Battery cell assembly

Abstract

The invention relates to a battery cell assembly comprising a battery tray 2 which is arranged on the lower face in an installed position and which is designed to receive multiple battery cells 4 arranged next to one another, a battery cell holder 6 which functions as a holding element with a plurality of battery cell receiving areas designed to receive battery cells 4 inserted therein, a plurality of battery cells 4 which are inserted into the battery cell receiving areas 64, a contact support 10 which is arranged on the upper face of the battery cells and which comprises contacts for electrical connection to the battery cells 4, and a casting resin 8 which can be filled into the battery tray 2 in order to enclose the battery cells 4 in the battery cell holder 6 and optionally the contact support 10. In order to reduce the cycle times, the battery cell holder 6 is designed as a shell-shaped battery cell holder which is open towards an opening end and defines a closed holding plane that functions as an installation surface, said holding plane being spaced from the opening end via a holder edge. The battery cell receiving areas comprise stub-shaped battery cell holder lateral surfaces, and an intermediate section 61 is formed between two adjacent battery cell holder lateral surfaces.

Description

[0001] Battery cell arrangement

[0002] Description

[0003] The invention relates to a battery cell arrangement, in particular for a motor vehicle, comprising a battery tray arranged on the underside in the installed position and designed to accommodate a plurality of battery cells arranged next to one another, a battery cell holder acting as a holding element and comprising a plurality of battery cell receptacles for receiving battery cells that can be inserted or are inserted therein. The battery cell holder positions the battery cells in relation to one another in the battery cell receptacles when these are or are inserted into the battery tray. A plurality of battery cells inserted into the battery cell receptacles of the battery cell holder are electrically connected to the battery cells and an output line via a contact carrier that can be placed or is placed on the top of the battery cells and has electrical contacts provided on it.Finally, a casting resin that can be felt into the battery tray encloses the battery cells in the battery cell carrier and the contact carrier and fixes them in relation to each other.

[0004] State of the art

[0005] A battery for an electric vehicle or an e-vehicle usually consists of several battery cells, comprising 200 battery cells and more, which are arranged in a battery cell arrangement, wherein the in the battery cell arrangement.

[0006] During assembly of such a battery cell arrangement, the individual battery cells, which usually have a cylindrical geometry, are inserted into the battery cell receptacles, i.e. the openings for receiving the battery cells within the battery cell holder. Preferably, the battery cell holder defines a holding plane in which the battery cell receptacles for receiving the battery cells are formed, extending transversely to this holding plane. During assembly, one battery cell is inserted into a corresponding battery cell receptacle within the battery cell holder. The battery cell holder with the inserted battery cells is then inserted into the battery tray, which surrounds and encloses the battery cells, now arranged at regular intervals from one another, from the bottom and the side.

[0007] The contact carrier, which is usually already equipped with metal terminals for electrical contact with the battery cells, is then placed on top of the battery cells. The contact carrier thus contacts the battery cells with an electrical line of the battery cell array.

[0008] Finally, the casting resin is poured into the battery tray, which, after curing, encloses the battery cells and the battery cell holder like a block.

[0009] A central component of this battery cell holder arrangement is therefore the battery cell holder, which positions and holds the battery cells in relation to one another in the battery tray, but at the same time also spaces them apart and has an important heat-insulating function of the individual battery cells against one another.

[0010] Generic battery cell arrangements are known from US 2020 / 0 127 350 A1 , and US 2021 / 0 184 190 A1 as well as DE 20 2018 102 801 U1.

[0011] Disadvantages of the state of the art

[0012] The battery cell holder is made of polyurethane due to its good thermal insulation properties, which also provides electrical insulation.

[0013] However, the production of the polyurethane battery cell holder is very time-consuming because these polyurethane parts require long cooling times of up to 10 minutes or more. Furthermore, the porous structure of this material limits the design options for the battery cell holder. Polyurethane and components made from it have relatively low strength and thus low elongation at break, so that thin components in particular can easily crack when bent. Therefore, scrap in polyurethane production is relatively high, and automation of production is limited anyway. Finally, polyurethane is not recyclable.

[0014] Task

[0015] Based on the previously described prior art and the associated disadvantages, the invention is therefore based on the object of at least partially avoiding these disadvantages and in particular of reducing the throughput times, i.e. the production times, of such a battery cell arrangement.

[0016] invention

[0017] This problem is already solved by the features of the independent claims. Advantageous, but not mandatory, features are recited in the subclaims.

[0018] In abstract terms, the battery cell holder is designed to provide thermal and electrical insulation between the battery cells it holds.

[0019] The electrical insulation is achieved by making the battery cell holder from plastic and further being designed in such a way that it accommodates the battery cells in a circumferentially enclosing manner and at a distance from one another.

[0020] The thermal insulation is achieved by providing intermediate sections and / or webs on the battery cell holder, which extend between the adjacent battery cells when the battery cells are inserted into the battery cell holder and form heat-insulating air pockets in the intermediate sections or on the sides of the webs.

[0021] In the simplest embodiment, this is achieved in that the battery cell holder is essentially designed as a shell-like battery cell holder shell or as (in short: holder shell) which has a closed holder shell surface and is spaced from the opening end by a holder shell edge that circumferentially surrounds the holder shell surface. When inserted into the battery tray, i.e. in the installed position, this battery cell holder shell defines a closed closure end with the holder shell surface, on which a holder edge (battery cell holder edge) is formed that runs completely around the circumference and extends transversely to this holder plane in the direction of the opening end. Furthermore, the socket-shaped battery cell receptacles for receiving the battery cells are formed in the holder shell surface, preferably formed integrally therein.

[0022] The cast resin complements this insulation. The resulting sandwich construction (cast resin, battery cell holder, cast resin) achieves a particularly high rigidity of the entire assembly. The insulation area is stretchable and depends on the rigidity and weight of the entire battery structure.

[0023] The holder shell surface acts as a mounting surface for the battery cells. Between two closely adjacent battery cell receptacles, an intermediate section is always formed. This intermediate section is open toward the opening end and closed at the holder shell surface or the closure end. Thus, the holder shell surface contains holder openings with socket-like battery cell holder surfaces provided thereon, into which the battery cells can be inserted. Each holder opening accordingly comprises a battery cell holder surface that completely surrounds the holder opening, extends socket-like toward the opening end, and is approximately as long as the holder edge.

[0024] The battery cell holder is therefore essentially shell-shaped as a "battery cell holder shell" which, with the holder shell surface, defines a holder plane which is enclosed and circumferentially bordered by a holder edge provided on this holder plane and extending transversely to the holder plane in the direction of the opening end. In the holder plane, holder openings protrude from each holder opening, each of which has a socket-like battery cell holder surface into which the battery cells can be inserted, thus being geometrically adapted to accommodate the battery cells. Each holder opening thus comprises, at a lower end directed towards the opening end, the battery cell holder surface which completely encloses it, also extends towards the opening end and is approximately as long as the holder edge.The battery cell holder shell surfaces therefore preferably form battery cell holder sockets or simply “sockets” formed integrally on the underside of the holder shell surface of the battery cell holder, into which the battery cells can be inserted.

[0025] Thus, the battery cell holder encloses an air space defined by the holder shell ("holder shell space"), the size of which corresponds to the volume of the holder shell less the volume of the holder shell surfaces. Between two adjacent holder shell surfaces, there is a minimum gap at the points of closest separation, i.e., at the points where two imaginary radii of the two adjacent holder shell surfaces are collinear or extend collinearly. At this point, a minimum gap is maintained, which is referred to according to the invention as the "intermediate section." This intermediate section also contains air.

[0026] The battery cell holder is thus designed like a shell or trough open towards the opening end, wherein a shell base defines the holder plane and a shell edge provided on this shell base forms the holder edge.

[0027] The battery cell holder is inserted "upside down," meaning with the tray bottom facing upwards and the opening end toward the battery tray. The tray bottom thus forms the top side or upper mounting level with the battery cell receptacles formed therein and the tray edge at the edge of the tray bottom or tray level.

[0028] When this holder shell, equipped with the battery cells inserted into the battery cell receptacles, is inserted into the battery tray and the casting resin is filled into it, the air trapped beneath the holder shell prevents the casting resin from penetrating into the holder shell space.

[0029] Depending on the viscosity of the casting resin used, an additional air gap may be created between the plastic wall of the battery cell holder and the battery cell, which improves thermal insulation. Therefore, it may be advisable for the battery cell holder's outer surface to be slightly larger than the battery's outer dimensions.

[0030] According to the invention, air trapped beneath the holder shell is used as a thermal insulator, which, with surprisingly simple means, enables significantly better thermal insulation than the prior art. The invention thus takes advantage of the finding that air provides particularly good and cost-effective thermal insulation.

[0031] According to the invention, the battery cell holder can be designed, for example, as a plastic injection-molded part or a plastic thermoformed "deep-drawn part," which are significantly more cost-effective than PUR foam, particularly because they cool down an injection-molded or deep-drawn part much faster (less than 1 minute), thus significantly reducing production throughput times. In addition, the material costs for injection-molded or deep-drawn parts are significantly lower, and they do not need to be manufactured in specialized factories. Therefore, the battery cell holder according to the invention can be integrated much more easily into existing production processes.

[0032] It goes without saying that the holder plane does not have to be straight, but can also be curved or have any desired structure. It is important that, in the installed position, a mounting plane is formed that is spaced from the battery tray by the edge of the tray. This creates a space within the holder tray with inserted battery cells that can trap air, preventing the penetration of casting resin during filling.

[0033] It will also be understood by the person skilled in the art that the shell plane or the shell edge do not necessarily have to be straight, but can also be curved, arched or have other geometries.

[0034] In terms of its shape, the battery cell holder can be constructed from a plurality of battery cell receptacles connected to one another via the intermediate sections, with a geometry adapted to the geometry of the battery cells. An intermediate section can be formed between each two adjacent battery cell receptacles. Except at the edge regions, each battery cell receptacle is enclosed or bordered by four intermediate sections. In the edge region, the battery cell holder is delimited or bordered by the holder edge. The battery cell holder therefore comprises a plurality of, preferably adjacent, battery cell receptacles, between which intermediate sections are formed, preferably consisting of a plurality of rows and lines of battery cell receptacles, which then form a battery cell grid.

[0035] The intermediate section can thus be formed between two adjacent outer walls of the battery cell receptacles. These outer walls of the often circular or hollow-cylindrical battery cell receptacles form the facing inner walls of the intermediate sections.

[0036] At least in the region of battery cell receptacles which are spaced slightly apart from one another and have the battery cell holder shell surfaces facing one another, a clear distance or an inner distance can be formed to form the intermediate section, which is also filled with air.

[0037] For conventional battery cells, a minimum clearance of 1 mm has proven sufficient. However, for larger battery cells, a larger internal clearance may be appropriate, as this provides better thermal insulation.

[0038] Due to the design according to the invention, air is also enclosed in the intermediate sections when the casting resin is poured into the battery tray, thus realizing the necessary thermal insulation between the adjacent battery cells.

[0039] An intermediate section can be formed between two adjacent battery cell receptacles. This intermediate section is closed at one end and has an inlet opening at the opposite end. Air can enter the intermediate section through the inlet opening and is enclosed in the intermediate section(s) when filled with casting resin. Thus, the intermediate section forms an air-filled pocket, which provides particularly good thermal insulation between the battery cells.

[0040] The intermediate sections can be pocket-shaped or channel-shaped.

[0041] The battery cell holder preferably has a plurality of battery cell receptacles, preferably a plurality of battery cell receptacles arranged in rows and lines to form a grid of battery cell receptacles, wherein an air-enclosing intermediate section is provided between adjacent battery cell receptacles.

[0042] The battery cell receptacles can be formed in regular structures in the battery cell holder, but can also be arranged or formed in irregular structures.

[0043] For the thermal insulation according to the invention, it has proven sufficient that the intermediate sections have a clear interior space of 1 mm, i.e. a distance from the outside of a first battery cell holder shell surface to an outside of a second, adjacent battery cell holder shell surface.

[0044] To improve thermal insulation, the intermediate section, i.e. the distance, can also be made larger.

[0045] Since air has significantly better thermal insulation than polyurethane, the invention achieves the necessary thermal insulation with significantly simpler means than the prior art, using a relatively simple and cost-effective plastic that can be injection-molded or thermoformed to the desired shape. Furthermore, the battery cell holder always achieves good electrical insulation between two adjacent battery cells via the plastic, also due to the circumferentially closed battery cell holder mandrel surfaces.

[0046] The inventive design also allows for significantly more delicate geometries compared to the prior art, such as features such as locking lugs, locking ribs, locking tabs, snap hooks, domes, or thin wall thicknesses of even less than 0.5 mm to be realized on the battery cell holder during the manufacturing process. This was not possible with previous battery cell holders made of polyurethane. Due to the material properties, these required a minimum wall thickness of 2.5 mm, which significantly limits the design options.

[0047] The plastic used to manufacture the battery cell holder is still lightweight, but exhibits significantly better elongation at break compared to polyurethane battery cell holders, while at the same time being lower in material costs due to the relatively high cost of polyurethane. The invention enables a reliable process with a high degree of automation and design freedom, a low probability of rejects, and good fracture strength.

[0048] Since the battery cell holder is made of plastic, preferably injection-molded or thermoformed, it only needs to cool for a maximum of 1 minute, but usually much less time, which significantly reduces processing times and thus production costs compared to the state of the art.

[0049] Preferably, the pocket- or channel-shaped intermediate section has a substantially smaller width than height.

[0050] In order to simplify the insertion of the battery cells into the battery cell receptacles, the intermediate section can be tapered from the opening end to the top of the holder shell, so that the outer surface of the battery cell receptacle does not lie flat against the battery cell everywhere.

[0051] For the same purpose, it is also possible for the battery cell holder receptacles with the battery cell holder surface to be designed somewhat larger than the outer geometry of the battery cells to be accommodated.

[0052] Particularly good results in terms of thermal insulation are achieved when the

[0053] The ratio of the inner distance between the intermediate section inner walls to the height of at least one intermediate section, i.e. the distance from the inlet end to the closure end, is approximately 9 / 100.

[0054] Advantageously, the at least one intermediate section has a significantly higher intermediate section height (distance from the inlet end to the closure end) than the intermediate section width. Particularly good results have been achieved when the intermediate section height is eight to ten times greater than the intermediate section width.

[0055] To reduce rejects due to incorrect installation and to enable the battery cell holder to be installed in any orientation, the opening end of the battery cell holder can be closed with a sealing film.

[0056] From a manufacturing point of view, it is particularly simple if this sealing film is applied to the entire opening end of the battery cell holder, so that the openings of the battery cell receptacles are also closed by the sealing film.

[0057] For assembly, the battery cells simply need to be inserted into the battery cell receptacles and pushed through the sealing film. However, assembly can also be done from below, which has the additional advantage that the separated sealing film adheres to the inner surface of the battery cell receptacles, improving thermal insulation.

[0058] To simplify assembly and to achieve a defined opening of the sealing film, a pre-perforation can be provided on the sealing film in the area of ​​the battery cell receptacles.

[0059] It is particularly expedient to provide the pre-perforation in the shape of cake slices above the battery cell receptacles, whereby the pre-perforations extend along at least two, preferably several diagonals to the battery cell receptacle, which are arranged at offset angles to one another and intersect at a common center point. The provision of the sealing film also increases thermal insulation, because the sealing film provides additional thermal and electrical insulation in addition to the intermediate section.

[0060] The sealing film also enables an even more compact design of the battery cell holder with narrower webs that prevent air pockets from forming. This means that the heat-insulating air pockets are not located within the intermediate sections, but rather between the outer surface of the battery cells and the inside of the battery cell receptacles. Here, the sealing film also serves to prevent the casting resin from penetrating the space between the battery cells and the battery cell receptacles.

[0061] The sealing film can be applied to the top and, if necessary, the bottom of the battery cell holder, which then deforms when the battery cells are inserted into the battery cell opening and thus forms an air-enclosing sealing lip between the battery cell and the partition wall of the battery cell holder, which prevents the penetration of casting resin into the space between the battery cell and the wall during filling and encloses air beneath the film and can thus fully form an air pocket between the battery cell and the battery cell holder.

[0062] For the defined circumferential bending of the sealing film when inserting the battery cells, additional film holes can be provided in the sealing film, which are preferably formed centrally to the battery cell receptacles.

[0063] The film can be provided on the holder shell surface or on the underside of the holder shell, possibly even on both surfaces, but is particularly preferably arranged on the top side of the holder shell.

[0064] The sealing film can be made of polyethylene (PET), for example. This can have a different material thickness depending on the application, but is preferably designed as a construction film with a greater material thickness of 100 - 30 microns. In special cases, a particularly stable film, e.g., an HDPE pond tarpaulin, is also conceivable. The contact carrier is therefore preferably designed to connect to the negative and positive poles of the battery cells. For this purpose, this contact carrier, preferably made of plastic, comprises metallic contact elements that are connected to conductors in the contact carrier and thus form the electrical connection.

[0065] In an alternative embodiment, the battery cells can also be electrically connected via the battery tray, in particular via the negative pole.

[0066] It is understood that particularly good thermal insulation and electrical insulation is achieved by forming an intermediate section between adjacent battery cell receptacles of the battery carrier, i.e. the battery carrier comprises a plurality of intermediate sections, each in the region of adjacent battery cell receptacles.

[0067] Preferably, the battery cell holder, as well as the battery tray and contact carrier, are constructed as one-piece plastic parts. Plastics with low moisture absorption capacity have proven particularly suitable for the manufacture of the battery cell holder.

[0068] Even better thermal insulation can be achieved by filling the holder shell with polyurethane foam (PUR foam) or another suitable heat-insulating material. This provides particularly good thermal insulation, while the electrical insulation is still provided by the plastic of the battery cell holder carrier.

[0069] The battery cell holder according to the invention has significantly better dimensional stability and higher dimensional tolerances compared to the prior art.

[0070] The resin can be filled to enclose either just the battery cells and the battery cell holder or also the contact carrier up to about half its height.

[0071] In the following detailed description of the figures, reference is made to the accompanying drawings which form a part of this specification, and in which are shown to illustrate specific embodiments in which the invention may be practiced. In this regard, directional terminology such as "top", "bottom", "front", "back", "fore", "rear", etc., will refer to the orientations of the described figure(s). Since components of embodiments can be positioned in a number of different orientations, the directional terminology is for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description is not to be taken in a limiting sense.

[0072] In this description, the terms “connected,” “attached,” and “integrated” are used to describe both direct and indirect connection, direct or indirect connection, and direct or indirect integration.

[0073] Unless otherwise stated, the indefinite article and the definite article do not refer solely to a single component, but should be understood as "at least one." The terminology includes the aforementioned words, variations thereof, and similar meanings. Furthermore, it should be understood that the terms "about," "substantially," and similar terms in connection with the dimensions and a characteristic of a component of the invention do not describe the described dimension and characteristic as a strict limit or parameter, and do not exclude minor variations thereof that are functionally similar. At a minimum, descriptions containing numerical parameters also include variations of these parameters according to mathematical and manufacturing principles in the prior art, e.g., rounding, deviations, and other systematic errors, manufacturing tolerances, etc.In the figures, identical or similar elements are provided with identical reference symbols where appropriate. Identical reference numbers in the figures thus refer to identical components or features.

[0074] Reference symbol lines are lines that connect the reference symbol to the part in question. An arrow that doesn't touch any part, on the other hand, refers to the entire unit to which it is directed.

[0075] The illustrations in the figures are not necessarily to scale. Certain areas may be exaggerated to illustrate details. Furthermore, the drawings may be simplistic and may not include every detail that may be present in the actual design.

[0076] All features of the respective embodiments are disclosed independently and independently of other features of the respective embodiments. Likewise, the above-mentioned and further-described features can be used individually or in any combination according to the invention. The embodiments shown and described are not to be understood as an exhaustive list, but rather are exemplary in nature for describing the invention.

[0077] They show:

[0078] Figure 1 is a schematic side view of a battery cell arrangement according to the invention;

[0079] Figure 2 is an enlarged schematic sectional view of two battery cells arranged side by side in the battery cell arrangement;

[0080] Figure 3 is a smaller side view of the side sectional view according to Figure 2 without battery cells;

[0081] Figure 4 shows the enlarged section IV according to Figure 3 of the lower end of an intermediate section with the casting resin arranged underneath; Figure 5 shows an isometric view of a battery cell holder from below;

[0082] Figure 6 is an isometric plan view of the upper closure end of the battery cell holder;

[0083] Figure 7 is an isometric view of the battery cell holder from below;

[0084] Figure 8 is an enlarged, side sectional view of a second embodiment of a battery cell holder with a sealing film on the opening end;

[0085] Figure 9 is an enlarged isometric plan view of the underside of the battery cell holder sealed with the sealing film according to Figure 8;

[0086] Figure 10 is a plan view of the sealing film to illustrate a pre-perforation in the area of ​​the battery cell receptacles;

[0087] Figure 11 is a side sectional view of a third embodiment of the battery cell holder according to the invention with a PUR foam;

[0088] Figure 12 is an enlarged isometric view of the battery cell holder filled with PUR foam according to Figure 11 from below;

[0089] Figure 13 is an enlarged side sectional view of a third embodiment of a battery cell holder with a sealing film with film holes on the opening end; and

[0090] Figure 14 is a plan view of a portion of the battery cell holder with the sealing film with film holes used in Figure 13.

[0091] Figure 1 shows the schematic structure of a battery cell arrangement according to the invention in a longitudinal section, which essentially consists of a trough-like battery trough 2, a plurality of battery cells 4 arranged therein, a battery cell holder 6 holding them, a contact carrier 10 arranged on top of the battery cells 4 and casting resin 8 filled into the battery trough 2, which surrounds or encloses the battery cells 4, the battery cell holder 6 and the contact carrier up to approximately half the height.

[0092] The battery tray 2, when installed in the motor vehicle in the installed position, forms the tray-shaped lower part and comprises a floor section defining a floor plane, on which a side part or an edge extending transversely to the plane of the floor section is / are integrally formed on all sides or circumferentially to form the battery tray 2 which is closed on all sides and in which the battery cells 4 and the battery cell holder are arranged.

[0093] In this battery tray 2, a plurality of battery cells 4 (only one is designated; in the present case, 200 pieces, by way of example) are arranged to form a battery cell grid, namely inserted into battery cell receptacles in the battery holder 6, which are designed to correspond to the receptacle of the battery cells 4 and are here ring-shaped.

[0094] Figure 2 shows an enlarged, schematic sectional side view of two battery cells 4 inserted into the battery cell holder 6 and enclosed with casting resin 8 with the contact carrier 10 attached. It is clearly visible how the pocket-shaped intermediate sections 61 are formed in the battery cell holder 6 in the area between two adjacent battery cell receptacles, which define inner air pockets.

[0095] At the opening end located at the bottom in the installed position, the shell- or trough-shaped battery cell holder 6 is open and at the opposite end, the holder shell surface 65, is closed, so that the overall structure forms a "battery cell holder shell." A holder edge enclosing or bordering the holder shell surface 65 is integrally formed along the entire side edge and extends transversely to the holder plane in the direction of the opening end. Holder openings into which the battery cells 4 can be inserted are formed in the holder shell surface 65. Each holder opening further comprises a battery cell holder shell surface 64 that completely encloses the holder opening and extends towards the opening end, here designed like a nozzle. The battery cell holder shell surfaces 64 are approximately as long as the holder edge and form the battery cell receptacles.

[0096] Thus, extending toward the opening end, several, in this case hollow-cylindrical, battery cell holder shell surfaces 64 are provided for receiving the correspondingly shaped battery cells 4. These battery cell holder shell surfaces 64 are designed as hollow cylinders in the present case, but can have any desired and even varying geometries that are adapted for the insertion reception of correspondingly shaped battery cells.

[0097] Figure 5 shows an isometric view of the battery cell holder 6 from below.

[0098] Where the battery cell holder shell surfaces 64 are located closest to one another, the downwardly open, pocket-shaped intermediate section 61 is formed between two adjacent battery cell holder shell surfaces 64 at two radii of the battery cell holder shell surfaces extending collinearly to one another, which is formed by the outer walls of the two adjacent battery cell holder shell surfaces 64.

[0099] As Figures 3 and 4 show, the internal distance or clear distance of this intermediate section 61 from the bottom inlet opening 62 to the closed end in the holder plane can taper slightly. In addition, the wall thickness can vary.

[0100] In the present preferred embodiment, the ratio of the internal distance to the height of the intermediate section 61 is approximately 9 / 100, but the internal distance is approximately 1 mm. The height of an intermediate section 61, i.e., the intermediate section height from the inlet opening 62 to the closure end 63, is 8 to 12 times, preferably 10 times, greater than the intermediate section width.

[0101] The holder shell surface 65 forming the holder plane may be located slightly above or below the closure end 63 of the intermediate sections 61.

[0102] To facilitate insertion and removal of the battery cells, the side walls of the intermediate section 61 can converge at a slight angle. The intermediate sections thus form a top-sealed air pocket at the closure end 63 in the region of the adjacent battery receptacles, with the air inlet opening 61 at the lower end in the installed position. Such an intermediate section 61 is formed at the adjacent narrowest points of the battery cell holder 6 between two adjacent battery cell holder surfaces 64, i.e., where the radii of two adjacent battery cell holder surfaces are collinear.

[0103] The contact carrier 10 is placed on the top side of the battery cells 4 at a distance from the battery cell holder 6 and can laterally enclose the battery cells 4, i.e. it rests with a horizontal section on the top side of the battery cells 4 and with a vertical section extending transversely to this horizontal section it rests laterally on the outer lateral surfaces of the battery cells 4.

[0104] The contact carrier 10 contains metallic contact elements (not shown in detail) which are connected to the terminals of the battery cells 4, i.e. are electrically connected to the positive and negative poles of the battery cells 4 and conduct the current to a connecting line.

[0105] Alternatively or additionally, connections can also be provided in the battery tray 2, preferably for the negative pole. Particularly from the lateral sectional views in Figures 3, 4, and 8, it can be seen how the intermediate sections 61 between two adjacent battery cell holder surfaces 64 are formed by two battery cell receptacles.

[0106] Due to the arrangement of the battery cell holder 6 fitted with the battery cells 4 in the battery cell receptacles with the opening end facing downwards in the battery tray 2, when the battery tray 2 is filled with casting resin 8, air is enclosed in the air space enclosed beneath the battery cell holder 6, in particular also in the narrow intermediate sections 61, i.e. the space defined by the narrow sections of two adjacent battery cell receptacles, and thus forms the air pockets for thermal insulation between the adjacent battery cell receptacles 64.

[0107] In the second embodiment of the battery cell holder 6 shown in Figures 8 and 9, the opening end of the otherwise identically constructed battery cell holder 6 is provided with a continuous sealing film 12, which thus closes the open underside of the battery cell holder 6.

[0108] In order to simplify the removal of this sealing film 12 when pressing the battery cells 4 into the battery cell receptacles, this sealing film 12 can be pre-perforated in the area of ​​the opening of the battery cell receptacles, as is shown in Figure 10 as an example for the sealing film in the area below a battery cell receptacle.

[0109] In fact, the sealing film 12 in Figure 10 is shown only as an example for a section in the area of ​​a battery cell receptacle in order to clarify the course of the perforation lines 13 of the pre-perforations. Such perforation lines 13 according to Figure 10 are preferably provided on the sealing film 12 in the area of ​​all battery cell receptacles.

[0110] In the present preferred embodiment, the perforation lines 13 run along several diagonal lines extending at offset angles to the respective battery cell receptacle, which intersect at a single point, similar to "pieces of cake." Thus, when the battery cells 4 are inserted into the battery cell receptacles, the sealing film 12 is separated along the perforation lines 13, but does not detach from the battery cell holder 6.

[0111] Figures 11 and 12 then show a third embodiment of the battery cell holder 6, into the opening end of which PUR foam 14 is filled, thus filling the entire gaps between the outer surfaces 64 of the battery cell receptacles, thus also the intermediate sections 61, as can be seen from the cross-section according to Figure 11. This third embodiment, like the second embodiment, can also be arranged in the opposite direction in the battery tray 4, i.e. with the opening end of the battery cell holder 6 facing upwards. Despite filling with PUR foam, which requires a longer time to cure, this embodiment also has the advantage according to the invention of short processing times, because the PUR foam is poured into the battery cell holder 6 for curing and can dry there during further processing. It is therefore not necessary to wait for complete curing before further processing.

[0112] Figure 13 shows an enlarged side sectional view of a third embodiment of a battery cell holder 16 with partition walls formed as webs 161 or regions between two adjacent battery cell holder mangle surfaces 162 formed between the sealing film and the webs 161 as air pockets. In this embodiment, too, a sealing film 18 is arranged on the upper side of the battery cell holder 16 in the installed position. This battery cell holder 18 differs from the previously illustrated embodiments in that the partition walls between the battery cell holder mangle surfaces forming the battery cell receptacles are not pocket-shaped, i.e., do not form air pockets, but rather as continuous webs 161, which are therefore not hollow on the inside. These webs 161 of the battery cell holder 16 thus delimit the cylindrical battery cell holder shell surfaces 182 from one another.

[0113] As can be seen from Figure 14 with an enlarged plan view of the embodiment of the battery cell holder according to Figure 13 with applied sealing film 18, either before the sealing film is connected to the top side of the battery cell holder 18, a plurality of film holes 181 are formed in this sealing film 18, which in the installed position, i.e. after the sealing film 18 is connected to the battery cell holder 16, are each arranged approximately centrally within the battery cell receptacles.

[0114] If the battery cells 4 are inserted into the battery cell receptacles of the battery cell holder 16, the sealing film 18 (indicated in Figure 13) bends circumferentially downwards into the battery cell receptacles and thereby encloses air with the upper side of the sealing film 18 in such a way that air pockets are formed circumferentially around the battery cells and between the battery cell receptacles or the battery cell holder casing surfaces 162.

[0115] In summary, this relates to a battery cell arrangement with a battery tray 2 arranged on the underside in the installed position, designed to accommodate a plurality of battery cells 4 arranged next to one another, a battery cell holder 6 acting as a holding element with a plurality of battery cell receptacles for receiving battery cells 4 inserted or insertable therein, a plurality of battery cells 4 inserted into these battery cell receptacles, a contact carrier 10 arranged on the top side of the battery cells, comprising contacts for electrical connection to battery cells 4, and a casting resin 8 which can be felt into the battery tray 2 for enclosing the battery cells 4 in the battery cell carrier and, if applicable, the contact carrier 10.

[0116] In order to reduce the throughput times, the battery cell holder 6 is designed as a shell-like battery cell holder shell which is open towards an opening end and which has a closed holder shell surface 65 and is spaced from the opening end by a circumferentially running and closed holder edge or forms this, that the battery cell receptacles comprise socket-like battery cell holder shell surfaces 64 for inserting the battery cells 4 and that between two adjacent battery cell holder shell surfaces 64 an intermediate section 61 is formed which, together with the surrounding casting resin, forms an air pocket which realizes particularly good thermal insulation between adjacent battery cells.

[0117] The subject matter of the present invention arises not only from the subject matter of the individual patent claims, but also from the combination of the individual patent claims. All information and features disclosed in the documents – including the abstract – in particular the spatial configuration illustrated in the drawings are claimed as essential to the invention, insofar as they are novel, individually or in combination, compared to the prior art.

[0118] List of reference symbols

[0119] 2 battery tray

[0120] 4 battery cells

[0121] 6 battery cell holders

[0122] 61 Intermediate section

[0123] 62 Entrance opening

[0124] 63 Closure end

[0125] 64 battery cell holder surfaces

[0126] 65 Holder shell surface

[0127] 8 Casting resin

[0128] 10 contact carriers

[0129] 12 sealing film

[0130] 13 perforation lines

[0131] 14 PUR foam

[0132] 16 battery cell holders

[0133] 161 jetty

[0134] 162 Battery cell holder surface

[0135] 18 Sealing film

[0136] 181 film hole

Claims

Claims 1. Battery cell arrangement, in particular for a motor vehicle, with a battery tray (2) arranged at a lower end in the installed position and designed to accommodate a plurality of battery cells (4), a battery cell holder (6) designed as a holding element with a plurality of battery cell receptacles (64) formed therein for receiving battery cells (4) inserted therein, battery cells (4) that can be inserted or are inserted into the battery cell receptacles of the battery cell holder (6), a contact carrier (10) that can be placed or is placed on top of the battery cells (4) inserted into the battery cell holder (6), comprising contacts for electrical contact with the battery cells (4), and a casting resin (8) that can be felt into the battery tray (2) for enclosing the battery cells (4) arranged in the battery tray (2) in a defined manner by the battery cell holder (6),CHARACTERIZED IN THAT the battery cell holder (6) is designed as a shell-like battery cell holder shell, which has a closed holder shell surface (65) and is spaced from the opening end by a circumferentially extending and likewise closed holder edge, that the battery cell receptacles comprise socket-like battery cell holder surfaces (64) for inserting the battery cells (4), and that between two adjacent battery cell receptacles an intermediate section (61) serving as an intermediate spacer is provided, which is open towards the opening end and is closed at the holder shell surface (65).

2. Battery cell arrangement according to claim 1, CHARACTERIZED BY, that the at least one intermediate section (61) is pocket-shaped or channel-shaped.

3. Battery cell arrangement according to claim 1 or 2, CHARACTERIZED IN THAT the at least intermediate section (61) is formed by the lateral surfaces of two adjacent battery cell receptacles, and a smallest clear distance of the intermediate section (61) is located where the radii of the lateral surfaces of the two adjacent battery cell receptacles are collinear.

4. Battery cell arrangement according to claim 3, CHARACTERIZED IN THAT the intermediate section and / or the battery cell receptacle tapers or reduces from the inlet opening (62) towards the holder plane.

5. Battery cell arrangement according to claim 4, CHARACTERIZED IN THAT the ratio of the clear distance of the intermediate section (61) to a height of the intermediate section (61) is approximately 9 / 100.

6. Battery cell arrangement according to one of the preceding claims, CHARACTERIZED in that the clear distance of the intermediate section (61) is at least 1 mm.

7. Battery cell arrangement according to one of the preceding claims, CHARACTERIZED IN THAT the at least one intermediate section (61) has a significantly greater intermediate section height than intermediate section width.

8. Battery cell arrangement according to claim 7, CHARACTERIZED BY the intermediate section height is 8 to 10 times greater than the intermediate section width.

9. Battery cell arrangement according to one of the preceding claims, CHARACTERIZED IN THAT the opening end of the battery cell holder (6) is completely or partially closed by a sealing film (12).

10. Battery cell arrangement according to claim 9, CHARACTERIZED IN THAT the sealing film (12) has a pre-perforation with perforation lines (14) in the area of ​​the battery cell receptacles. 11 . Battery cell arrangement according to claim 10, CHARACTERIZED IN THAT the perforation lines (14) are formed like the cutting lines of cake pieces.

12. Battery cell arrangement according to one of the preceding claims, CHARACTERIZED BY Contact carrier (10) designed to connect to the positive and negative poles of the battery cells (4).

13. Battery cell arrangement according to one of the preceding claims, CHARACTERIZED IN THAT the battery tray (2) is also designed for electrical connection to the battery cells (4).

14. Battery cell arrangement according to one of the preceding claims, CHARACTERIZED IN THAT a plurality of intermediate sections (61) are formed between adjacent battery cell receptacles.

15. Battery cell arrangement according to one of the preceding claims, CHARACTERIZED IN THAT the battery cell holder (6) has a wall thickness and that the minimum thickness of this wall thickness is 0.5 mm.

16. Battery cell arrangement according to claim 15, CHARACTERIZED BY the fact that the wall thickness of the battery cell holder (6) is different in different areas.

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