produced or can be produced by condensation of one or more organic condensation resins, or i.ii) is produced or can be produced by drying an aqueous solution of one or more water glasses, ii) one or more reinforcing elements embedded in the matrix, which consist at least partially of one or more reinforcing materials selected from the group consisting of ceramic materials and mineral materials, where the combined mass fraction of reinforcing materials is 60% or more, based on the mass of the composite material.

[0025] The subject matter of the invention is a three-dimensional component. In accordance with the understanding of those skilled in the art, this refers to a component that is not an essentially one-dimensional product, such as a plastic thread, or an essentially two-dimensional product, such as a flat product like a sheet or a film. Rather, a three-dimensional product exhibits significant longitudinal extents in three mutually orthogonal spatial directions. This definition is consistent with the understanding of those skilled in the art and with the usual practice in the industry. This is not contradicted by the fact that even essentially one- or two-dimensional products, such as threads or sheets, have a small finite extent in the spatial directions orthogonal to the main direction of extension.In other words, it is a three-dimensional component according to the invention, wherein the three-dimensional component is not a uniform plate.

[0026] In practice, the three-dimensional component will usually be three-dimensional because, during its manufacture, it is shaped in such a way as to form specific structures required for the battery assembly, for example, for the battery housing or the gas venting system. An exemplary three-dimensional component according to the invention is one in which the three-dimensional component is curved, at least in some sections. An exemplary three-dimensional component according to the invention is also, or alternatively, one in which the three-dimensional component is angled or curved, at least in some sections. Another exemplary three-dimensional component according to the invention is one in which the three-dimensional component has a plurality of raised or recessed features on its surface.

[0027] A preferred three-dimensional component according to the invention is one that is macroscopically structured in three dimensions. A preferred additional or alternative three-dimensional component according to the invention is one that forms at least one receiving space or at least one conduit.

[0028] The three-dimensional component is designed and intended for use in a battery assembly. In principle, it is conceivable, for example, that the three-dimensional component could be used as a separating element between individual battery units in such a battery assembly. However, in the inventor's opinion, the three-dimensional component is particularly suitable for use as part of the battery container, for example, as part of the lining for receiving the battery units in the container's tray, but most preferably also as part of the lid. A three-dimensional component according to the invention is preferred, wherein the three-dimensional component is intended for use as a component of a battery container, in particular as part of a protective cover component.

[0029] A particularly advantageous embodiment arises when the three-dimensional component is used as part of the gas drainage system, which can, for example, also be integrated into a protective cover component, such as a lid. The three-dimensional component of the present invention is particularly well-suited for the design of the often quite complex gas drainage systems with their conduits for the discharge of hot fluids, due to its excellent manufacturability. A three-dimensional component according to the invention is therefore preferred, wherein the three-dimensional component is intended for use as part of a gas drainage system.

[0030] In light of the foregoing, a person skilled in the art will understand that the present invention also relates to a battery arrangement comprising a corresponding three-dimensional component, preferably as part of the battery container and / or as part of the gas drainage system.

[0031] The invention therefore also relates to a battery arrangement, in particular for use in electric vehicles and stationary applications, comprising: I) a battery container, with a receiving space for receiving at least one battery unit, II) at least one battery unit arranged in the receiving space of the battery container, and III) a gas venting system for venting gases from the receiving space of the battery container, wherein the battery container and / or the gas drainage system is at least partially formed from one or more three-dimensional components according to the invention.

[0032] Battery arrangements with a battery container are generally known to those skilled in the art. The battery arrangement according to the invention is particularly suitable for use in electric vehicles and stationary applications or their battery systems. The term "vehicle" is to be understood broadly and can include, in particular, aircraft, rail vehicles, watercraft, but also unmanned vehicles such as drones and spacecraft. In the present case, the term "vehicles" thus includes, in particular, independent mobile devices that have a battery arrangement. A battery arrangement according to the invention is preferred in this respect, wherein the electric vehicles are selected from the group consisting of cars, trucks, rail vehicles, aircraft, watercraft, drones, and spacecraft.

[0033] According to the invention, the battery arrangement comprises a battery container with a receiving space. It is conceivable that the battery container is designed as a box or in the shape of a tray, with the receiving space in practice usually being substantially completely surrounded by boundary elements.

[0034] In this context, a limiting element can be designed as a protective cover component, particularly as a lid or base plate, to allow the receiving space to be reversibly closed, thereby facilitating the insertion and maintenance of the battery units. A battery arrangement according to the invention is preferred, wherein the battery container is multi-part, preferably two-part. A battery arrangement according to the invention is particularly preferred, wherein the battery container comprises a first container part and a second container part.

[0035] Within the scope of the present invention, a receiving space suitable for accommodating a plurality of battery units is preferred, since a better energy density of the battery arrangement can be achieved through the appropriate packing. A battery arrangement according to the invention is preferred, wherein the receiving space is suitable for accommodating two or more, preferably four or more, particularly preferably eight or more, and most preferably twelve or more, battery units. Additionally or alternatively, a battery arrangement according to the invention is preferred, wherein the battery arrangement comprises two or more, preferably four or more, particularly preferably eight or more, and most preferably twelve or more, battery units.

[0036] It is clear to those skilled in the art that the battery arrangement according to the invention is advantageously not limited with regard to the type of battery units used. In principle, the battery units can be, for example, primary or secondary battery units. Secondary batteries typically have an advantageous energy density and allow them to be recharged after a discharge process without significant losses in charge density, thus offering considerably more diverse applications, particularly when used as batteries in electric vehicles and stationary applications. Accordingly, a battery arrangement according to the invention is preferred in which the battery units are at least partially, preferably predominantly, and most preferably essentially entirely secondary batteries.

[0037] The inventor considers battery units based on alkaline-ion technology to be particularly preferred. However, other technologies would also be conceivable in principle. A battery arrangement according to the invention is preferred in that the battery units are at least partially, preferably predominantly, and most preferably essentially entirely lithium-ion batteries or sodium-ion batteries, preferably lithium-ion batteries.

[0038] The battery units in the battery arrangement according to the invention can be of different or identical design, such that all battery units are, for example, designed as prismatic cells. However, those skilled in the art understand that the battery units can also have different designs. For example, it is conceivable that the battery units could be cylindrical cells, pouch cells, or prismatic cells.

[0039] To prevent thermal runaway between adjacent battery units of the battery arrangement, separating elements can be provided between the battery units. These elements serve, in particular, to thermally insulate the battery arrangements and to suppress flame spread. A battery arrangement according to the invention is preferred, wherein the battery arrangement additionally comprises: IV) one or more separating elements, wherein the one or more separating elements are each positioned between two adjacent battery units.

[0040] The major advantages of the battery arrangements according to the invention arise particularly from the use of the three-dimensional component according to the invention. The three-dimensional component can be used, in particular, as part of the battery container or the protective cover component that serves to close the battery container. A preferred battery arrangement according to the invention is therefore one in which the battery container of the battery arrangement is formed at least partially, preferably predominantly, from one or more three-dimensional components according to the invention, and / or in which a protective cover component of the battery container is formed partially, preferably predominantly, from one or more three-dimensional components according to the invention.

[0041] However, it is particularly preferred to use the three-dimensional component according to the invention as part of the gas drainage system of the battery assembly, i.e., to design the fluid guide channels provided in the battery assembly for the drainage of hot gases from corresponding three-dimensional components. A battery assembly according to the invention is preferred in which the gas drainage system of the battery assembly is formed at least partially, preferably predominantly, from one or more three-dimensional components according to the invention.

[0042] A key feature of the three-dimensional component according to the invention is that it consists at least partially of a specific composite material. In accordance with the understanding of those skilled in the art, it is possible for the three-dimensional component to comprise, in addition to the specific composite material, further components, for example, to further adapt the three-dimensional component to the application-specific requirements of the respective intended use, which can be achieved, for example, by an applied metallic reinforcement or a coating. Thus, a three-dimensional component according to the invention is conceivable in which the composite material additionally comprises one or more further components different from the matrix and the reinforcing elements.A three-dimensional component according to the invention is preferred in principle, wherein the three-dimensional component additionally comprises a protective layer arranged on the composite material, wherein the surface of the composite material is at least partially, preferably predominantly, and particularly preferably substantially completely, covered with the protective layer. A three-dimensional component according to the invention is particularly preferred in this respect, wherein the protective layer consists at least partially of one or more materials selected from the group consisting of polysiloxanes and intumescent organic coating compositions, in particular varnishes, paints, and pastes, for example, based on polyurethanes.

[0043] To optimally utilize the manufacturing advantages, the inventor believes that in the vast majority of cases it is preferable to manufacture the three-dimensional component as extensively as possible from the corresponding composite material according to the invention. A three-dimensional component according to the invention is preferred in that the three-dimensional component consists of the composite material to a mass fraction of 50% or more, preferably 70% or more, particularly preferably 90% or more, most preferably 95% or more, and most preferably substantially 100%, based on the mass of the three-dimensional component.

[0044] In accordance with the understanding of a person skilled in the art, composite materials within the scope of the present invention are those materials which consist of two or more different materials which are joined together, in particular by a material bond.

[0045] In the composite material according to the invention, specific reinforcing materials are embedded in a specific matrix. Here, the vast majority of the composite material, relative to its mass, consists of the reinforcing materials, while the proportion of the matrix is ​​kept comparatively low. This advantageously allows for high mechanical strength and excellent fire resistance. The inventor has succeeded in identifying preferred ranges for the mass fractions of the two core components.With regard to the matrix, a three-dimensional component according to the invention is preferred, wherein the mass fraction of the matrix is ​​2.5% or more, preferably 3.0% or more, particularly preferably 3.5% or more, and most preferably 4.0% or more, and most preferably 4.5% or more, based on the mass of the composite material, and / or wherein the mass fraction of the matrix is ​​40.0% or less, preferably 30.0% or less, particularly preferably 20.0% or less, and most preferably 15.0% or less, and most preferably 10.0% or less, based on the mass of the composite material. A three-dimensional component according to the invention is particularly preferred in this respect, wherein the mass fraction of the matrix is ​​in the range of 2.0% to 30.0%, preferably in the range of 3.0% to 20.0%, and most preferably in the range of 4.0% to 10.0%.With regard to the reinforcing materials, a three-dimensional component according to the invention is preferred, either additionally or alternatively, wherein the mass fraction of the reinforcing materials is 70.0% or more, preferably 80.0% or more, particularly preferably 85.0% or more, and most preferably 90.0% or more, based on the mass of the composite material, and / or wherein the mass fraction of the reinforcing materials is 98.0% or less, preferably 97.5% or less, particularly preferably 97.0% or less, and most preferably 96.5% or less, based on the mass of the composite material. A three-dimensional component according to the invention is particularly preferred in this respect, wherein the mass fraction of the reinforcing materials is in the range of 70.0% to 98.0%, preferably in the range of 80.0% to 97.5%, and most preferably in the range of 90.0% to 97.0%.

[0046] For the matrix, the inventor has identified two different types of possibilities, which result in high-performance three-dimensional components and which, despite certain differences in terms of physicochemical and mechanical properties, have in common that they exhibit excellent manufacturability.

[0047] The first of two options is to use plastics that can be obtained by condensing organic condensation resins. The above formulation, which defines the matrix by the process used to produce it, is common in the field of plastics, since the polymeric materials underlying plastics can hardly be described structurally in practice other than by the manufacturing process and the starting materials used. A three-dimensional component according to the invention is therefore preferred, wherein the matrix is ​​a thermoset plastic matrix that can be produced by condensing one or more organic condensation resins.

[0048] Organic condensation resins are widely known from other fields of technology and are commercially available from numerous suppliers. According to the understanding of experts, condensation resins are low-molecular-weight compounds that are liquid at room temperature or can at least be liquefied at relatively moderate temperatures, and from which thermosetting plastics can be produced. The production of these thermosetting plastics occurs through the reaction of the components of the organic condensation resins with one another. The defining characteristic of this process is that, during the conversion to the polymer, byproducts, particularly water, are released.

[0049] This circumstance advantageously allows the kinetics of the condensation reaction to be shifted towards the polymer by removing water from the system. This makes it particularly suitable for the use of corresponding embodiments of the three-dimensional component according to the invention in the inventive process, in which the demolding of the molding material is promoted or effected by applying a vacuum. As explained above, suitable organic condensation resins that can be used within the scope of the present invention are commercially available from numerous suppliers.The inventor has succeeded in identifying among the organic condensation resins those that are particularly suitable for use in the process according to the invention, whereby, in the inventor's opinion, particularly advantageous results can be achieved with phenolic resins and amino resins, especially those based on melamine or urea, both with regard to processing and with regard to the resulting fire-related properties.A preferred three-dimensional component according to the invention is one in which the condensation resin(s) are selected from the group consisting of phenolic resins, amino resins, polyimide resins, polyurethane resins, shellac, and polyester resins; preferably selected from the group consisting of phenolic resins, amino resins, and polyester resins; particularly preferred selected from the group consisting of phenolic resins and amino resins; very preferably selected from the group consisting of phenolic resins, melamine resins, and urea resins; and most preferably selected from the group consisting of phenolic resins and melamine resins. A preferred additional or alternative three-dimensional component according to the invention is one in which the matrix is ​​a thermosetting polymer matrix made of a phenolic resin or an amino resin.

[0050] As an alternative to the use of organic condensation resins, the inventor has found that, surprisingly, aqueous solutions of water glasses are also suitable for production. Analogous to the foregoing, the matrix produced by drying such an aqueous solution of water glasses can only be meaningfully categorized by the method used for its production. A preferred embodiment is a three-dimensional component according to the invention, wherein the matrix is ​​an inorganic matrix that is produced or producible by drying an aqueous solution of one or more water glasses.

[0051] The term "water glass" is clear to a person skilled in the art. According to their understanding, it refers to an aqueous solution of alkali silicates, which can be produced in particular by dissolving silicon dioxide (SiO2) in alkali hydroxides or alkali carbonates. Such aqueous solutions of water glass are typically clear to opalescent liquids and are characterized by their ability to solidify upon dehydration.

[0052] Suitable solutions of water glasses are commercially available, but can also be prepared relatively easily from basic chemicals by skilled personnel. The inventor has succeeded in identifying particularly suitable water glasses for use in three-dimensional components according to the invention, which are especially well suited for the production of high-performance three-dimensional components. A preferred three-dimensional component according to the invention is one in which the water glass(s) is selected from the group consisting of lithium water glasses, sodium water glasses, and potassium water glasses, preferably sodium water glasses and potassium water glasses, and particularly preferably sodium water glasses, and / or in which the water glass(s) is selected from the group consisting of silicate glasses.

[0053] In addition to the matrix, the composite material to be used comprises specific reinforcing elements which, according to the invention, are embedded in the matrix. According to the invention, the reinforcing elements embedded in the matrix consist at least partially of reinforcing materials which, according to the invention, must be ceramic or mineral.

[0054] In principle, it is conceivable that the reinforcing elements could comprise not only the specific reinforcing materials to be used, but also other materials, for example, because the reinforcing elements include metallic components in addition to the ceramic and / or mineral materials. However, from both a cost perspective, particularly regarding the manufacturing effort of such reinforcing elements, and with regard to the achievable fire protection properties, the inventor considers it far more advantageous to construct the reinforcing elements as largely as possible from the corresponding reinforcing materials.A preferred three-dimensional component according to the invention is wherein the reinforcing element(s) consist of reinforcing materials to a mass fraction of 50% or more, preferably 70% or more, particularly preferably 90% or more, very preferably 95% or more, and particularly preferably substantially 100%, based on the mass of the reinforcing element.

[0055] The use of ceramic materials, for example oxide ceramics such as aluminum oxide, regularly results in particularly advantageous fire protection properties, but also, in particular, particularly resistant mechanical properties, enabling the production of especially hard and rigid materials. A three-dimensional component according to the invention is therefore preferred, wherein the reinforcing materials are selected from the group consisting of ceramic materials, in particular oxide ceramics, and especially preferably aluminum oxide.Particularly preferred is a three-dimensional component according to the invention, wherein the reinforcing materials are selected from the group consisting of ceramic materials, wherein the ceramic materials are selected from the group consisting of silicate ceramics, oxide ceramics, glass ceramics, clay ceramics and non-oxide ceramics, in particular nitrides, in particular metal-based nitrides, are particularly preferably selected from the group consisting of silicate ceramics, glass ceramics, and oxide ceramics, and are most preferably selected from the group consisting of silicate ceramics and oxide ceramics.

[0056] The inventor considers the use of mineral materials for the reinforcing elements to be particularly advantageous. Such materials are typically very cost-effective and exhibit excellent fire-retardant properties. The inventor has found that minerals of the mica group, and especially the so-called "true micas" such as "muscovite," are particularly well-suited for use in three-dimensional components, both in terms of their excellent fire-retardant properties and, in particular, the processability of the precursor materials used in their manufacture.For this embodiment, a three-dimensional component according to the invention is preferred, wherein the reinforcing materials are selected from the group consisting of mineral materials, preferably layered silicates, particularly preferably layered silicates of the mica group, particularly preferably true mica.

[0057] According to the inventor, particularly favorable performance profiles for the three-dimensional components according to the invention result especially when different reinforcing materials are used in the composite materials to be employed according to the invention, whereby a synergistic improvement of the resulting performance profile can be obtained in particular through the combination of ceramic and mineral materials, especially with regard to the mechanical properties of the resulting composite materials as well as their fire-related properties.A preferred component according to the invention is a three-dimensional component, wherein the composite material comprises two or more different reinforcing elements that differ with respect to the reinforcing materials, preferably at least one reinforcing element with ceramic reinforcing materials, in particular aluminum oxide, and at least one reinforcing element with mineral reinforcing materials, in particular a layered silicate. A preferred additional or alternative component according to the invention is a three-dimensional component wherein the mass ratio of the mass of ceramic materials in the composite material divided by the mass of mineral materials in the composite material is in the range of 2:1 to 1:20, preferably in the range of 1:1 to 1:17.5, particularly preferably in the range of 1:2 to 1:15, and most preferably in the range of 1:4 to 1:12.5.

[0058] The reinforcing elements can generally be used as particulate fillers, for example, as essentially spherical particles, which are then dispersed in the matrix. This configuration is particularly suitable for the use of ceramic materials, but is also an option for reinforcing elements made of mineral materials. A three-dimensional component according to the invention is therefore preferred, wherein the reinforcing element(s) are at least partially, preferably to a mass fraction of 25% or more, more preferably 50% or more, particularly preferably 75% or more, and most preferably to an mass fraction of essentially 100%, present as particulate fillers dispersed in the matrix, based on the mass of the reinforcing elements in the composite material.A three-dimensional component according to the invention is preferred, either additionally or alternatively, wherein the reinforcing element(s) are spherical, platelet-shaped, or splinter-shaped fillers, preferably platelet-shaped or spherical fillers, and particularly preferably spherical fillers. A three-dimensional component according to the invention is again preferred, either additionally or alternatively, wherein the particulate fillers have a shape factor of 1.5 or less (the largest diameter of the particle divided by the smallest diameter of the corresponding particle), preferably 1.4 or less, particularly preferably 1.15 or less, and most preferably 1.05 or less.A three-dimensional component according to the invention is also preferred, or alternatively, wherein the particulate fillers have a mean particle diameter D50 of 1.0 mm or less, preferably 0.5 mm or less, particularly preferably 0.2 mm or less, measured by laser diffraction in a wet dispersion process, for example with a Mastersizer 3000 from Malvern.

[0059] Particularly when using mineral reinforcing materials, layered structures can also be employed as reinforcing elements, which are embedded in the matrix during the production of the three-dimensional components according to the invention. In accordance with the understanding of those skilled in the art, layered structures are essentially two-dimensional structures that have a significantly greater extent in the two spatial directions perpendicular to each other within the layer plane than in the thickness direction perpendicular to it. Semi-finished products made of layered silicates, such as muscovite, are frequently used in such layered structures, where they are stabilized by a binder.In this context, a three-dimensional component according to the invention is preferred, wherein the reinforcing element(s) are at least partially, preferably to a mass fraction of 25% or more, more preferably 50% or more, particularly preferably 75% or more, and most preferably to substantially 100%, arranged as macroscopic layer structures embedded in the matrix, based on the mass of the reinforcing elements in the composite material. A three-dimensional component according to the invention is additionally or alternatively preferred, wherein the macroscopic layer structures are paper-like layer structures or pieces of film, preferably paper-like layer structures. A three-dimensional component according to the invention is again additionally or alternatively preferred, wherein the macroscopic layer structures have an average thickness in the range of 200 to 1500 µm, preferably in the range of 300 to 1000 µm.A three-dimensional component according to the invention is also preferred, either additionally or alternatively, wherein the reinforcing material(s) are embedded in a binder or impregnated with a binder in the macroscopic layered structure, wherein the binder is, for example, an organic plastic.

[0060] In particular, when using mineral reinforcing materials, for example in the form of basalt, fibrous materials can also be used, e.g., in the form of wool or fabric. In this case, a three-dimensional component according to the invention is preferred, wherein the reinforcing element(s) are at least partially, preferably to a mass fraction of 25% or more, more preferably 50% or more, particularly preferably 75% or more, and most preferably to essentially 100%, as fibers, preferably in the form of essentially statistically distributed fibers, fiber strands, or a textile fabric, preferably in the form of essentially statistically distributed fibers, a fiber roving, a nonwoven, or a woven fabric, and especially preferably in the form of essentially statistically distributed fibers.The shape of essentially statistically distributed fibers can be advantageously realized in the inventive method if the fibers originate from the pulp of the molding material and are skimmed off, for example, in a sieve mold.

[0061] As explained above, the advantageous manufacturability of corresponding three-dimensional components can be seen as a particular advantage of the present invention. In this context, the inventor has succeeded in identifying a particularly advantageous method for the production of corresponding three-dimensional components, with which these advantages can be realized particularly well.

[0062] The invention therefore also relates to a method for manufacturing a three-dimensional component for use in battery arrangements, preferably a three-dimensional component according to the invention, comprising the following method steps: a) Manufacturing or providing a molding material, comprising: ai) one or more matrix formers: aii) wherein the matrix formers are selected from the group consisting of liquid condensation resins, or aiii) wherein the matrix formers are selected from the group consisting of aqueous solutions of one or more glasses of water, a.ii) one or more reinforcing elements, which consist at least partially of one or more reinforcing materials selected from the group consisting of ceramic materials and mineral materials, b) Shaping the molding material into a three-dimensional component precursor; and c) Producing a composite material by curing one or more matrix formers in the component precursor to form the matrix, so that the reinforcing element(s) are embedded in the matrix, cii) wherein the curing of the condensation resins is carried out by means of a condensation reaction, or ciii) wherein the hardening of the aqueous solutions of one or more water glasses is carried out by drying, wherein the method is carried out, in particular by selecting the mass fractions of the components of the molding material, such that the mass fraction of the matrix in the composite material is 2% or more and that the combined mass fraction of reinforcing materials is 60% or more, in each case based on the mass of the composite material.

[0063] In the process according to the invention, a molding material is first provided, from which the composite material is subsequently to be obtained. The corresponding molding material can be produced, for example by mixing the components during the process, or provided, for example by purchasing it from a commercial supplier.

[0064] For the purpose of subsequent shaping of the composite material, the molding material comprises one or more matrix formers, which, in accordance with the foregoing descriptions, serve to form the matrix of the composite material to be used according to the invention and which are accordingly liquid condensation resins or aqueous solutions of water glass. A preferred embodiment is thus a method according to the invention in which the molding material comprises one or more liquid condensation resins as matrix formers. A particularly preferred embodiment is a method according to the invention in which the molding material additionally comprises one or more catalysts or condensation aids for catalyzing or accelerating the condensation reaction.Particularly preferred is also or alternatively a method according to the invention, wherein the matrix former is produced by mixing two or more components, preferably by mixing the condensation resins with one or more catalysts or condensation aids.

[0065] Alternatively, a method according to the invention is preferred, wherein the molding material as matrix former comprises one or more aqueous solutions of one or more water glasses.

[0066] In addition to the matrix former, the molding material also includes the reinforcing elements, which can be designed as described above. The composition of the molding material is selected such that the mass proportions of the matrix and the reinforcing materials described above for the composite material to be used according to the invention are also achieved in the manufactured molding material. In practice, this can be readily calculated by a person skilled in the art or determined through routine experiments, whereas a preemptive definition of the necessary mass proportions in the molding material is not possible. In accordance with the understanding of a person skilled in the art, the mass proportions of the matrix former and the reinforcing elements in the molding material will depend on which matrix former is used, i.e.,, in particular, which condensation products are removed during hardening or which concentration of the water glass solution is used.

[0067] In the inventive method, the molding material is formed into a three-dimensional component precursor. The molding material is thus brought into the shape of the later three-dimensional component, or into a shape from which the desired shape results after hardening of the matrix former, so that any shrinkage effects are taken into account.

[0068] After demolding, the composite material to be used according to the invention is obtained by curing the matrix former to form the matrix. In the case of condensation resins, this occurs, as understood by those skilled in the art, through a condensation reaction, which is optionally supported by the addition of catalysts or condensation aids and optionally by the application of heat. It is particularly preferred that the low-molecular-weight condensation products, for example water, are removed from the chemical equilibrium during the condensation reaction. In these cases, this is therefore a process according to the invention, wherein the curing of the condensation resins is carried out by means of a condensation reaction, preferably a catalyzed condensation reaction.A preferred method according to the invention is one in which the curing of the condensation resins is promoted or effected by means of a condensation reaction through the addition of heat or catalysts or condensation aids, preferably by the addition of heat. A further or alternative preferred method according to the invention is one in which the curing of the condensation resins is promoted or effected by removing water produced during the condensation reaction, preferably by the addition of heat or by negative pressure, particularly preferably by negative pressure.

[0069] In the case of using aqueous solutions of water glasses, curing can be achieved by drying. This is a method according to the invention, wherein the curing of the aqueous solutions of one or more water glasses is achieved by drying. A preferred method according to the invention is one in which the curing of the aqueous solutions of one or more water glasses is promoted or effected by the application of heat and / or a vacuum.

[0070] Regardless of the type of matrix former to be cured, the inventor considers it preferable to promote or effect curing by applying elevated temperatures. A preferred method according to the invention is one in which the curing of the matrix former in the component precursor takes place at least partially using a heating device, preferably a heated mold or a heated molding press. For the use of condensation resins, a method according to the invention is particularly preferred in which the curing of the matrix former in the component precursor takes place at least partially, preferably throughout the entire curing process, at temperatures of 40 °C or more, preferably 80 °C or more, and particularly preferably 120 °C or more.A preferred method for the use of water glasses is one according to the invention, wherein the curing of the matrix formers in the component precursor takes place at least partially, preferably over the entire curing process, at temperatures of 80 °C or more, preferably 100 °C or more, particularly preferably 120 °C or more, in the case of curing aqueous solutions of one or more water glasses.

[0071] A preferred example is a three-dimensional component according to the invention which comprises ceramic fibers as reinforcing elements, which are present in the molding compound in a water glass during production, wherein the green component, which is formed using a vacuum, can be produced by compression molding. This green component is then pre-dried, for example, at 60 °C, and subsequently cured at 150 to 200 °C.

[0072] The inventor has succeeded in identifying a particularly advantageous manufacturing process. This process utilizes a manufacturing principle for the forming of the component that is known in principle from another industrial sector, namely paper processing and the manufacture of paper products, especially egg cartons. Such processes employ a screen mold, which, within the scope of the present invention, refers to a mold that includes recesses in its base and / or side walls through which a liquid can escape. The forming of the component precursor is achieved by scooping the mold material from the screen mold, which continues to harden within the mold while simultaneously allowing some of it to pass through the openings. This process essentially concentrates the reinforcing materials within the screen mold.Particularly suitable embodiments result from applying a vacuum to the back of the sieve mold, as is known, for example, from the production of egg cartons. This vacuum allows the molding material to be drawn into the sieve mold, thereby removing condensation products of the condensation resin or water from the aqueous water glass. A preferred method according to the invention is one in which the molding of the molding material into a three-dimensional component precursor takes place in a mold. A particularly preferred method according to the invention is one in which the mold is a sieve mold with sieve openings through which a liquid can flow out of the mold.Particularly preferred is, additionally or alternatively, a method according to the invention, wherein the shaping of the mold material into a three-dimensional component precursor is promoted or effected by applying a vacuum to the mold, preferably the sieve mold.

[0073] The invention and preferred embodiments of the invention are explained and described in more detail below with reference to the accompanying figures. The figures show: Fig. 1 a schematic representation of a three-dimensional component according to the invention in a preferred embodiment in a) a side view and b) a top view; Fig. 2 a schematic cross-sectional representation through three different composite materials in various preferred embodiments;

[0074] Fig. Figure 1 shows a schematic representation of a three-dimensional component 10 according to the invention in a preferred embodiment in a) a side view and b) a top view.

[0075] The three-dimensional component 10 of the Fig. 1 is angled laterally and has two elongated recesses in its base, which function as a conduit 18. Accordingly, the three-dimensional component 10 of the Fig. 1 intended to function in a battery assembly as part of the gas venting system to make the corresponding battery assemblies safer in the event of thermal runaway, so that, for example, the occupants of a vehicle can be protected.

[0076] In the example shown, the Fig. 1 the three-dimensional component 10 is made entirely of a composite material 12 and was produced in the inventive method by bringing a corresponding molding material into the corresponding shape while curing the matrix 14, which can preferably be done by scooping out the molding material with a sieve mold on which a vacuum is applied, as is known, for example, in a similar form from the production of egg cartons.

[0077] The corresponding three-dimensional component 10 can be manufactured in a particularly time- and cost-efficient manner, especially compared to silicone-based systems, and still has excellent fire-resistant properties.

[0078] In Fig. Figure 2 shows exemplary composite materials 12 in a schematic cross-sectional view, which can be used in three-dimensional components 10 according to the invention, wherein the proportion of the matrix 14 is exaggerated for better comprehensibility. In the upper figure a), the composite material 12 consists of a matrix 14, which was obtained by drying sodium silicate, in which particulate, largely spherical reinforcing elements 16 are substantially uniformly dispersed, wherein the reinforcing elements 16 consist of aluminum oxide.

[0079] In the middle figure b), 16 mica flakes are used as reinforcing elements, which are dispersed in a matrix 14 formed by a condensed condensation resin, namely a phenolic resin, whereby it is also possible to embed larger layers of mica paper in the corresponding matrix 14.

[0080] In the lower Fig. The two reinforcing elements 16 described above are combined so that, in addition to flakes of layered mica, particles of aluminum oxide are also used, resulting in a particularly preferred embodiment. In the example shown, Fig. ) the Fig. 2 is the matrix 14, a thermoset obtained by condensation of a melamine-based condensation resin. Reference sign 10 three-dimensional components 12 Composite material 14 Matrix 16 reinforcing elements 18 conduit

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