Plastic battery shell with molding material and endless fiber-reinforced insert, mould and method for producing a battery shell, traction battery and automobile

Abstract

The present invention relates to a battery shell, in particular a battery shell for a traction battery, which is molded from a molding material and an endless fiber-reinforced insert, the endless fiber-reinforced insert having a first side which is not overpressed by the molding material by at least 50%, preferably at least 60%, particularly preferably at least 75%. The present invention further relates to a mold for the production of this battery shell and to a method for producing the battery shell. The present invention further relates to a traction battery with the same battery shell and to a vehicle with the same battery shell.

Description

[Technical field]

[0001] This patent application claims priority from German patent application no. 102021210758.3, the disclosure content of which is expressly incorporated herein by reference.

[0002] The present invention relates to a plastic battery shell having a molding material and an endless fiber-reinforced insert, a mold and a method for manufacturing the battery shell, a traction battery and a motor vehicle.

[0003] In particular, the invention relates to a battery shell, in particular a battery shell for a traction battery, which is molded from a molding material and an endless fiber-reinforced insert, the endless fiber-reinforced insert having a first surface which is not overpressed by the molding material by at least 50%, preferably by at least 60%, particularly preferably by at least 75%.

[0004] Current efforts in the automotive industry to mass-produce plastic-based lightweight structural components economically drive resource optimization by reducing the use of fibers and semi-finished products, exploiting the inherent performance and cost advantages of materials through multi-material construction techniques, and striving to reduce costs through part functionalization while simultaneously consolidating production and reducing the number of process steps.

[0005] Impact extrusion of long-fiber-reinforced thermoplastics occupies a high position in the production of large-area, ribbed components. For structurally-relevant lightweight construction applications, especially for battery shells, and the associated high demands on the stiffness and strength of the components, the components made of long-fiber-reinforced thermoplastics need to be joined to further structures in a subsequent process step.

[0006] The problem on which the invention is based is to provide an improvement or alternative to the state of the art.

[0007] According to a first aspect of the present invention, the above problem is solved by a battery shell, in particular a battery shell for a traction battery, the battery shell having a bottom and at least four side walls, the battery shell having an inner side and an outer side, the battery shell being molded from a molding material and an endless fiber-reinforced insert, the endless fiber-reinforced insert having a first side which is not overpressed by the molding material by at least 50%, preferably at least 60%, particularly preferably at least 75%, and the endless fiber-reinforced insert having a second side arranged opposite the first side which is overpressed by the molding material by at least 95%, preferably at least 97%, particularly preferably at least 99%.

[0008] In this regard, the following terms are explained. It is expressly mentioned at the outset that within the scope of this patent application, indefinite articles and numerical indications such as "one", "two", etc., are generally to be understood as the indication "at least", i.e. as "at least one...", "at least two...", etc., unless it is clear from the respective context or is not obvious to a person skilled in the art or it can technically only be meant as "exactly one", "exactly two...", etc.

[0009] 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" and "ie".

[0010] By "battery shell" is understood a housing component of a battery, in particular a traction battery.

[0011] 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.

[0012] Preferably, a battery shell is understood to be a lower battery shell or an upper battery shell, the lower battery shell and the upper battery shell preferably together forming the main component of the housing of the traction battery.

[0013] In particular, the battery shell has a "bottom" and, in the preferred case of a traction battery that is substantially rectangular in plan, has at least four "side walls."

[0014] The bottom and side walls of the battery shell define a storage volume of the battery shell, which represents the "inside" of the battery shell.

[0015] Starting from the storage volume of the battery shell, the "outside" of the battery shell is on the bottom surface and on the side wall surface that are on the opposite side of the storage volume.

[0016] By "moulding material" is meant in particular plastics, in particular thermoplastic or thermosetting plastics, preferably mixed with fibre materials, in particular glass fibres, carbon fibres, aramid fibres or the like.

[0017] Preferably, the moulding material has fibres with a length of 15 mm or less, preferably fibres with a length of 12 mm or less, particularly preferably fibres with a length of 10 mm or less, especially if the moulding material is a polyamide.

[0018] Preferably, the moulding material has fibres with a length of 35 mm or less, preferably fibres with a length of 30 mm or less, particularly preferably fibres with a length of 25 mm or less, in particular if the moulding material is polypropylene.

[0019] Preferably, the molding material has fibers with a length of 65 mm or less, preferably fibers with a length of 57 mm or less, particularly preferably fibers with a length of 50 mm or less, especially if the molding material is a thermosetting plastic SMC (sheet molding compound), and more preferably, the molding material has fibers with a length of 8 mm or more, preferably fibers with a length of 10 mm or more, particularly preferably fibers with a length of 12 mm or more, especially if the molding material is a thermosetting plastic SMC.

[0020] Preferably, the molding material comprises a polyamide, in particular polyamide 6, polyamide 6.6 or polyamide 12. Furthermore, it is also preferable for the molding material to comprise polypropylene or polycarbonate.

[0021] By "insert" is understood a component which can be introduced into the battery shell already during primary molding in order to locally reinforce the battery shell. In other words, an insert is a reinforcement which is molded together with the molding material into the plastic battery shell, the insert being set in particular by its material properties and / or its geometric alignment and / or its positioning in or on the molding material to at least locally reinforce the battery shell.

[0022] Preferably, the insert has a higher tensile strength than the molding material that is to be solidified.

[0023] Preferably, the insert is a semi-finished product, in particular a semi-finished product which extends with a constant cross section at least in areas in the main extension direction of the insert part.

[0024] By "endless fiber-reinforced insert" is understood an insert having endless fibers, preferably an insert having endless fibers and a thermoplastic matrix material which allows the endless fiber-reinforced insert to be deformable and / or to be material-bonded to the molding material.

[0025] By face of the endless fiber reinforced insert is understood a face that defines the endless fiber reinforced insert and that is defined by a corner of the insert. Preferably, by a first face of the insert is understood one of two surfaces of the endless fiber reinforced insert that are at least approximately the same size and that do not extend along the thickness of the endless fiber reinforced part.

[0026] By "overpressed" by the molding material, it is understood that the endless fiber-reinforced insert has the molding material flowing at least in areas over the relevant surface, preferably during the designated molding of the battery shell, on the relevant surface or partial surface. Since a driving force is necessary for the molding material to flow, it is also called overpressing. The driving force of the molding material is always also resisted by a reaction force. The reaction force is also transmitted to the molding material by the endless fiber-reinforced insert, in particular at least in the region where the endless fiber-reinforced insert adjoins the molding material. By the action of the melt pressure of the molding material, it can be achieved that the endless fiber-reinforced insert at least partially traces the flow front of the molding material and is brought into contact with the molding cavity of the mold used for molding until it reaches the molding cavity locally and is then pressed against the molding cavity. This advantageously makes it possible to achieve that the endless fiber-reinforced insert is arranged in the desired position in the battery shell by overpressing with the molding material, in particular in the edge layer of the battery shell, preferably reproducibly arranged.

[0027] Preferably, the surfaces or partial surfaces to be overpressed by the molding material of the endless fiber-reinforced insert are referred to as surfaces or partial surfaces if the relevant surfaces or partial surfaces have a molding material directly connected thereto with a thickness of 1 mm or more, preferably with a thickness of 0.5 mm or more, particularly preferably with a thickness of 0.2 mm or more, whereby it is possible, inter alia, to achieve that the corresponding regions are formed medium-tight and at the same time that a minimum proportion by weight of molding material is sufficient.

[0028] It is known in the prior art that battery shells made of long-fiber reinforced thermoplastics, due to the high demands placed on the stiffness and strength of the components, are joined in subsequent process steps with further structures in order to achieve the required properties.

[0029] In contrast to this, a battery shell is proposed here that is reinforced by an endless fiber-reinforced insert directly during the primary molding of the battery shell, for which purpose the endless fiber-reinforced insert is integrally molded with the molding material to form the battery shell proposed here.

[0030] In that case, it is to be borne in mind, inter alia, that the endless fiber-reinforced insert has a thermoplastic matrix material, whereby the endless fiber-reinforced insert can be molded, inter alia, under the action of the melt temperature and melt pressure of the molding material.

[0031] The endless fiber reinforced insert is configured to reinforce the battery shell, the reinforcement being based inter alia on the material properties of the endless fiber reinforced insert and / or on the alignment of the endless fiber reinforced insert, in particular on the contour-true alignment of the endless fiber reinforced insert with minimal, if any, creases and / or dents and / or interaction of the endless fiber reinforced insert with the battery shell.

[0032] Preferably, the endless fiber-reinforced insert is completely surrounded by the molding material in the first partial region and is arranged adjacent to the molding material in the second partial region, whereby a positive connection between the molding material and the endless fiber-reinforced insert can be achieved in the first partial region.

[0033] Preferably, the plastic material of the molding compound and the plastic material of the endless fiber-reinforced insert are materially compatible such that they can form a material-bonding connection with one another, whereby a particularly rigid configuration of the battery shell and / or the battery shell and / or a particularly long service life of the battery shell can be achieved. In this case, a monolithic molding of the battery shell can also be achieved.

[0034] According to a preferred embodiment, the endless fiber-reinforced insert has a first side which is not overpressed by the molding material by 55% or more, preferably by 66% or more, particularly preferably by 70% or more. It is also advantageous for the endless fiber-reinforced insert to have a first side which is not overpressed by the molding material by 80% or more, preferably by 85% or more, particularly preferably by 90% or more. It is further advantageous for the endless fiber-reinforced insert to have a first side which is not overpressed by the molding material by 92.5% or more, preferably by 95% or more, particularly preferably by 97.5% or more.

[0035] It is expressly mentioned that the above values ​​for the proportion of the first and / or second face of the endless fiber-reinforced insert that is overpressed by the molding material should not be understood as strict limits, but rather can be exceeded or exceeded on an engineering scale without departing from the described embodiment of the invention. In simple terms, these values ​​provide a clue as to the magnitude of the here proposed proportion of the first and / or second face of the endless fiber-reinforced insert that is overpressed by the molding material.

[0036] By means of the embodiment proposed here it can be advantageously achieved that battery shells reinforced with endless fiber-reinforced inserts can be produced particularly efficiently and reproducibly, in particular without the endless fiber-reinforced inserts being applied after shaping of the molding material in a separate process step. Another advantage of the battery shells proposed here is the high positional accuracy of the endless fiber-reinforced inserts, which can improve the reproducible production of the battery shells.

[0037] Furthermore, it can be achieved particularly advantageously that the endless fiber-reinforced insert can be arranged at least partially directly on the surface of the battery shell, whereby a high contour fidelity of the arrangement of the endless fiber-reinforced insert can be achieved, whereby undesirable dents and / or folds of the endless fiber-reinforced insert in the battery shell can be avoided or at least have a smaller exposed profile compared to the prior art.

[0038] Overall, a battery shell can be achieved having endless fiber-reinforced inserts for reinforcing the battery shell that are adaptively and reproducibly positioned in the load paths.

[0039] It is also proposed that a second face of the endless fiber-reinforced insert, which is located opposite the first face, is overpressed mainly by the molding material.

[0040] This allows, among other things, to improve the reproducible positioning of the endless fiber-reinforced insert within the battery shell.

[0041] Furthermore, due to the large contact area between the second side of the endless fiber-reinforced insert and the molding material, a particularly stable transmission of forces between the molding material and the endless fiber-reinforced insert can be achieved.

[0042] The area of ​​the second face of the endless fiber-reinforced insert proposed here that is overpressed by the molding material allows, inter alia, more complex and / or thicker geometric configurations of the battery shell, making it possible, inter alia, for functional elements to be better integrated into the battery shell.

[0043] Furthermore, this allows the area at least partially surrounded by the endless fibre reinforced insert to adopt any desired complex shape, in particular a reinforcing rib structure, in particular a rib structure of the internal reinforcing means.

[0044] Preferably, the second side of the endless fiber-reinforced insert, which is overpressed to a greater extent by the molding material, allows the battery shell proposed here to be media-tight. The organosheets are not necessarily media-tight, but media-tightness in these areas can be achieved by backpressing the organosheets.

[0045] It is explicitly mentioned that the battery shell can also have a plurality of endless fiber reinforced inserts, in particular two endless fiber reinforced inserts, three endless fiber reinforced inserts, four endless fiber reinforced inserts, five endless fiber reinforced inserts, six endless fiber reinforced inserts, seven endless fiber reinforced inserts, eight endless fiber reinforced inserts, nine endless fiber reinforced inserts, etc. It is to be envisaged in particular that a plurality of endless fiber reinforced inserts are arranged adjacent to one another. Alternatively, it is to be envisaged that the endless fiber reinforced inserts are arranged in several different regions.

[0046] Furthermore, it is particularly proposed here that the battery shell has a functional element, whereby inter alia connection means are envisaged which are arranged to connect the battery shell to a specified traction battery and / or a specified motor vehicle component, whereby inter alia connection means are envisaged which have a cavity which is molded in the region of the endless fibre-reinforced insert, in particular a connection means which has an internal thread.

[0047] Additionally, functional elements include, among others, fluid lines molded into the battery shell.

[0048] According to one preferred embodiment, the endless fiber reinforced insert comprises an organo sheet and / or tape scrim.

[0049] In this regard, the following terms are explained. By "organosheet" is understood a fiber composite material comprising endless fibers, in particular endless fibers having a fiber length of 40 mm or more, and a thermoplastic. Preferably, the endless fibers are unidirectionally oriented. Furthermore, the organosheet preferably comprises a fabric or scrim made of the endless fibers moistened with a thermoplastic matrix material.

[0050] By "tape scrim" is understood a scrim made of unidirectionally oriented endless fibers wetted with a thermoplastic matrix material.

[0051] It is proposed here that the endless fiber-reinforced insert comprises or consists of an organo sheet and / or tape scrim.

[0052] This advantageously achieves that the endless fiber-reinforced insert can be constructed from components that are both readily available and efficiently processable.

[0053] According to one particularly expedient embodiment, the endless fiber-reinforced insert is molded out of the plane.

[0054] In this regard, the following terms are explained. An endless fiber-reinforced insert that is "molded out of a plane" is understood to have a three-dimensional geometry that does not extend flat. In particular, an endless fiber-reinforced insert that initially has a flat geometry before molding of the battery shell is molded in such a way that it does not have a flat geometry after molding. In other words, the endless fiber-reinforced insert protrudes out of a plane. In that case, the endless fiber-reinforced insert has a mold-dependent non-flat geometry that is defined by the mold specified for manufacturing the battery shell.

[0055] Preferably, a flat surface is understood to mean a flat geometry having a finite thickness, preferably a thickness of less than 10 mm, preferably a thickness of less than 5 mm, particularly preferably a thickness of less than 2 mm. The endless fiber-reinforced insert can therefore also be molded into a plane with relatively small indentations and / or folds, but the upper geometry of which extends with the above-mentioned thickness of the flat geometry.

[0056] Advantageously, an endless fiber-reinforced insert molded out of a plane can increase rigidity, in particular because an endless fiber-reinforced insert molded out of a plane has a greater moment of area, at least in relation to the axis, than a flat endless fiber-reinforced insert.

[0057] Optionally, the endless fiber-reinforced insert has, in a cross section in its main extension direction, at least one first leg and a second leg, the first leg and the second leg being connected to each other and the first leg and the second leg forming an angle with each other of less than 100°, preferably an angle of less than 50°, particularly preferably an angle of less than 30°.

[0058] In this regard, the following terms are explained. By "main direction of extension" of the endless fiber-reinforced insert is preferably understood the direction in which the endless fiber-reinforced insert substantially maintains its cross section. Preferably, the main direction of extension means the longitudinal direction of the endless fiber-reinforced insert.

[0059] By "leg" is understood a partial region of the endless fiber-reinforced insert which extends substantially linearly at least in each region. Preferably, a leg is understood as a partial region of the endless fiber-reinforced insert which is arranged at least at one end, the leg extending substantially linearly.

[0060] It is to be borne in mind that preferably the first leg of the endless fibre-reinforced insert is connected indirectly via the moulding material or directly to the second leg of the endless fibre-reinforced insert.

[0061] Preferably, the first and second legs are not aligned parallel to one another, so that a linear extension of the legs leads to a vertex, but the endless fiber-reinforced insert does not necessarily surround this vertex. In that case, inter alia, a V- or U-shaped cross-section of the endless fiber-reinforced insert should be considered, and in particular the two legs can be connected to one another by a differentiable curvature or bend. The angle between the legs can be determined by linearly extending the legs to form the vertex.

[0062] Due to the contour shape of the legs, a geometric alignment of the endless fiber reinforcing inserts can be achieved, which results in advantageous reinforcement of the battery shell.

[0063] Preferably, one leg has a leg length surrounded by the endless fiber-reinforced insert of at least 1 cm, preferably at least 2 cm, particularly preferably at least 3 cm, and more preferably at least 5 cm, preferably at least 7 cm, particularly preferably at least 10 cm.

[0064] The first leg may preferably have a leg length surrounded by the endless fiber reinforced insert that is equal to or greater than the leg length of the second leg surrounded by the endless fiber reinforced insert.

[0065] The endless fiber-reinforced insert can also have more than two legs, in particular three, four, five, etc. legs, again with the understanding that these are indirectly or directly connected to one another via the molding material. Furthermore, adjacent legs preferably form a vertex by the intersection of their linear extensions. In particular, endless fiber-reinforced inserts extending from the bottom surface of the battery shell to the internal reinforcing means by more than two legs are considered here. In that case, an endless fiber-reinforced insert with at least four or five legs can have an omega-shaped cross-sectional shape, the legs defining both sides of the endless fiber-reinforced insert being preferably arranged on the bottom surface of the battery shell.

[0066] If the endless fiber-reinforced insert has more than two legs, indirectly or directly adjacent legs of the endless fiber-reinforced insert can still be connected to one another indirectly or directly via the molding material.

[0067] It should preferably be borne in mind that, inter alia, the two legs are aligned parallel to one another and are connected to one another indirectly or directly via the molding material.

[0068] Expediently, the first leg and the second leg form an angle with respect to one another of 5° or more, preferably 10° or more, particularly preferably 15° or more.

[0069] In this way, localized reinforcement of the battery shell can be advantageously achieved, requiring a relatively small required structural space.

[0070] Particularly preferably, the endless fiber-reinforced insert has at least one void.

[0071] In this regard, the following terms are explained. By "voids" is meant areas at least partially surrounded by the endless fiber-reinforced insert, in particular areas completely surrounded by the endless fiber-reinforced insert, in other words areas that do not have penetrations and / or openings in the endless fiber-reinforced insert, i.e. endless fibers.

[0072] Preferably, the voids are created by punching an endless fiber reinforced insert at the void location.

[0073] Preferably, the voids enable functional elements, in particular hollow functional elements at least in each region, in particular functional elements whose hollow regions extend through the plane of the endless fiber-reinforced insert, to be arranged in the regions of the endless fiber-reinforced insert.

[0074] In particular, it can be achieved by the voids in the endless fiber-reinforced insert that during a defined molding of the battery shell the molding material can flow through the voids in the endless fiber-reinforced insert, so that the area adjacent to the first side of the endless fiber-reinforced insert can also be molded by the molding material. In other words, the voids in the endless fiber-reinforced insert make it possible to have a battery shell which on the one hand has an integration of the endless fiber-reinforced insert which can accommodate a load path and at the same time has functional elements which are arranged on the first side of the endless fiber-reinforced insert and / or which are formed hollow and can penetrate the plane of the endless fiber-reinforced insert.

[0075] The voids can therefore also act as flow aids for the molding material when molding the battery shell and allow additional geometrical freedom when shaping the battery shell, which may be useful, in particular, for additional local reinforcement, functional elements and / or improved geometric bonding between the endless fiber-reinforced insert and the molding material.

[0076] Expediently, the endless fibre-reinforced insert has a rib directly adjacent to its first face.

[0077] In this regard, the following terms are explained. By "rib" is understood a localized material projection adjacent to the endless fiber-reinforced insert and directly adjacent to the first face of the endless fiber-reinforced insert.

[0078] Preferably, the ribs are configured to locally reinforce the areas of the battery shell having the endless fibre reinforced insert, in particular the areas which interact with and / or are indirectly or directly connected to the functional elements.

[0079] By functional elements are meant, inter alia, connection means by which an external load can be introduced into the battery shell.

[0080] Preferably, the cross-section of the rib comprises or is filled with molding material, whereby it can be achieved that during the specified production of the battery shell the molding material can flow through the cross-section of the rib, whereby the first side of the endless fiber-reinforced insert can be partially over-pressed by the molding material to form the rib. Furthermore, the molding material flowing through the cross-section of the rib during the specified production of the battery shell can mold a functional element adjacent to the rib, which is arranged adjacent to the first side of the endless fiber-reinforced insert.

[0081] Furthermore, the ribs can advantageously improve the positive bond between the endless fiber-reinforced insert and the molding material.

[0082] Preferably, the endless fibre reinforced insert at least partially surrounds the transverse rib with its second surface.

[0083] In this regard, the following terms are explained. By "transverse rib" is meant a narrow continuous section of molding material formed in the shape of a rib, which extends at least partially transversely to the main extension direction of the endless fiber-reinforced insert, in particular transversely to the main extension direction of the endless fiber-reinforced insert, and which is designed to provide additional reinforcement to the area at least partially surrounded by the endless fiber-reinforced insert and in which the endless fiber-reinforced insert is arranged, in particular to prevent or reduce transverse shrinkage in this area.

[0084] In that case, in particular, a plurality of transverse ribs, which may be arranged at regular or irregular intervals, are also contemplated.

[0085] Preferably, the transverse ribs are arranged in pairs, more preferably one on each side of the area enclosed by the endless fiber-reinforced insert, with the same value of longitudinal extension of the endless fiber-reinforced insert.

[0086] Optionally, an endless fiber reinforced insert is disposed in the internal reinforcement means of the battery shell.

[0087] In this regard, the following terms are explained. By "internal reinforcing means" is understood a geometrical feature of the battery shell that is inside the battery shell and is provided to reinforce the battery shell.

[0088] 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.

[0089] Preferably, the partition is a vertical partition extending in the longitudinal direction of the battery shell and provided to increase at least one, and more preferably two, moments of area of ​​a cross section of the battery shell passing perpendicular to the longitudinal direction, thereby stiffening the battery shell.

[0090] Preferably, the partition is a transverse partition extending in the transverse direction of the battery shell and provided to increase at least one, and particularly preferably two, moments of area of ​​a cross section of the battery shell passing perpendicular to the transverse direction, thereby stiffening the battery shell.

[0091] 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 the internal reinforcement means, and more preferably, the battery modules are supported by the internal reinforcement means.

[0092] 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 each other.

[0093] Furthermore, internal reinforcing means are envisaged which preferably are arranged inside the battery shell and divide the storage space of the battery shell in its main transverse and / or longitudinal direction of extension, in particular in the middle.

[0094] This makes it possible to achieve a particularly advantageous introduction of the endless fiber-reinforced insert into the battery shell in a manner that corresponds to the load path, while at the same time making use of the available structural space, for example in a separating partition arranged between designated battery modules.

[0095] Likewise expediently, endless fiber-reinforced inserts are arranged in the external reinforcement means of the battery shell.

[0096] In this regard, the following terms are explained. By "external reinforcing means" is understood a geometrical form of the battery shell and / or a material modification of the battery shell that is on the outside of the battery shell and is provided to reinforce the battery shell.

[0097] Preferably, external reinforcing means are provided for reinforcing the bottom surface of the battery shell and / or at least one side wall of the battery shell.

[0098] Preferably, the external reinforcement means refers to a contouring of at least one side wall of the battery shell, the contouring of the at least one contoured side wall of the battery shell increasing at least one moment of inertia of the at least one contoured side wall of the battery shell, particularly preferably two moments of inertia of the at least one contoured side wall of the battery shell, compared to a side wall of the battery shell having a comparable wall thickness and a comparable material composition but without a contouring.

[0099] By contouring is preferably meant I-shaped contours, U-shaped contours, T-shaped contours, Z-shaped contours, L-shaped contours, contours cumulatively formed from these contours or different contourings.

[0100] It should be explicitly pointed out that contouring may be understood as any geometrical change to the flat extension of at least one side wall and / or bottom surface of the battery shell.

[0101] It is expressly pointed out that the embodiment of the external reinforcement means proposed herein is not limited to the reinforcement of one side wall of the battery shell, but rather two or more side walls of the battery shell, preferably all side walls of the battery shell may have external reinforcement.

[0102] It is expressly pointed out that the side walls may be components of the external stiffening means.

[0103] Advantageously, this allows endless fiber-reinforced inserts to be arranged as localized reinforcement measures in areas of the battery shell that are particularly advantageous for this purpose. The external reinforcement means are used in most use cases to fasten the battery shell to the specified vehicle, and therefore in this case larger loads act on the battery shell than alone. Furthermore, areas of the battery shell that are exposed to larger loads acting from the outside in the event of a side collision can be reinforced in this way.

[0104] Particularly preferably, the endless fiber-reinforced insert is arranged on the inside of the battery shell, in particular the endless fiber-reinforced insert is arranged on the inside of the battery shell with a first side of the endless fiber-reinforced insert.

[0105] Preferably, the endless fiber reinforced insert is disposed directly adjacent to the receiving space of the battery shell.

[0106] Advantageously, this allows for optimal utilization of the geometrical construction space in order to increase the moment of inertia resulting from the endless fiber-reinforced insert. In particular, an optimal fiber end distance can be achieved. Overall, this allows for improved reinforcement of the battery shell resulting from the endless fiber-reinforced insert.

[0107] Expediently, the battery shell is formed using a compression molding process.

[0108] In this regard, the following terms are explained. By "press moulding" is understood a primary moulding process in which in a first step the moulding material is introduced into the cavity of an associated press mould and in a second step the press mould is closed, in particular by means of a pressure piston. By closing the press mould, the moulding material takes on the shape set by the press mould, in particular the shape of the part cavity of the press mould. Preferably, the press mould is temperature regulated.

[0109] In particular, the compression molding process can also be understood as a direct molding process, in which the fiber material is drawn into an extruder, impregnated there with an already molten matrix polymer, in particular a thermoplastic or thermosetting plastic, fed to an injection piston and subsequently introduced into the press die as molding compound.

[0110] Advantageously, the proposed battery shell can use established manufacturing methods, thus saving costs and minimizing process risks in the manufacturing process.

[0111] Furthermore, compared with the injection molding method, fiber damage during plasticization and pressing can be reduced, which leads to a longer average fiber length and therefore better mechanical properties in the battery shell.

[0112] Preferably, the battery shell has at least one linearly extending recess, preferably a linearly extending recess, on the inside of the bottom surface.

[0113] In this regard, the following terms are explained. By "linearly extending depression" is understood a hollow shape in the relief of the surface of the battery shell. Preferably, the depression in a cross section arranged perpendicular to the main extension direction has a concave and / or convex depression in the surface of the battery shell. Preferably, the depression can have multiple spatial curvatures.

[0114] In the area of ​​the recess, the material thickness of the molding compound of the battery shell may be reduced.

[0115] Preferably, the linearly extending recess is arranged adjacent to the internal and / or external reinforcement means. Preferably, the main direction of extension of the recess extends perpendicularly to the main direction of extension of the internal and / or external reinforcement means.

[0116] Preferably, the battery shell has a plurality of linearly extending recesses, which may be arranged in pairs on either side of the internal reinforcing means.

[0117] According to a particularly expedient embodiment, the insert has a chamfer, in particular two chamfers.

[0118] In this regard, the following terms are explained. By "chamfer" is understood an inclined surface at the first corner of the insert. The chamfer may have an angle of 20° or more, preferably an angle of 30° or more, more preferably an angle of 40° or more, particularly preferably an angle of 50° or more. The chamfer may have an angle of 70° or less, preferably an angle of 60° or less, more preferably an angle of 50° or less, particularly preferably an angle of 40° or less.

[0119] Preferably, the insert has a chamfer at a corner of the insert opposite the designated mold cavity and / or surface of the battery shell.

[0120] The chamfer may extend through at least 20% of the thickness of the insert, preferably at least 40% of the thickness of the insert, more preferably at least 60% of the thickness of the insert, and particularly preferably at least 80% of the thickness of the insert.

[0121] The inclined surface of the chamfer may coincide with the second edge, in which case the second edge is disposed adjacent to the first edge, such that at least one side of the insert terminates in a sharp corner, the sharp corner having an opening angle of 70° or less, preferably 50° or less, particularly preferably 30° or less.

[0122] When the mold is closed, the molding material flows over the insert with a moving flow front, which can change the position of the insert or damage the structure of the insert.

[0123] The chamfer can be set to interact with the flow front of the molding material during molding of the battery shell, in particular by a special design of the end of the insert that first comes into contact with the flow front, in particular by a chamfer at the corner of the insert. The chamfer can be provided at the edge around which the flow front of the molding material flows at a specified angle, and thus the edge can have an inclined surface. This can reduce the flow resistance acting from the insert to the molding material and / or the forces transmitted from the molding material to the insert are smaller, so that possible structural damage of the insert can be reduced or prevented. Furthermore, this can achieve that the compression forces transmitted from the molding material to the insert have a component that runs normal to the inclined surface. This can, inter alia, make it possible for the insert to be pressed by the molding material into the molded part cavity of the mold, which can result in a reproducible positioning of the insert in the battery shell.

[0124] More preferably, the insert can have a chamfer at each of the mutually opposing ends of the insert transversely to its main extension direction, in particular at the corners of the insert facing away from the surface of the molded article cavity and / or the battery shell, which can help to position the insert inside the battery shell, in particular when the insert is overpressed on both sides by the molding material. Furthermore, the inclined surfaces arranged on both sides of the molded article cavity can achieve, by interaction with the molding material, that the corners facing the molded article cavity can be pressed by the molding material into the molded article cavity and / or against a specified surface of the battery shell, thereby achieving a reproducible positioning of the entire insert.

[0125] According to a second aspect of the present invention, the above problem is solved by a mold, in particular a press mold, for producing a battery shell according to the first aspect of the present invention, the mold forming a molded part cavity, the mold preferably having means for filling the molded part cavity with molding material.

[0126] In this regard, the following terms are explained. By "mold" is understood an apparatus for pre-molding, in particular for pre-molding a battery shell according to the first aspect of the invention from molten molding material and at least one endless fiber-reinforced insert.

[0127] Preferably, dies are understood to mean press dies, in particular press dies.

[0128] Preferably, a mould is understood to mean a mould station, in particular a mould station which, in addition to the means for filling the moulding cavity and / or the mould, comprises further functional elements, in particular a manipulator system and / or a heating device.

[0129] By "moulded part cavity" is understood a cavity formed by a mould for forming a component produced in a specific mould, in particular a battery shell, in a region-by-region manner.

[0130] 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. Alternatively, the molding material can be introduced manually into the open mold cavity.

[0131] Preferably, means for filling is understood to mean a device which can introduce, in particular charge, the molten molding material into a pre-opened tool, in particular in the context of a pressing mould and / or pressing device.

[0132] Preferably, the means for filling the molded article cavity with molding material is arranged to deposit the molding material directly onto the previously inserted endless fibre reinforced insert.

[0133] Here, a mould for manufacturing a battery shell according to a first aspect of the present invention is proposed.

[0134] It will be apparent that the advantages of the battery shell according to the first aspect of the present invention already described extend to a mold for manufacturing the battery shell according to the first aspect of the present invention.

[0135] According to a particularly preferred embodiment, the mold has local protrusions in the molding cavity, in particular a plurality of mutually corresponding local protrusions which are designed to partially set the endless fiber-reinforced insert in the molding cavity.

[0136] In this regard, the following terms are explained. By "local protrusions" is understood local protrusions in the relief of the surface of the molding cavity.

[0137] Preferably, the local protrusion is a protrusion that extends concavely and / or convexly on the surface of the molded part cavity, and preferably the local protrusion can have multiple spatial curvatures. According to a preferred embodiment, the geometry of the local protrusion corresponds to a segment of a sphere.

[0138] In other words, the local protrusions are formed such that the endless fiber-reinforced insert does not have to be fully set in the molded part cavity, so that the endless fiber-reinforced insert can be supported far away from the wall of the molded part cavity adjacent to the local protrusions, thereby reducing the heat flow between the molded part cavity and the endless fiber-reinforced insert. To this extent, this case can also be called "partial surface setting".

[0139] In this context, "setting" means that the endless fiber-reinforced insert is at least statically defined and supported by one or more localized protrusions.

[0140] By "mutually corresponding local projections" is understood a plurality of local projections which are set together so that an endless fibre-reinforced insert can be placed thereon.

[0141] It is to be noted that preferably, mutually corresponding local projections are webs which are arranged parallel to one another in the moulding cavity and which preferably extend at least mainly horizontally.

[0142] This can advantageously prevent or reduce, inter alia, excessive cooling of the heated endless fiber-reinforced insert by contact with a mold, in particular a mold having a lower temperature than the endless fiber-reinforced insert, and in particular can achieve that the endless fiber-reinforced insert is deformable and / or material-bondably connectable to the molding material.

[0143] Expediently, the mould comprises positioning means arranged to position the endless fibre-reinforced insert in the mould.

[0144] In this regard, the following terms are explained. By "positioning means" is understood means configured to center the endless fiber reinforced insert within the molded article cavity and / or to prevent or reduce undesirable misalignment of the endless fiber reinforced insert within the molded article cavity.

[0145] According to one preferred embodiment, positioning means are understood to mean end and / or edge stops, in particular a number of stops which are correspondingly arranged on several sides of the endless fibre-reinforced insert.

[0146] Preferably, the positioning means are designed in the form of a local protrusion in the moulding cavity, in which case it should be borne in mind, inter alia, that the local protrusion for setting the endless fibre-reinforced insert merges into the positioning means on one side, the protrusion height of the positioning means being higher than the protrusion height of the corresponding local protrusion.

[0147] Advantageously, this can prevent or reduce displacement of the endless fiber-reinforced insert due to setting or introduction of the molding material.

[0148] Preferably, the mould has a temperature regulation system for regulating the temperature of the mould.

[0149] In this regard, the following terms are explained. By "temperature regulation system" is understood an equipment that is set up to control or regulate the temperature of the mould, in particular by cooling and / or heating the mould.

[0150] Preferably, the temperature regulation system is set to maintain the temperature of the mold above 80°C.

[0151] Advantageously, this can improve the surface quality of the battery shell, and / or can improve the positioning of the endless fiber reinforced insert, and / or can reduce cycle times when molding the battery shell.

[0152] Particularly expediently, the mold has a preform mold, which is designed for preforming an endless fiber-reinforced insert.

[0153] In this regard, the following terms are explained. By "preform mould" is understood a mould set up to preform an endless fibre-reinforced insert. Preferably, the preform mould is set up to preform an endless fibre-reinforced insert before or after its insertion into a moulding cavity. Preferably, the preform mould has one or more slides, which are further preferably actively controlled and / or capable of performing a mainly vertical movement.

[0154] It should be borne in mind here that the exact shaping of the endless fiber-reinforced insert and therewith of the battery shell is achieved by means of a mould core forming the moulding cavity, which can then be designed in such a way that the pressing material flows partially over the pre-formed insert, in particular to form the ribs.

[0155] Preferably, the preform mould is a component of a mould and is movable at least in regions relative to at least a portion of the mould to allow preforming of the endless fibre reinforced insert.

[0156] In particular, it will be borne in mind that the preform mold is hydraulically supported, and in particular hydraulically supported on a portion of the mold.

[0157] The preform mould can be set up to preform the endless fibre-reinforced insert over only a portion of its longitudinal extension or, alternatively, over its entire longitudinal extension.Furthermore, it is envisaged that the preform mould directly interacts with the endless fibre-reinforced insert or, alternatively, at least partially interacts with a moulding material which deforms the endless fibre-reinforced insert.

[0158] This advantageously allows for increased positioning accuracy of the endless fiber-reinforced insert and thus reproducibility during a given production of the battery shell.

[0159] Particularly preferably, the mould has localised recesses in the moulding cavity, the localised recesses being configured to mould the ribs of the battery shell.

[0160] In this regard, the following terms are explained. By "local recesses" in the molding cavity of the mold is understood hollow shapes in the surface relief of the molding cavity, which local recesses are set to mold the ribs of the battery shell.

[0161] Advantageously, battery shells having ribs can be molded, the aforementioned advantages of which also apply to the mould claimed herein.

[0162] Further, preferably, the mold has a transverse rib cavity configured to mold the transverse ribs of the battery shell.

[0163] In this regard, the following terms are explained. By "transverse rib cavity" is understood the geometry of a molding cavity designed to mold a transverse rib into a battery shell, in particular a transverse rib that is at least partially surrounded by an endless fiber-reinforced insert.

[0164] The transverse rib cavity presented herein allows for the molding of battery shells having transverse ribs, thereby applying the previously mentioned advantages of transverse ribs to the mold proposed herein.

[0165] Optionally, the mold has or is configured to interact with a manipulator, the manipulator being configured to place an endless fiber reinforced insert within the molded part cavity.

[0166] In this regard, the following terms are explained. By "manipulator" is understood a device allowing physical interaction with its surroundings, the manipulator being configured to perform mechanical tasks.

[0167] Preferably, the manipulator has at least one axis with an associated drive unit.

[0168] This advantageously makes it possible to achieve that the endless fibre-reinforced insert can be automatically set in the part cavity of the mould in a highly accurate and reproducible manner.

[0169] Expediently, the mould comprises or is arranged to interact with a heating device, which is arranged to heat the endless fibre-reinforced insert.

[0170] In this regard, the following terms are explained. By "heating device" is understood an apparatus which is adapted to heat the endless fibre-reinforced insert, in particular to a temperature above the melting temperature of the matrix material of the endless fibre-reinforced insert, in particular to a temperature above 200°C.

[0171] Preferably, a heating device is understood to mean an infrared radiator.

[0172] Thereby, it can be advantageously achieved that the endless fiber-reinforced insert can be heated before and / or after being introduced into the molding cavity, whereby it is possible to achieve better deformation processing and / or the formation of a material-bonding connection with the molding material.

[0173] 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 / or cumulatively in any combination.

[0174] According to a third aspect of the present invention, the above problem is solved by a method for manufacturing a battery shell according to the first aspect of the present invention, in particular using a mould according to the second aspect of the present invention, the method for manufacturing a battery comprising the following steps: a) inserting an endless fiber reinforced insert into an open molded article cavity; b) introducing a molding material into the molded article cavity; c) forming a battery shell; and d) removing the battery shell; and Includes.

[0175] In this regard, the following terms are explained. By "inserting" an endless fiber-reinforced insert into a molding cavity is understood in particular the inserting and / or setting and / or introducing the endless fiber-reinforced insert into the molding cavity.

[0176] Here, a process-integrated method for the production of highly loaded battery shells by at least partially combined deformation and pressing of a molding compound with an endless fiber-reinforced insert is proposed, whereby efficient and reproducible battery shells can be produced by directly, material- and / or form-fittingly connecting the endless fiber-reinforced insert during the primary molding, whereby the endless fiber-reinforced insert can be locally integrated into the battery shell in a manner that corresponds to the load path.

[0177] Naturally, the advantages of the battery shell according to the first aspect of the invention and / or the advantages of the mould according to the second aspect of the invention apply to a method of manufacturing a battery shell according to the first aspect of the invention and / or using a mould according to the second aspect of the invention.

[0178] Preferably, the endless fibre-reinforced insert is heated before it is inserted into the moulding cavity, in particular by means of a heating device, in particular to a temperature above the melting point of the matrix material of the endless fibre-reinforced insert.

[0179] This advantageously makes it possible to achieve better or even to deform the endless fiber-reinforced insert, and in particular makes it possible to prevent or reduce the endless fibers from breaking or being otherwise damaged during preforming and / or molding.

[0180] Furthermore, this makes it possible to achieve a material-bonding connection between the matrix material of the endless fiber-reinforced insert and the molding material.

[0181] Advantageously, heating the endless fiber reinforced insert can also improve the surface quality of the surface of the battery shell adjacent to the endless fiber reinforced insert.

[0182] It is expressly mentioned that according to an alternative embodiment, it is also proposed to heat the endless fiber-reinforced insert in the part cavity of the mould, in particular by means of an infrared radiator. Moreover, it is conceivable that the endless fiber-reinforced insert is heated both before and after its insertion into the part cavity.

[0183] Optionally, the endless fiber reinforced insert is set on a localized protrusion of the molded part cavity during insertion into the molded part cavity.

[0184] This can minimize surface contact between the endless fiber reinforced insert and the molded article cavity, thereby preventing or reducing cooling of the endless fiber reinforced insert.

[0185] Preferably, upon insertion into the moulding cavity, the endless fibre reinforced insert is set in correspondence with the locating means.

[0186] Preferably, the endless fiber reinforced insert is set adjacent to an edge stop or set inside edge stops located on either side within the molded part cavity.

[0187] This allows for improved positioning accuracy of the endless fiber-reinforced insert within the battery shell, and therefore improved reproducibility in the manufacture of the battery shell.

[0188] Optionally, the endless fiber reinforced insert is preformed using a preform mold prior to molding of the battery shell.

[0189] The positional accuracy of the endless fiber reinforced insert in the battery shell can be improved by preforming the endless fiber reinforced insert before insertion into the open molded cavity or after insertion into the open molded cavity.

[0190] It is expressly mentioned that the subject matter of the third aspect may be advantageously combined with the subject matter of the preceding aspects of the invention either individually or cumulatively in any combination.

[0191] According to a fourth aspect of the present invention, the above object is achieved by a battery shell, in particular a battery shell for a traction battery, which is manufactured using a mould according to the second aspect of the present invention and / or by using a method according to the third aspect of the present invention.

[0192] It will be appreciated that the advantages of a battery shell manufactured using a mould according to the second aspect of the invention, as described above, and / or a battery shell manufactured using a method according to the third aspect of the invention, as described above, apply directly to a battery shell manufactured using a mould according to the second aspect of the invention and / or a battery shell manufactured using a method according to the third aspect of the invention.

[0193] It is expressly mentioned that the subject matter of the fourth aspect can be advantageously combined with the subject matter of the above aspects of the invention, either individually or cumulatively in any combination.

[0194] According to a fifth aspect of the present invention, the above problem is solved by a traction battery, in particular an automotive traction battery, comprising a battery shell according to the first aspect of the present invention and / or a battery shell manufactured using a mould according to the second aspect of the present invention and / or a battery shell manufactured using a method according to the third aspect of the present invention.

[0195] In this regard, the following terms are explained. By "motor vehicle" is understood a vehicle that is driven by an engine. Preferably, the motor vehicle is not rail-bound or at least only temporarily bound to a lane.

[0196] Naturally, the advantages of a battery shell according to the first aspect of the invention, as described above, and / or a battery shell manufactured using a mould according to the second aspect of the invention, as described above, and / or a battery shell manufactured using a method according to the third aspect of the invention, as described above, apply directly to a traction battery comprising a battery shell according to the first aspect of the invention, and / or a battery shell manufactured using a mould according to the second aspect of the invention, and / or a battery shell manufactured using a method according to the third aspect of the invention.

[0197] 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 / or cumulatively in any combination.

[0198] According to a fifth aspect of the present invention, the above problem is solved by a vehicle comprising a battery shell according to the first aspect of the present invention and / or a battery shell manufactured using a mould according to the second aspect of the present invention and / or a battery shell manufactured using a method according to the third aspect of the present invention.

[0199] It will be appreciated that the advantages of a battery shell according to the first aspect of the invention, as described above, and / or a battery shell manufactured using a mould according to the second aspect of the invention, as described above, and / or a battery shell manufactured using a method according to the third aspect of the invention, as described above, apply directly to automobiles having a battery shell according to the first aspect of the invention, and / or a battery shell manufactured using a mould according to the second aspect of the invention, and / or a battery shell manufactured using a method according to the third aspect of the invention.

[0200] It is expressly mentioned that the subject matter of the sixth aspect can be advantageously combined with the subject matter of the above aspects of the invention either individually or cumulatively in any combination. Further advantages, details and features of the invention will become apparent from the examples described below. [Brief description of the drawings]

[0201] [Figure 1] 1 is a schematic partial perspective view of a first embodiment of a battery shell, the battery shell having a cross-sectional view. FIG. [Diagram 2] 1 is a schematic partial perspective view of a second embodiment of a battery shell, the battery shell having a cross-sectional view. FIG. [Diagram 3] 1 is a schematic partial perspective view of a third embodiment of a battery shell, the battery shell having a cross-sectional view. [Figure 4] FIG. 2 is a schematic partial perspective view of a mold, the mold having a cross-sectional view.

[0202] In the following description, the same reference numerals denote the same components or features, so that the description of the components given in one figure is valid for the other figures and repetition of the description is avoided. Moreover, individual features described in connection with one embodiment can also be used separately in other embodiments.

[0203] The portion of one embodiment of a battery shell 100 in FIG. 1 includes a battery shell 100 having a bottom surface 102 and at least one sidewall (not shown), with the battery shell 100 having an interior side 108 configured to house components (not shown) of a designated traction battery (not shown).

[0204] The battery shell 100 is molded from a molding material 140 and an endless fiber reinforced insert 120, the endless fiber reinforced insert 120 having a first surface 122 that is not overpressed by the molding material 140 by 50% or more. Additionally, the endless fiber reinforced insert 120 has a second surface 124 disposed opposite the first surface 122 that is overpressed by the molding material 140 by 95% or more.

[0205] Here, the endless fiber reinforced insert 120 comprises an organo sheet, and the endless fiber reinforced insert is disposed on the inside 108 of the battery shell 100, particularly with a first surface 122 of the endless fiber reinforced insert 120 disposed on the inside 108 of the battery shell 100.

[0206] The endless fiber reinforced insert 120 is disposed in the internal reinforcement means 150 of the battery shell 100 and has a three-dimensional geometry rather than a flat extending geometry. In particular, the endless fiber reinforced insert 120, which initially has a flat geometry before the formation of the battery shell 100, is molded such that after molding it no longer has a flat geometry. In other words, the endless fiber reinforced insert 120 protrudes from a flat plane. In other words, the endless fiber reinforced insert 120 is formed out of one plane.

[0207] The endless fiber-reinforced insert 120 has, in a cross section in its main extension direction, a first leg 126 and a second leg 127, which are connected to each other, in particular directly connected to each other.

[0208] The endless fiber reinforcement insert 120 at least partially surrounds the transverse rib 130 with its second face 124. The transverse rib 130 is configured to reinforce the internal reinforcing means 150 and thereby the battery shell 100.

[0209] On the inside 108 of the battery shell 100 , a functional element 132 , also molded from a molding material 140 , is arranged between the first leg 126 and the second leg 127 of the endless fiber-reinforced insert 120 .

[0210] The insert 120 may have a chamfer. Preferably, the insert 120 has a chamfer configured to interact with a flow front of the molding material 140 during molding of the battery shell 100, and in particular, the flow pressure of the molding material 140 advantageously interacts with the chamfer during molding of the battery shell 100. This may achieve that the flow pressure of the molding material 140 may be utilized to reproducibly press the insert into a molded part cavity (not shown) of a mold (not shown), thereby assisting in reproducible positioning of the insert 120 in the battery shell 100 as a whole and / or improving the reproducibility of the positioning of the insert 120 in the battery shell 100.

[0211] More preferably, the insert 120 has a chamfer at each of the opposing ends transversely to the main extension direction of the insert 120, which can help position the insert 120 on the inside 108 of the battery shell 100.

[0212] 2 has the battery shell 100 including the bottom surface 102 and allows for a side view of the endless fiber reinforced insert 120 disposed in the internal reinforcement means 150. In particular, this perspective view allows for a good view of the first face 122 of the first leg 126 of the endless fiber reinforced insert 120.

[0213] At least three functional elements 132 are disposed on the upper side of the endless fiber reinforced insert 120, also formed from the molding material 140, at least two of which are connecting elements 132 that are configured to connect the battery shell 100 to other components (not shown) of a designated traction battery (not shown).

[0214] 3, shown cut away through functional element 132, includes battery shell 100 including bottom surface 102 and internal reinforcement means 150. Additionally, a cut away surface (not shown) extends through rib 129 of internal reinforcement means 150.

[0215] The endless fiber-reinforced insert 120 has a void 128 between its first leg 126 and its second leg 127. In particular, the void 128 of the endless fiber-reinforced insert 120 allows the molding material 140 to advantageously flow therethrough during molding of the battery shell 100 (not shown). Thus, the molding material 140 can reach and mold the area of ​​the functional element 132, which is likewise molded from the molding material 140, during molding of the battery shell 100 by an impact extrusion molding method (not shown).

[0216] The ribs 129 molded on both sides of the endless fiber reinforcement insert 120 can increase the rigidity of the internal reinforcement element 150. During molding of the battery shell 100, the molding material 140 can flow into the area of ​​the functional element 132 and contribute to the molding of the functional element 132.

[0217] The mold 170 portion of Figure 4 shows the inside of an open mold 170, with the mold set to mold a battery shell (not shown) with its mold cavity 172. The mold 170 is shown cut away from the back side.

[0218] The mold 170 has a number of mutually corresponding local protrusions 174 that are configured to partially set an endless fiber-reinforced insert (not shown) in the molded part cavity 172. The endless fiber-reinforced insert (not shown), which may have a flat geometry prior to molding of the battery shell (not shown), may then be set on the local protrusions 174. Due to the inherent rigidity of the endless fiber-reinforced insert (not shown), after setting, it contacts the mold 170, at least primarily only on the local protrusions 174, which may reduce cooling of the endless fiber-reinforced insert (not shown).

[0219] For reproducibly positioning an endless fiber-reinforced insert (not shown) in the mould 170 , the mould 170 further comprises positioning means 176 arranged to correspond to the local projections 174 .

[0220] Additionally, the mold 170 has localized recesses 178 within the molded part cavity 172 that are designed to form ribs (not shown) of a battery shell (not shown). [Explanation of symbols]

[0221] 100 Battery Shells 102 Bottom 108 Inside 120 Endless fiber reinforced insert 122 First Side 124 Second Side 126 First Leg 127 Second Leg 128 Vacant Space 129 Ribs 130 Horizontal ribs 132 Functional elements 140 Molding materials 150 Internal reinforcement means 170 Mold 172 Molded product cavity 174 Local convexity 176 Positioning means 178 Localized depression

Claims

1. A battery shell (100), in particular a traction battery battery shell (100), said battery shell (100) having a bottom surface (102) and at least four side walls, said battery shell (100) having an inner side (108) and an outer side; In the battery shell (100), 1. A battery shell (100) molded from a molding material (140) and an endless fiber-reinforced insert (120), characterized in that the endless fiber-reinforced insert (120) has a first side (122) that is not overpressed by the molding material (140) by 50% or more, preferably by 60% or more, particularly preferably by 75% or more, and that the endless fiber-reinforced insert (120) has a second side (124) arranged opposite the first side (122) that is overpressed by the molding material (140) by 95% or more, preferably by 97% or more, particularly preferably by 99% or more.

2. 2. The battery shell (100) of claim 1, wherein the endless fiber reinforced insert (120) comprises an organo sheet and / or tape scrim.

3. 3. The battery shell (100) according to claim 1 or 2, characterized in that the endless fiber reinforced insert (120) is molded out of a plane.

4. 4. The battery shell (100) according to claim 1, characterized in that, in a cross section in the main extension direction of the endless fiber-reinforced insert (120), the endless fiber-reinforced insert (120) has at least one first leg (126) and a second leg (127), the first leg (126) and the second leg (127) being connected to each other, the first leg (126) and the second leg (127) forming an angle with each other of less than 100°, preferably less than 50°, particularly preferably less than 30°.

5. 5. The battery shell (100) according to claim 4, characterized in that the first leg (126) and the second leg (127) have an angle of 5° or more with respect to each other, preferably an angle of 10° or more, particularly preferably an angle of 15° or more.

6. The battery shell (100) according to any one of claims 1 to 5, characterized in that the endless fiber reinforced insert (120) has at least one void (128).

7. The battery shell (100) of any one of claims 1 to 6, characterized in that the endless fiber reinforced insert (120) has a rib (129) directly adjacent the first surface (122) of the endless fiber reinforced insert.

8. The battery shell (100) according to any one of claims 1 to 7, characterized in that the endless fiber reinforced insert (120) at least partially surrounds a transverse rib (130) with a second surface (124) of the endless fiber reinforced insert.

9. The battery shell (100) according to any one of claims 1 to 8, characterized in that the endless fibre reinforced insert (120) is arranged in an internal reinforcement means (150) of the battery shell (100).

10. The battery shell (100) according to any one of claims 1 to 9, characterized in that the endless fiber reinforced insert is arranged on the inner side (108) of the battery shell (100), in particular by the first surface (122) of the endless fiber reinforced insert (120) on the inner side (108) of the battery shell (100).

11. The battery shell (100) according to any one of claims 1 to 10, characterized in that the battery shell (100) is formed using a press molding method.

12. The battery shell (100) according to any one of claims 1 to 11, characterized in that the battery shell (100) has at least one linearly extending recess, preferably a linearly extending recess on the inner side (108) of the bottom surface (102).

13. The battery shell (100) according to any one of the preceding claims, characterized in that the insert (120) has a chamfer, preferably two chamfers.

14. A mold (170), in particular a press mold, for manufacturing a battery shell (100) according to any one of claims 1 to 13, said mold (170) forming a molded part cavity (172), said mold (170) preferably having means for filling said molded part cavity (172) with a molding material (140).

15. The mold (170) according to claim 14, characterized in that the mold (170) has localized protrusions (174) in the molding cavity (172), in particular a plurality of mutually corresponding localized protrusions (174) configured to partially set the endless fiber reinforced insert (120) in the molding cavity (172).

16. 16. The mold (170) according to claim 14 or 15, characterized in that the mold (170) has positioning means (176) configured to position the endless fiber reinforced insert (120) in the mold (170).

17. The mold (170) according to any one of claims 14 to 16, characterized in that the mold (170) comprises a temperature regulation system for regulating the temperature of the mold (170).

18. The mold (170) according to any one of claims 14 to 17, characterized in that the mold (170) comprises a preform mold, the preform mold being configured to preform the endless fiber reinforced insert (120).

19. The mold (170) according to any one of claims 14 to 18, characterized in that the mold (170) has a local recess (178) in the molding cavity (172), the local recess (178) being configured to mold a rib (129) of the battery shell (100).

20. The mold (170) according to any one of claims 14 to 19, characterized in that the mold (170) has a transverse rib cavity, the transverse rib cavity being configured to mold the transverse rib (130) of the battery shell (100).

21. The mold (170) according to any one of claims 14 to 20, characterized in that the mold (170) has or is configured to interact with a manipulator, the manipulator being configured to set the endless fiber reinforced insert (120) in the molding cavity (172).

22. The mold (170) according to any one of claims 14 to 21, characterized in that the mold (170) has a heating device or is configured to interact with a heating device, the heating device being configured to heat the endless fiber reinforced insert (120).

23. A method for manufacturing a battery shell (100), in particular according to any of claims 1 to 13, using a mould (170), in particular according to any of claims 13 to 21, said method for manufacturing said battery shell (100) comprising the following steps: a) inserting an endless fiber reinforced insert (120) into an open mold cavity (172); b) introducing a molding material (140) into said mold cavity (172); c) forming the battery shell (100); d) removing the battery shell (100); The method includes:

24. 24. The method according to claim 23, characterized in that the endless fiber-reinforced insert (120) is heated, in particular by means of a heating device, in particular to a temperature equal to or higher than the melting point of the matrix material of the endless fiber-reinforced insert (120) before being inserted into the moulding cavity (172).

25. 25. The method according to claim 23 or 24, characterized in that the endless fiber reinforced insert (120) is set on a local protrusion (174) of the molded part cavity (172) when inserted into the molded part cavity (172).

26. The method according to any one of claims 23 to 25, characterized in that the endless fibre reinforced insert (120) is set in correspondence with positioning means (176) when inserted into the moulding cavity (172).

27. The method according to any one of claims 23 to 26, characterized in that the endless fiber reinforced insert (120) is preformed using a preform mould before moulding the battery shell (100).

28. A battery shell (100), in particular a battery shell (100) of a traction battery, said battery shell (100) being manufactured using a mould (170) according to any one of claims 14 to 22 and / or using a method according to any one of claims 23 to 27.

29. A traction battery, in particular an automotive traction battery, comprising a battery shell (100) according to any one of claims 1 to 13 and / or a battery shell (100) manufactured using a mould (170) according to any one of claims 14 to 22 and / or a battery shell (100) manufactured using a method according to any one of claims 23 to 27.

30. A motor vehicle comprising a battery shell (100) manufactured using a battery shell (100) according to any one of claims 1 to 13 and / or a mould (170) according to any one of claims 14 to 22 and / or a battery shell (100) manufactured using a method according to any one of claims 23 to 27.

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