Battery shell, traction battery, motor vehicle, tool for producing battery shell, and method for producing battery shell

Abstract

To provide a battery shell, a traction battery, a motor vehicle, a tool for producing the battery shell, and a method for producing the battery shell.SOLUTION: The invention relates to a battery shell comprising at least one inner stiffening means and / or at least one outer stiffening means, which are configured to stiffen the battery shell and to protect a designated battery module from an outer impact. The invention also relates to a traction battery comprising the same battery shell, and to a motor vehicle comprising the same battery shell. Furthermore, the invention relates to a tool for producing this battery shell, and a method for producing the battery shell.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] This patent application claims the priority of German patent application publication no. 102020128527.2, the content of which is expressly incorporated herein by reference.

[0002] The present invention relates to a battery shell, a traction battery, a vehicle, a tool for manufacturing a battery shell, and a method for manufacturing a battery shell.

[0003] Batteries, especially traction batteries for energy storage in motor vehicles, are made up of numerous components, with the battery housing having at least one battery shell primarily tasked with securing and protecting the battery modules and other necessary components.

[0004] Flat battery housings, particularly those used in electric vehicles, are required to safely and robustly support the large mass of the battery modules at relatively high acceleration values, so today's battery housings have a relatively large mass.

[0005] Furthermore, electric vehicle batteries are subject to requirements to protect the battery modules from damage in the event of an accident.

[0006] In the prior art, battery shells made of plastic are known in various specifications.

[0007] The present invention is based on the problem of providing an improvement or alternative to the prior art.

[0008] According to a first aspect of the invention, the object is achieved by a battery shell, in particular a battery shell for a traction battery, which is molded from plastic, the battery shell having a bottom and side walls, an inner side and an outer side, the battery shell having a maximum lateral extension in a lateral direction and a maximum height extension in a height direction, and the battery shell having internal reinforcing means, in particular internal reinforcing means extending in the lateral or longitudinal direction of the battery shell, in particular internal reinforcing means extending in the lateral direction of the battery shell and in the longitudinal direction of the battery shell, and / or external reinforcing means, in particular at least one external reinforcing means extending in the longitudinal direction of the battery shell.

[0009] In this regard, the following terms are explained.

[0010] First, it is expressly pointed out that in this patent application, indefinite articles and numerical indications such as "one", "two", etc. are generally to be understood as "minimum" indications, i.e. "at least one", "at least two", etc., unless it is expressly clear from the respective context that they can only mean "exactly one", "exactly two", etc., or if this is obvious to a person skilled in the art or technically necessary.

[0011] In this patent application, the expression "particularly" is always to be understood as introducing any preferred features. This expression should not be understood in the sense of "and" or "i.e."

[0012] By "traction battery" is understood an energy storage device, in particular an electrical energy storage device. Preferably, the traction battery is suitable for installation in and for driving an electric vehicle. Preferably, the traction battery is suitable for use in a battery-electric vehicle and / or a vehicle with a battery-electric drive and an engine.

[0013] "Plastic" is understood to be a material that consists mainly of polymers.

[0014] Preferably, the plastic is a thermoplastic, which can be deformed over a temperature range depending on the material, and the process is reversible and can be repeated any number of times by cooling and reheating to a molten state.

[0015] By "battery shell" is understood a housing component of a battery, in particular a traction battery.

[0016] In particular, the battery shell is provided for housing the components of the battery and accordingly has a housing space for housing the components, so that these components are protected from external influences by the battery shell and / or can be at least indirectly fixed within the battery shell.

[0017] Preferably, a battery shell is understood to be a lower battery shell or an upper battery shell, which preferably together form the main component of the housing of the traction battery.

[0018] In particular, the battery shell has a "bottom" and, in the preferred case of a traction battery that is substantially rectangular in plan view, at least four "side walls."

[0019] The bottom and side walls of the battery shell define the storage volume of the battery shell, which represents the "inside" of the battery shell.

[0020] Starting from the storage volume of the battery shell, the "outside" of the battery shell is on the surface of the bottom and side walls that are on the opposite side of the storage volume.

[0021] "Internal reinforcing means" is understood to be a geometrical configuration of the battery shell that is located inside the battery shell and is provided to reinforce the battery shell.

[0022] Preferably, the internal reinforcing means is a partition wall, which is understood to be a geometric shape in the internal space of the battery shell, which is provided to reinforce the battery shell.

[0023] Preferably, the partition is a longitudinal partition, which extends in the longitudinal direction of the battery shell and is provided to increase at least one, and particularly preferably two, moments of inertia of the cross section of the battery shell passing perpendicular to the longitudinal direction, thereby reinforcing the battery shell.

[0024] The battery shell may have a rectangular base area, and in this case, the "longitudinal direction" of the battery shell refers to the direction along the sidewall of the battery shell, preferably the direction of travel of a given vehicle.

[0025] If the battery shell has a rectangular base or a base area different from that of another quadrilateral, the longitudinal direction is understood to be the direction of extension of at least one side wall of the battery shell that has the longest extension.

[0026] In particular, the longitudinal extension direction is parallel to the bottom surface of the battery shell.

[0027] "Height direction" is understood to be the direction normal to the plane formed by the transverse and longitudinal directions.

[0028] Preferably, the partition is a horizontal partition, which extends in the horizontal direction of the battery shell and is provided to increase at least one, and particularly preferably two, moments of inertia of the cross section of the battery shell passing perpendicular to the horizontal direction, thereby reinforcing the battery shell.

[0029] Preferably, the partition is arranged to provide a predetermined spatial separation between two adjacent battery shells and / or battery modules. Particularly preferably, the battery modules can be fixed to an internal reinforcing means, and more preferably, the battery modules are supported by the internal reinforcing means.

[0030] Preferably, the internal reinforcing means comprises at least a regional material change relative to the battery shell.

[0031] Preferably, the layer of the internal reinforcing means has a material modification to the material of the battery shell, preferably in the form of a fibrous material disposed within the layer, preferably the fibrous material being provided to increase the stiffness of the cover layer in the direction of extension of the cover layer.

[0032] The battery shell may have a rectangular base area, in which case the "lateral direction" of the battery shell refers to the direction along the sidewall of the battery shell.

[0033] If the battery shell has a base area different from a rectangular base or other quadrangular base, the transverse direction is understood to be the direction of extension perpendicular to at least one of the side walls of the battery shell that has the longest extension.

[0034] In particular, the lateral extension direction is parallel to the bottom surface of the battery shell.

[0035] Preferably, the internal stiffening means comprises at least one longitudinal bulkhead and at least one transverse bulkhead. Preferably, the at least one longitudinal bulkhead and the at least one transverse bulkhead are connected to one another.

[0036] "External reinforcing means" is understood to be a geometrical form of the battery shell and / or a material modification of the battery shell that is located on the outside of the battery shell and is provided to reinforce the battery shell.

[0037] Preferably, external reinforcing means are provided to reinforce the bottom surface of the battery shell and / or at least one side wall of the battery shell.

[0038] Preferably, the external reinforcing means refers to a profiling of at least one side wall of the battery shell, which profiling of the at least one profiled side wall of the battery shell increases at least one moment of inertia of the at least one profiled side wall of the battery shell, particularly preferably two moments of inertia of the at least one profiled side wall of the battery shell, compared to a side wall of a battery shell with an equivalent wall thickness and an equivalent material composition but without a profiling.

[0039] By contouring is preferably intended an I-shaped contour, a U-shaped contour, a T-shaped contour, a Z-shaped contour, an L-shaped contour, a contour cumulatively formed from these contours or a different contouring.

[0040] It should be explicitly pointed out that contouring can be understood as any geometrical change to the planar extension of at least one side wall and / or bottom surface of the battery shell.

[0041] Preferably, the external reinforcing means refers to a material modification of at least one side wall of the battery shell, which material modification of the at least one material-modified side wall of the battery shell increases at least one bending stiffness about a first axis and / or torsional stiffness, particularly preferably a first bending stiffness about a first axis and a second bending stiffness about a second axis, of the at least one material-modified side wall of the battery shell compared to a side wall of a battery shell having a comparable wall thickness and a comparable contouring but without the material modification.

[0042] Material modification to modify the external reinforcement means particularly contemplates the addition of fibrous material within at least one wall and / or bottom surface of the battery shell, the fibrous material being arranged to increase at least one bending stiffness and / or torsional stiffness about a first axis of at least one side wall and / or bottom surface of the battery shell, preferably a first bending stiffness about the first axis and a second bending stiffness about a second axis.

[0043] It is expressly pointed out that the embodiment of the external reinforcement means proposed here is not limited to the reinforcement of one side wall of the battery shell, but that two or more side walls of the battery shell, preferably all side walls of the battery shell, may have external reinforcement.

[0044] It is expressly pointed out that the side walls may be components of the external stiffening means.

[0045] "Lateral extension" is understood to be the lateral extension of the battery shell in the bottom area.

[0046] By "height extension" is understood an extension of the battery shell in the height direction.

[0047] Here, a battery shell is proposed which is made of plastic, in particular thermoplastic, and which has internal and / or external reinforcing means for reinforcement.

[0048] Advantageously, the internal and / or external reinforcement means proposed here make it possible for the battery shell and a given traction battery comprising the battery shell to be protected from side impacts by the external reinforcement means.

[0049] Further advantageously, the internal and / or external reinforcement means can increase the stiffness of the battery shell and / or reduce the mass of the battery shell without changing the load capacity of the battery shell, thereby saving material.

[0050] According to a particularly preferred embodiment, the battery shell is monolithically molded.

[0051] In this regard, the following terms are explained.

[0052] A battery shell that is "monolithically" formed is understood to be a battery shell that is manufactured from a single component in one continuous piece.

[0053] In other words, a monolithically formed battery shell is not made up of multiple individual parts, nor is it made up of multiple individual parts joined together by a material bond using a welding process. Rather, a monolithically formed battery shell has no seams.

[0054] Preferably, a monolithically formed battery shell is understood to be an off-tool battery shell.

[0055] An off-tool battery shell is understood to be a battery shell that is manufactured in one operation using one tool.

[0056] This advantageously allows the battery shell together with the internal and / or external reinforcing means to be produced in a single manufacturing step at low cost, without the transition from the reinforcing means to the side walls and / or bottom of the battery shell having any additional risk of failure due to welding or different connections.

[0057] Advantageously, an inherent gas tightness of the battery shell can therefore also be achieved.

[0058] According to a suitable embodiment, the battery shell is manufactured by injection molding or compression molding.

[0059] In this regard, the following terms are explained.

[0060] "Injection molding" is understood to be a one-step molding process in which the material to be processed, in particular plastic, is liquefied by an injection molding machine and injected under pressure into a mold, i.e. an injection molding tool, where the material passes through cooling and / or crosslinking reactions to return to a solid state and can be removed as a component after the injection molding tool is opened.

[0061] "Compression molding" is understood to mean a one-step molding process in which the molding material is introduced into the cavity of an attached compression tool in a first step, and the compression tool is closed in a second step, in particular using a pressure piston. By closing the compression tool, the molding material acquires the shape set by the compression tool. Preferably, the compression tool is temperature-controlled.

[0062] The term "molding material" particularly refers to a thermoplastic or thermosetting material, optionally mixed with a fibrous material, in particular glass fiber, carbon fiber, aramid fiber, or the like.

[0063] In particular, the compression molding process may be understood to be a direct molding process (D-LFT), in which the fibrous material is drawn into an extruder, where it is impregnated with an already molten matrix polymer, in particular a thermoplastic or thermosetting material, and is then conveyed to an injection piston and subsequently introduced into a compression tool as molding compound.

[0064] Preferably, the molding material has fibres that are no longer than 5mm in length.

[0065] Preferably, in particular when an extrusion molding method is used to manufacture the battery shell and / or in the case of a battery shell manufactured by an extrusion molding method, the molding material has fibers with a length of 0.5 mm to 20 mm, preferably fibers with a length of 1.0 mm to 15 mm, particularly preferably fibers with a length of 1.0 mm to 10 mm.

[0066] Advantageously, the proposed battery shell can use established manufacturing methods, thereby saving costs and minimizing process risks in the manufacturing process.

[0067] According to a particularly preferred embodiment of the battery shell with at least one internal reinforcing means, the at least one internal reinforcing means comprises a core, in particular a structured core, in particular a core in the middle of two cover layers that bound the core, in particular a structured core with a cross rib structure.

[0068] In this regard, the following terms are explained.

[0069] Preferably, the internal reinforcing element, preferably the partition, has a sandwich structure, by which is understood a structure that combines different geometries and / or material properties in different regions, whereby the various regions have different material properties.

[0070] In particular, a sandwich structure is understood to be a planar or substantially planar structure of a reinforcing means, which has a core bordered by two cover layers directly adjacent to the core.

[0071] The "core" can be described as having a low specific weight compared to the cover layer. Preferably, the core has particularly high stability against lateral shrinkage, especially against lateral shrinkage caused by bending of the reinforcing means.

[0072] Preferably, the core has a different geometry relative to the cover layer, which allows for advantageous realization of unique core properties.

[0073] Preferably, the core has different material properties than the cover layer, which allows the unique properties of the core to be advantageously realized.

[0074] Preferably, the core comprises a porous material.

[0075] Preferably, the core is made of wood, especially balsa wood.

[0076] By "structured core" is understood a core that has a different geometric shape relative to the cover layer and / or a core that has different material properties relative to the cover layer, the structured core having a structure.

[0077] By "cross-rib structure" is understood the geometric shape of the core, which core has ribs, preferably each end of which forms a node of the rib structure.

[0078] Preferably, the cross rib structure is provided to direct compressive and / or shear forces occurring within the core to the adjacent cover layer.

[0079] Preferably, the structured core, in particular the structured core having a cross-rib structure, is formed from inside the battery shell and / or from outside the battery shell by means of a corresponding structural core tool.

[0080] Preferably, the ribs are formed flat or substantially flat.

[0081] Preferably, adjacent ribs each share only one common node.

[0082] Preferably, the cross rib structure has a zigzag pattern.

[0083] Preferably, the cross ribs intersect like diagonals of a rectangle.

[0084] "Cover layer" is understood to be a layer of material that limits the core of the reinforcing means of the sandwich structure.

[0085] Preferably, the cover layer has a material modification to the material of the battery shell, preferably in the form of a fibrous material disposed within the cover layer, which fibrous material is preferably provided to increase the stiffness of the cover layer in the extension direction of the cover layer.

[0086] The proposed sandwich internal reinforcing means advantageously allows for a lightweight construction of the internal reinforcing means, thus saving weight and material compared to an internal reinforcing means without a sandwich structure, without changing its stiffness. Alternatively, the stiffness of the internal reinforcing means can be significantly increased without changing its weight.

[0087] Particularly preferably, at least one internal reinforcing means of a battery shell having at least one internal reinforcing means comprises at least regionally a layer of fiber-plastic composite, in particular a layer of fiber-plastic composite in a first cover layer of the internal reinforcing means and / or a layer of fiber-plastic composite in a second cover layer of the internal reinforcing means.

[0088] In this regard, the following terms are explained.

[0089] By "fiber-plastic composite" is understood a crystalline material consisting of oriented fibers and a plastic matrix, the plastic matrix surrounding the fibers and the fibers being bonded to the plastic matrix by adhesive interactions, preferably the fibers being glass fibers, carbon fibers, aramid fibers, etc.

[0090] A "layer" of a fiber-plastic composite is understood to be an internal layer of the battery shell made of fiber-plastic composite, which is delimited from areas of the battery shell that do not belong to the layer by the presence of fibers that make up the fiber-plastic composite. Those areas that are located outside the layer are molded by a molding compound made of plastic.

[0091] Preferably, the molding material is also used as the plastic matrix of the fiber-plastic composite during the production of the battery shell. However, the molding material may itself also have fibers, the fibers of which differ in length and arrangement from the fibers in the layers of the fiber-plastic composite, in particular the fibers in the molding material being shorter and more randomly oriented than the fibers in the layers of the fiber-plastic composite.

[0092] Preferably, the layer of fiber plastic composite material allows to increase the stiffness of the internal reinforcing means and / or to reduce the weight of the internal reinforcing means without changing its stiffness.

[0093] According to an optional embodiment of the battery shell having at least one internal reinforcing means, the at least one internal reinforcing means comprises at least one transverse rib.

[0094] In this regard, the following terms are explained.

[0095] By "transverse rib" is understood a rib-shaped elongated extension of the internal reinforcing means, running perpendicular to the main direction of extension of the internal reinforcing element, which extension is provided to support the internal reinforcing means against the bottom surface of the battery shell.

[0096] Specifically, what is intended herein is a plurality of transverse ribs, spaced at regular or irregular intervals.

[0097] Preferably, the transverse ribs are arranged in pairs, more preferably one transverse rib on each side of the internal reinforcing means, with the same value of longitudinal extension of the internal reinforcing means.

[0098] Advantageously, the transverse rib or ribs contribute to stiffening the bottom surface of the battery shell, especially in the transition region between the bottom surface and the internal stiffening means.

[0099] According to an optional embodiment of the battery shell having at least one internal reinforcing means, the at least one internal reinforcing means extends over a height of at least 30%, preferably at least 50%, particularly preferably at least 70% of the maximum height extension.

[0100] Optionally, at least one internal reinforcing means extends over a height of at least 40% of the maximum height extension, preferably at least one internal reinforcing means extends over a height of at least 60% of the maximum height extension, even more preferably at least one internal reinforcing means extends over a height of at least 80% of the maximum height extension, and particularly preferably at least one internal reinforcing means extends over a height of at least 90% of the maximum height extension.

[0101] Advantageously, the stiffness of the internal reinforcing means can therefore be optimally adapted to the requirements of the battery shell and the amount of plastic used can also be reduced.

[0102] It is expressly pointed out that the above values ​​for the height of the internal reinforcing means are not to be understood as strict limits, but rather may be exceeded or exceeded by engineering standards without departing from the described aspects of the invention. In short, these values ​​provide a guide as to the magnitude of the range of heights of the internal reinforcing means proposed herein.

[0103] According to an optional embodiment of the battery shell having at least one external reinforcing means, the at least one external reinforcing means extends over a height of at least 30%, preferably at least 50%, particularly preferably at least 70% of the maximum height extension.

[0104] Optionally, at least one external reinforcing means extends over a height of at least 40% of the maximum height extension, preferably at least one external reinforcing means extends over a height of at least 60% of the maximum height extension, even more preferably at least one external reinforcing means extends over a height of at least 80% of the maximum height extension, and particularly preferably at least one external reinforcing means extends over a height of at least 90% of the maximum height extension.

[0105] Advantageously, the stiffness and material requirements of the external reinforcing means can therefore be optimally adapted to the requirements of the battery shell.

[0106] It is expressly pointed out that the above values ​​for the height of the external reinforcement means are not to be understood as strict limits, but rather may be exceeded or exceeded by engineering standards without departing from the described aspects of the invention. In short, these values ​​provide a guide as to the magnitude of the range of heights of the external reinforcement means proposed herein.

[0107] According to an expedient embodiment of the battery shell with at least one external reinforcing means, the at least one external reinforcing means extends over a width of at least 5%, preferably at least 10%, particularly preferably at least 15% of the maximum lateral extension.

[0108] Optionally, at least one external reinforcing means extends over a width of at least 7.5% of the maximum transverse extension, preferably at least one external reinforcing means extends over a width of at least 12.5% ​​of the maximum transverse extension, more preferably at least one external reinforcing means extends over a width of at least 17.5% of the maximum transverse extension, and especially preferably at least one external reinforcing means extends over a width of at least 20% of the maximum transverse extension.

[0109] Advantageously, the stiffness and material requirements of the external reinforcement means can therefore be optimally adapted to the requirements of the battery shell, in particular the protection of the battery modules from side impacts.

[0110] It is expressly pointed out that the above values ​​for the width of the external reinforcing means are not to be understood as strict limits, but rather may be exceeded or exceeded by engineering standards without departing from the described aspects of the invention. In short, these values ​​provide a guide as to the magnitude of the width range of the external reinforcing means proposed herein.

[0111] An expedient battery shell has at least one external reinforcing means with at least two belts, preferably at least three belts, at least two belts being at least indirectly interconnected by spacer elements, in particular webs.

[0112] In this regard, the following terms are explained.

[0113] A "belt" is understood to mean a band of an elongated profile, and in particular belts are understood to mean bands of an elongated profile that are spaced apart by a spacer element, in particular a continuous web, and that are provided to increase at least one moment of inertia of the elongated profile.

[0114] Preferably, belts are understood to be side walls of the battery shell, and specifically here it is intended that the side walls forming the belts of the external reinforcing means are followed by spacer elements that transition into another belt.

[0115] Particularly preferably, the battery shell of interest has at least one external reinforcing means with at least one belt.

[0116] By "spacer elements" is understood all geometric shapes provided to maintain the distance between two belts extending substantially in a common direction. Preferably, the spacer elements have a ribbed or cellular structure.

[0117] Preferably, a spacer element is understood to be a web. By "web" is understood a flat connection between two belts, preferably between a belt in the form of a side wall of a battery shell and a corresponding belt. Preferably, the web connects adjacent belts so that the belts and webs together form an I- or U-shaped profile.

[0118] Preferably, this increases the stiffness of the at least one external reinforcing element, which can also increase the stiffness of the battery shell.

[0119] Particularly preferably, a structured core, in particular a structured core having a cross rib structure, is arranged at least regionally between the two belts.

[0120] It is proposed here to connect adjacent belts of the external reinforcing element, at least in each region, by a structured core, which advantageously makes it possible to achieve a particularly good ratio between the stiffness of the external reinforcing means and the weight of the external reinforcing means.

[0121] Particularly preferably, the at least one external reinforcing means comprises at least regionally a layer of a fiber-plastic composite, in particular a layer of a fiber-plastic composite on the belt and / or web.

[0122] This advantageously allows the external reinforcing means to be reinforced by layers of fiber-plastic composite material and / or allows for further weight reduction with the same dimensional load.

[0123] According to a particularly expedient embodiment, the external reinforcing means have fastening means, in particular at the intersections of the intersecting cross ribs.

[0124] In this regard, the following terms are explained.

[0125] By "fixing means" it is understood that means are provided to fix the battery shell to the structure surrounding it in a given motor vehicle.

[0126] Preferably, the fastening means are formed together with the structured core of the external reinforcing means and are provided for fastening without further processing. Furthermore, it is intended that the fastening means are already formed as a cavity together with the molding of the battery shell. Preferably, the cavity is provided for accommodating a threaded bushing.

[0127] Advantageously, the arrangement of the fixing means proposed here allows possible loads to be transferred directly to relatively stiff areas of the battery shell, particularly in the event of stronger deformations in connection with the operating loads that occur, to areas that are quite far away from the battery modules protected by the battery shell, making it possible to avoid or at least reduce damage to the battery modules.

[0128] Particularly preferably, the external reinforcing means has a sealing surface.

[0129] In this regard, the following terms are explained.

[0130] By "sealing surface" is understood a surface which is formed in the form of a contact surface for the sealing means.

[0131] Preferably, the sealing surface is flat.

[0132] Preferably, the sealing surfaces have in particular a very low surface roughness.

[0133] Preferably, the sealing surface is provided to produce a sealing effect in interaction between a corresponding second component, in particular a corresponding second sealing surface of a corresponding battery cover or a corresponding second battery shell, and a corresponding sealing means arranged between the battery shell and the corresponding second component, in particular when an effective normal force exists between the battery shell and the corresponding second component.

[0134] Advantageously, the sealing surface allows a given traction battery having a battery shell with the sealing surface to have a particularly good and robust seal between the battery shell and a second battery shell or battery cover.

[0135] According to an expedient embodiment, the external reinforcement means has a contact area.

[0136] In this regard, the following terms are explained.

[0137] "Contact area" is understood to be that part of the geometry of the external reinforcement means that is provided as a contact surface between the battery shell and the vehicle that surrounds the battery shell in a defined manner.

[0138] Advantageously, the contact areas allow for positioning of the battery shell on a given vehicle, thereby simplifying installation and maintenance of a given traction battery, and also allow for load transfer from the vehicle to the battery shell and vice versa by forming a predetermined shape fit with adjacent vehicle areas.

[0139] Particularly preferably, at least one layer of the fiber-plastic composite has fibers that are oriented relative to one another in a substantially unidirectional manner.

[0140] The unidirectional orientation of the fibers can further increase the stiffness at the layer of fiber-plastic composite, at least if the direction of internal stress loading has a component in the direction of fiber orientation.

[0141] According to a particularly expedient embodiment, the inner reinforcing means is engaged with the outer reinforcing means.

[0142] It is proposed here that the structural form of the inner reinforcing means extends at least regionally through the outer reinforcing means.

[0143] Advantageously, therefore, the transition area between the inner and outer reinforcing means can be additionally reinforced.

[0144] According to a particularly expedient embodiment, the external and internal reinforcing means are engaged with each other, in other words the battery shell has at least one external and at least one internal reinforcing means, the external and internal reinforcing means having a common penetration area so that at least one reinforcing means extends into the other reinforcing means.

[0145] Advantageously, this can increase the stiffness of the battery shell for complex load cases.

[0146] According to a second aspect of the invention, the problem is solved by a traction battery, in particular a traction battery for a motor vehicle, comprising a battery shell according to the first aspect of the invention.

[0147] In this regard, the following terms are explained.

[0148] By "motor vehicle" is understood a vehicle driven by an engine. Preferably, the motor vehicle is not rail-bound or at least only temporarily lane-bound.

[0149] It is self-evident that the advantages of the battery shell according to the first aspect of the invention, as described above, extend directly to a traction battery comprising a battery shell according to the first aspect of the invention.

[0150] It is expressly pointed out that the subject matter of the second aspect may be advantageously combined with the subject matter of the above aspects of the invention, both individually and cumulatively in any combination.

[0151] According to a third aspect of the present invention, the problem is solved by a motor vehicle comprising a battery shell according to the first aspect of the present invention and / or a traction battery according to the second aspect of the present invention.

[0152] It is self-evident that the advantages of the battery shell according to the first aspect of the invention and / or the traction battery according to the second aspect of the invention as described above extend directly to a motor vehicle comprising a battery shell based on the first aspect of the invention and / or a traction battery according to the second aspect of the invention.

[0153] It is expressly pointed out that the subject matter of the third aspect may be advantageously combined with the subject matter of the above aspects of the invention, both individually and cumulatively in any combination.

[0154] According to a fourth aspect of the present invention, the problem is solved by a tool for the production of battery shells made of plastic with internal and / or external reinforcing means, in particular battery shells according to the first aspect of the present invention, which tool forms a molded part cavity and which tool has means for filling the molded part cavity with a molding compound made of plastic.

[0155] In this regard, the following terms are explained.

[0156] By "tool" is understood an apparatus for pre-molding, in particular for pre-molding battery shells according to the first aspect of the invention from molten molding material.

[0157] Preferably, a tool is understood to be an injection molding tool.

[0158] Preferably, a tool is understood to be a compression tool.

[0159] Preferably, tool is understood to be a dip forming tool.

[0160] By "moulding cavity" is understood a cavity formed by a tool for forming a tooled component in a predetermined manner, in particular a battery shell, in a regional manner.

[0161] By "means for filling" is understood a device which is directly or indirectly assigned to the tool and which is provided for introducing the molten molding material into the tool.

[0162] Preferably, means for filling is understood, in particular in connection with injection moulding tools and / or injection moulding apparatus, to be a device provided for filling the moulding material into the moulding cavity of the tool and / or the moulding cavity of the tool.

[0163] Preferably, means for filling is understood to mean a device by which the molten molding material can be introduced, in particular loaded, into a pre-opened tool, in particular in connection with a compression tool and / or a compression device.

[0164] Here, a tool for manufacturing battery shells according to a first aspect of the invention is proposed.

[0165] It will be apparent that the advantages of the battery shell according to the first aspect of the invention already described extend to tools for manufacturing the battery shell according to the first aspect of the invention.

[0166] According to a particularly preferred embodiment, the tooling comprises at least one structural core tool, in particular at least one cross-rib tool, which is provided for molding a structured core, in particular for molding a structured core having a cross-rib structure.

[0167] In this regard, the following terms are explained.

[0168] A "structural core tool" is understood to be an optional component of a tool for forming a battery shell, which structural core tool is provided for forming a structured core of the internal reinforcement means and / or the external reinforcement means.

[0169] Preferably, the structural core tool is capable of relative movement, particularly translational movement, with respect to adjacent areas of the tool for forming the battery shell.

[0170] By "cross-rib tooling" is understood a structural core tooling provided for forming a cross-rib structure in the core of the internal and / or external reinforcing means.

[0171] This advantageously enables the battery shell to have a structured core, in particular regions of the core with cross ribs and / or separation regions.

[0172] It is self-evident that the above-mentioned advantages of battery shells with structured cores and / or separation areas in the region of the internal and / or external reinforcing means directly extend to tools for the production of battery shells with structured cores in the region of the internal and / or external reinforcing means.

[0173] According to an expedient embodiment, the tool comprises at least one means for clamping the fiber material, in particular the impact-frozen fiber material and / or the fiber material melted in the surface layer.

[0174] In this regard, the following terms are explained.

[0175] By "clamping" is understood the fixing, in particular removably fixing, of the fibrous material, in particular the impact-frozen fibrous material and / or the fibrous material melted in the surface layer, in the tool.

[0176] In particular, the clamping means is intended to clamp the fibrous material as long as it is not completely saturated with the molding material. Preferably, the clamping means proposed here is arranged so that it is pushed out by the molding material as soon as the molding material reaches the clamping means due to the required molding material pressure. This advantageously allows the clamping means to clamp the fibrous material as long as necessary.

[0177] In particular, it is proposed here that the fibrous material is partially or completely melted in the surface layer, while the core of the fibrous material is still surrounded by the crystalline matrix, so that the fibrous material still has its inherent rigidity, while the fibrous material is clamped in the tool by a clamping means.

[0178] Fiber materials that have a core with a crystalline matrix and are melted only in the surface region and / or impact-frozen can advantageously be easily grasped and positioned by a robot.

[0179] Thus, advantageously, a battery shell can be manufactured which has fibrous material in the region of the internal and / or external reinforcing means, thereby increasing the stiffness of the battery shell.

[0180] It is expressly pointed out that the subject matter of the fourth aspect may be advantageously combined with the subject matter of the above aspects of the invention, both individually and cumulatively in any combination.

[0181] According to a fifth aspect of the present invention, the problem is solved by a method for producing a battery shell made of plastic having internal and / or external reinforcement means, in particular a battery shell according to the first aspect of the present invention, by means of an injection molding or compression apparatus using a tool for forming a molded part cavity, in particular a tool according to the fourth aspect of the present invention, and means for filling the molded part cavity with a molding compound made of plastic, the method comprising the steps of a) filling the molded part cavity with the molding compound made of plastic, and b) demolding the battery shell.

[0182] In this regard, the following terms are explained.

[0183] "Filling" is understood, according to a first variant, to mean the filling and packing of the molten molding material into the injection molding tool directly or indirectly by means of an extruder.

[0184] In the second variation, "filling" is understood to mean loading the molding material directly or indirectly into the compression tool by the extruder, followed by the stroke of the compression tool to distribute the molding material into the molding cavity, thereby packing the molding material into the molding cavity.

[0185] By "de-moulding" it is understood that the battery shell according to the first aspect of the invention, which has been produced in a predetermined manner, is removed from the tool.

[0186] "Molding" is understood to mean any deformation of the body, by which a three-dimensional shaping can be achieved, in particular a three-dimensionally shaped battery shell.

[0187] Preferably, molding is understood to mean molding by injection molding methods.

[0188] Preferably, molding refers to molding by compression molding or extrusion molding. In this case, the molding material is introduced into the cavity of a press mold, which is heated or heated and / or cooled. The cavity is then closed using a compression piston. This compression causes the molding material to assume the shape set by the cavity and the compression piston.

[0189] Here, a method for manufacturing a battery shell according to a first aspect of the invention is proposed, in which the battery shell according to the first aspect of the invention is molded using a molding material and a tool that forms a molded part cavity, in particular by injection molding or compression molding, in particular compression molding using a dip molding tool.

[0190] It is obvious that the advantages of the battery shell according to the first aspect of the present invention extend to the method for manufacturing the battery shell according to the first aspect.

[0191] According to a particularly expedient embodiment, the tool forming the molded part cavity is fitted with a fibrous material, in particular an impact-frozen fibrous material, at least in regions before the molding compound consisting of plastic is filled into the molded part cavity.

[0192] It is specifically proposed here that the fiber material of a layer of fiber-plastic composite in a given component is first introduced into the mold in a dimensionally stable state, in particular by impact freezing.

[0193] This advantageously allows the fiber material to be gripped and positioned by a robot. During the molding of the battery shell, the molding compound flows around and partially through the previously introduced fiber material, thereby forming a layer of fiber-plastic composite.

[0194] Alternatively, it is proposed that the fiber material of a layer of fiber-plastic composite in a given component is first at least partially or completely melted at its surface layer, while the core of the fiber material still has a crystalline matrix, and then this fiber material is introduced into the mold, which preferably gives the fiber material an inherent rigidity that allows it to be advantageously grasped and positioned by a robot.

[0195] It is expressly pointed out that the subject matter of the fifth aspect may be advantageously combined with the subject matter of the above aspects of the invention, both individually and cumulatively in any combination.

[0196] Further advantages, details and features of the invention will become apparent from the examples described below. [Brief explanation of the drawings]

[0197] [Figure 1] FIG. 1 is a cross-sectional view of an embodiment of a battery shell. [Figure 2] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 3] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 4] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 5] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 6] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 7] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 8]FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 9] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell. [Figure 10] FIG. 10 is a cross-sectional view of a further embodiment of a battery shell.

[0198] In the following description, the same reference numerals indicate the same components or features, so that the description of components given in one figure is valid for the other figures to avoid repetition. Furthermore, individual features described in connection with one embodiment can be used individually in other embodiments.

[0199] The cross section of the embodiment of a monolithically formed battery shell 100 in FIG. 1 includes a battery shell 100 having a bottom 102, at least one sidewall 104, an exterior reinforcement means 130, and an interior reinforcement means 140, the battery shell 100 having an interior 108, an exterior 106, and a height 110.

[0200] The external reinforcing means 130 extend in the longitudinal direction 136 of the battery shell 100 and consist essentially of two belts 132 (one of the belts 132 coincides with the side wall 104 of the battery shell 100) and spacer elements 134 that maintain the mutual distance of the belts 132 even under load and the associated deformations, and therefore contribute significantly to at least one moment of inertia of the battery shell 100.

[0201] The internal reinforcing means 140 extends in a transverse direction 148 of the battery shell 100 and consists essentially of two cover layers 144 arranged around a core 142, in particular a structured core 142 having a cross-rib structure 146.

[0202] The internal reinforcement means 140 and the external reinforcement means 130 each have layers 150 of fiber-plastic composite material at different locations, which can further increase the stiffness and / or reduce the weight of the battery shell 100.

[0203] In the embodiment of the battery shell 100 of FIG. 2, the external reinforcement means 130 has a different embodiment.

[0204] The external reinforcing means 130 has a total of three belts 132 , one of which coincides with the side wall 104 of the battery shell 100 .

[0205] The outer belts 132 are connected by spacer elements 134 that are positioned at half the height of the battery shell 100 in the height direction 110 .

[0206] Both inner belts 132 are similarly connected to spacer elements 134, which are positioned at the maximum height specification (not shown) of the outer reinforcement means 130, and the upper side of the inner spacer elements 134 is provided with a sealing surface 135 so as to fit tightly with the corresponding battery shell (not shown).

[0207] A further embodiment of the battery shell 100 of FIG. 3 has a structured core 131 with different regions between the belts 132 of the external reinforcing means 130, in particular a structured core 131 with cross rib structures 133, which connect the belts 132 in addition to spacer elements 134, allowing for additional stiffness or weight reduction for the external reinforcing means 130.

[0208] 4 has two spacer elements 134 between the belts 132 of the external reinforcement means 130, the spacer elements 134 being positioned at the maximum height specification (not shown) of the external reinforcement means 130. These spacer elements have sealing surfaces 135 on their upper sides.

[0209] The embodiment of the battery shell 100 of Figure 5 has contact areas 137 provided for connecting and / or positioning the battery shell 100. Preferably, the contact areas 137 are seamlessly disposed around the periphery of the battery shell 100.

[0210] In the embodiment of the battery shell 100 of FIG. 6, external reinforcement means (not shown) are cut away in select sections.

[0211] A further embodiment of the battery shell 100 of Figure 7 has an alternative internal reinforcing means 140. The internal reinforcing means 140 does not have a central structured core, but instead is similarly fitted with a layer 150 of fiber-plastic composite material, which preferably extends over the height of the internal reinforcing element 140.

[0212] A further embodiment of the battery shell 100 in FIG. 8 has a plurality of transverse ribs 141 to further reinforce the internal reinforcing means 140 .

[0213] In a further embodiment of the battery shell 100 of FIG. 9, the external reinforcing means 130 and the internal reinforcing means 140 are engaged with each other, and the shapes of the structured cores 131, 142 are adapted to each other, so that additional reinforcement of the battery shell 100 can be maximized.

[0214] The embodiment of the battery shell 100 of FIG. 10 includes a number of fastening means 138 that can be used to connect the battery shell 100 to a vehicle. [Additional note 1] A battery shell (100), particularly a traction battery shell (100), said battery shell (100) being molded from plastic, said battery shell (100) having a bottom (102) and a side wall (104), said battery shell (100) having an inner side (108) and an outer side (106), said battery shell (100) having a maximum lateral extension in a lateral direction (148) and a maximum height extension in a height direction, The battery shell (100) comprises internal reinforcing means (140), in particular internal reinforcing means (140) extending in the transverse direction (148) or the longitudinal direction (136) of the battery shell (100), in particular internal reinforcing means (140) extending in the transverse direction (148) of the battery shell (100) and in the longitudinal direction (136) of the battery shell (100); and / or external reinforcing means (130), in particular at least one external reinforcing means (130) extending in the longitudinal direction (136) of the battery shell (100). [Additional note 2] The battery shell (100) according to claim 1, wherein the battery shell (100) is formed into a monolithic shape. [Additional note 3] The battery shell (100) according to claim 1 or 2, characterized in that the battery shell (100) is manufactured by injection molding or compression molding. [Additional note 4] 4. The battery shell (100) according to any one of claims 1 to 3, comprising at least one internal reinforcing means (140), characterized in that the at least one internal reinforcing means (140) comprises a core (142), in particular a structured core (142), in particular a core (142) in the middle of two cover layers (144) that bound the core (142), in particular a structured core (142) with a cross rib structure (146). [Additional note 5] 5. A battery shell (100) according to any one of claims 1 to 4, comprising at least one internal reinforcing means (140), characterized in that the at least one internal reinforcing means (140) comprises at least regionally a fiber-plastic composite layer (150), in particular a fiber-plastic composite layer (150) in a first cover layer (144) of the internal reinforcing means (140) and / or a fiber-plastic composite layer (150) in a second cover layer (144) of the internal reinforcing means (140). [Additional note 6] 6. The battery shell (100) according to any one of claims 1 to 5, comprising at least one internal reinforcing means (140), characterized in that the at least one internal reinforcing means (140) comprises at least one transverse rib (141). [Additional note 7] 7. A battery shell (100) according to any one of claims 1 to 6, comprising at least one internal reinforcing means (140), the at least one internal reinforcing means (140) extending over a height of at least 30%, preferably at least 50%, particularly preferably at least 70% of the maximum height extension. [Additional note 8] 8. A battery shell (100) according to any one of claims 1 to 7, comprising at least one external reinforcing means (130), the at least one external reinforcing means (130) extending over a height of at least 30%, preferably at least 50%, particularly preferably at least 70% of its maximum height extension. [Additional note 9] 9. A battery shell (100) according to any one of claims 1 to 8, comprising at least one external reinforcing means (130), the at least one external reinforcing means (130) extending over a width of at least 5%, preferably at least 10%, particularly preferably at least 15% of the maximum lateral extension. [Additional Note 10] 10. A battery shell (100) according to any one of claims 1 to 9, comprising at least one external reinforcing means (130), said external reinforcing means (130) comprising at least two belts (132), preferably at least three belts (132), said at least two belts (132) being at least indirectly connected to one another by spacer elements (134), in particular webs (134). [Additional Note 11] A battery shell (100) according to claim 10, characterized in that a structured core (131), in particular a structured core (131) having a cross-rib structure (133), is arranged at least in each region between two belts (132). [Additional Note 12] 12. A battery shell (100) according to claim 10 or 11, comprising at least one external reinforcing means (130), characterized in that the at least one external reinforcing means (130) comprises a layer (150) of fiber-plastic composite material at least in each region, in particular in the belts (132) and / or webs (134). [Additional Note 13] 13. The battery shell (100) according to any one of claims 1 to 12, comprising at least one external reinforcing means (130), characterized in that the external reinforcing means (130) comprises fastening means (138), in particular at the intersections of intersecting cross ribs. [Additional Note 14] 14. The battery shell (100) according to any one of claims 1 to 13, comprising at least one external reinforcement means (130), the external reinforcement means (130) having a sealing surface (135). [Additional Note 15] 15. The battery shell (100) according to any one of claims 1 to 14, comprising at least one external reinforcement means (130), characterized in that the external reinforcement means (130) has a contact area (137). [Additional Note 16] 16. A battery shell (100) according to any one of claims 1 to 15, comprising at least one layer (150) of a fiber-plastic composite, characterized in that the at least one layer (150) of fiber-plastic composite has fibers oriented substantially in one direction relative to one another. [Additional Note 17] 17. The battery shell (100) according to any one of claims 1 to 16, comprising an internal reinforcement means (140) and an external reinforcement means (130), wherein the internal reinforcement means (140) is engaged with the external reinforcement means (130). [Additional Note 18] A traction battery, in particular a traction battery for a motor vehicle, comprising a battery shell (100) according to any one of claims 1 to 17. [Additional Note 19] A motor vehicle comprising the battery shell (100) according to any one of claims 1 to 17 and / or the traction battery according to claim 18. [Additional Note 20] 18. A tool for producing a battery shell (100) made of plastic having internal reinforcing means (140) and / or external reinforcing means (130), in particular a battery shell (100) according to any one of claims 1 to 17, wherein the tool forms a molded part cavity and the tool has means for filling the molded part cavity with a molding compound made of plastic. [Additional Note 21] 21. The tool according to claim 20, characterized in that the tool comprises at least one structural core tool, in particular at least one cross-rib tool, provided for forming a structured core (131, 142), in particular for forming a structured core (131, 142) having a cross-rib structure (133, 146). [Additional Note 22] 22. The tool according to claim 20 or 21, characterized in that the tool has at least one means for clamping the fiber material, in particular the impact-frozen fiber material and / or the melted fiber material in the surface layer. [Additional Note 23] 1. A method for producing a battery shell (100) made of plastic, in particular a battery shell (100) according to any one of claims 1 to 17, having internal reinforcing means (140) and / or external reinforcing means (130), by means of a tool for forming a molded part cavity, in particular an injection molding or compression device using a tool according to any one of claims 1 to 17, and a means for filling said molded part cavity with a molding material made of plastic, said method comprising: a) filling a molding cavity with a molding material made of plastic; b) demolding the battery shell; A method including: [Additional note 24] 24. The method according to claim 23, characterized in that the tool forming the molded part cavity is fitted with a fibrous material, in particular an impact-frozen fibrous material and / or a surface layer-melted fibrous material, at least in some areas before the molding material consisting of plastic is filled into the molded part cavity. [Explanation of symbols]

[0215] 100 Battery Shells 102 bottom 104 Side wall 106 Outside 108 Inside 110 Height 130 External reinforcement means 131 Core, Structured Core 132 Belt 133 Cross-rib structure 134 Spacer element, web 135 sealing surface 136 vertical 137 Contact area 138 Fixing means 140 Internal reinforcement means, bulkheads 141 Horizontal rib 142 Core, Structured Core 144 Cover Layer 146 Cross-rib structure 148 Horizontal 150 layers of fiber-plastic composite

Claims

1. A battery shell (100), the battery shell (100) being molded from plastic, the battery shell (100) having a bottom (102) and a sidewall (104), the battery shell (100) having an inner side (108) and an outer side (106), the battery shell (100) having a maximum lateral extension in a lateral direction (148) and a maximum height extension in a height direction, The battery shell (100) comprises an internal reinforcing means (140) having a core (142) and a cover layer (144); and / or an external reinforcing means (130) having two belts (132), one of which is the side wall (104) and the other of which is offset relative to the side wall (104), The battery shell (100) is characterized in that it is formed into a monolithic shape.

2. 2. A battery shell (100) according to claim 1, comprising at least one internal reinforcing means (140), characterized in that the at least one internal reinforcing means (140) comprises a layer (150) of fiber-plastic composite material at least in each region.

3. 3. A battery shell (100) according to claim 1 or 2, comprising at least one internal reinforcing means (140), characterized in that the at least one internal reinforcing means (140) comprises at least one transverse rib (141).

4. 4. A battery shell (100) according to any one of claims 1 to 3, comprising at least one internal reinforcing means (140), the at least one internal reinforcing means (140) extending over a height of at least 30% of the maximum height extension.

5. 5. A battery shell (100) according to any one of claims 1 to 4, comprising at least one external reinforcing means (130), the at least one external reinforcing means (130) extending over a height of at least 30% of its maximum height extension.

6. 6. A battery shell (100) according to any one of claims 1 to 5, comprising at least one external reinforcing means (130), the at least one external reinforcing means (130) extending over a width of at least 5% of the maximum lateral extension.

7. 7. A battery shell (100) according to any one of claims 1 to 6, comprising at least one external reinforcing means (130), said external reinforcing means (130) comprising at least two belts (132), said at least two belts (132) being at least indirectly connected to each other by spacer elements (134).

8. 2. The battery shell (100) according to claim 1, characterized in that an at least regionally structured core (131) is arranged between two belts (132).

9. 2. A battery shell (100) according to claim 1, comprising at least one external reinforcing means (130), characterized in that the at least one external reinforcing means (130) comprises a layer (150) of fiber-plastic composite material at least in each area.

10. 10. A battery shell (100) according to any one of claims 1 to 9, comprising at least one external reinforcing means (130), characterized in that the external reinforcing means (130) comprises a fastening means (138).

11. 11. A battery shell (100) according to any one of claims 1 to 10, comprising at least one external reinforcing means (130), the external reinforcing means (130) having a sealing surface (135).

12. 12. A battery shell (100) according to any one of claims 1 to 11, comprising at least one external reinforcing means (130), characterized in that the external reinforcing means (130) has a contact area (137).

13. 13. A battery shell (100) according to any one of claims 1 to 12, comprising at least one layer (150) of fiber-plastic composite material, the at least one layer (150) of fiber-plastic composite material having fibers oriented substantially in one direction relative to one another.

14. 14. The battery shell (100) of any one of claims 1 to 13, having an internal reinforcing means (140) and an external reinforcing means (130), wherein the internal reinforcing means (140) is engaged with the external reinforcing means (130).

15. A traction battery comprising a battery shell (100) according to any one of claims 1 to 14.

16. A motor vehicle comprising a battery shell (100) according to any one of claims 1 to 14 and / or a traction battery according to claim 15.

17. 15. A tool for manufacturing a battery shell (100) according to any one of claims 1 to 14, wherein the tool forms a molded part cavity and the tool has means for filling the molded part cavity with a molding material made of plastic.

18. 18. Tool according to claim 17, characterized in that the tool comprises at least one structured core tool provided for forming a structured core (131, 142).

19. 19. Tool according to claim 17 or 18, characterized in that the tool comprises at least one means for clamping the fibrous material.

20. 20. A method for manufacturing a battery shell (100) according to any one of claims 1 to 14 by means of an injection molding or compression device using a tool according to any one of claims 17 to 19, with means for filling the molding cavity with a molding material made of plastic, said manufacturing method comprising: a) filling a molding cavity with a molding material made of plastic; b) demolding the battery shell; A method including:

21. 21. The method of claim 20, wherein the tool forming the molded part cavity is fitted with a fibrous material at least in areas before the molding material consisting of plastic is filled into the molded part cavity.

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