Battery component holder for a battery housing for receiving battery components, battery housing for receiving a plurality of battery components, traction battery and motor vehicle having a traction battery

Abstract

The invention relates to a battery component holder (1) for a battery housing for receiving battery components (2), the battery component holder (1) having a housing body (3) and at least one holding element (4), wherein the housing body (3) has at least one receiving device (5) for receiving at least one battery component (2), wherein the housing body (3) consists at least partially of a particle foam, wherein the holding element (4) has at least one bearing surface (6) and at least one connecting element (7), wherein the holding element (4), when the battery component holder (1) is in the mounted state, is designed to secure a battery component (2) located in the receiving device (5), wherein the holding element (4), when the battery component holder (1) is in the mounted state, rests at least partially by means of its bearing surface (6) against a surface of a battery component (2) located in the receiving device (5) and is connected to the housing body (3) in such a manner that the at least one connecting element (7) at least partially penetrates into the housing body (3) and thus establishes a form-fitting and / or integral connection with the housing body (3). The invention further relates to a battery housing (13) for receiving a plurality of battery components (2), to a traction battery, to a motor vehicle, and to a method for mounting a battery component holder (1).

Description

[0001] Page 1 of 39

[0002] Applicant: KAUTEX TEXTRON GmbH & Co. KG

[0003] Our reference number: P81032DE

[0004] September 5, 2024

[0005] Battery component holder for a battery housing to accommodate battery components, battery housing to accommodate a variety of battery components, traction battery and motor vehicle with a traction battery

[0006] The invention relates to a battery component holder for a battery housing for receiving battery components. The invention further relates to a battery housing. The invention further relates to a traction battery. The invention further relates to a motor vehicle, in particular an electric car. The invention also relates to a method for mounting a battery component holder.

[0007] New-generation traction batteries are often designed according to the "gel-to-pack" principle, where battery cells are integrated directly into the battery housing instead of being housed in separate modules. This is achieved by fully bonding or embedding the cells in potting compounds such as medium-density polyurethane foams, which ensure adhesion to the cells and the housing and act as electrical and thermal insulators. This design allows for a more compact battery construction with the same capacity compared to conventional modular batteries.

[0008] However, this method has several technological disadvantages. The process of casting and curing the potting compound is difficult to control and time-consuming, which increases the battery's manufacturing costs. There is a risk that page 2 / 39

[0009] P81032DE

[0010] Potting compound may seep into unintended areas of the battery casing or incompletely fill the intended areas, which can impair mechanical and thermal performance. Furthermore, the cured potting compound may exhibit inhomogeneous density. Preventing this requires complex manufacturing steps, thus increasing the production costs of these batteries.

[0011] Another significant disadvantage is recyclability. Particularly with battery casings made of plastics or fiber-reinforced plastics, complex surface pretreatment is required to ensure sufficient adhesion. Separating the potting compound from these materials during the recycling process is even more difficult than with metal casings, considerably hindering recyclability.

[0012] There is therefore a need for a battery that combines the advantages of low weight with the advantages of low manufacturing costs and high recyclability.

[0013] The invention is therefore based on the objective of providing a battery component holder for a battery housing for receiving battery components, which has a low weight, can be manufactured cost-effectively and also has a high recyclability.

[0014] The problems underlying the invention are solved by a battery component holder for a battery housing for receiving battery components, having the features of claim 1 of the present invention. Advantageous embodiments are described in the dependent claims.

[0015] More precisely, the problem underlying the invention is solved by a battery component holder for a battery - Page 3 / 39

[0016] P81032DE Housing for receiving battery components, the battery component holder comprising a housing body and at least one retaining element, wherein the housing body has at least one receiving device for receiving at least one battery component, wherein the housing body consists at least partially of a particle foam, wherein the retaining element has at least one bearing surface and at least one connecting element, wherein the retaining element is configured to fix a battery component located in the receiving device when the battery component holder is mounted, wherein the retaining element, when the battery component holder is mounted, bears at least partially with its bearing surface against a surface of a battery component located in the receiving device and is thus connected to the housing body.that at least one connecting element penetrates at least partially into the housing body and thereby forms a form-fit and / or material-fit connection with the housing body.

[0017] The battery component holder according to the invention has the advantage of being particularly lightweight. This is achieved by making the housing body of the battery component holder at least partially, and preferably entirely, from a particle foam that has a particularly low density and high specific strength. The battery component holder according to the invention also has the advantage of being particularly cost-effective to manufacture. This is achieved by using a retaining element to fix the battery component, thus avoiding the need for complex gluing or screwing processes, as are common in the prior art. Furthermore, the battery component holder according to the invention has the advantage that a battery component held in the receiving device is securely and vibration-resistantly held by means of the retaining element.Fixation is achieved solely by radially extending into the recording area - page 4 / 39.

[0018] The P81032DE device's extending fixing ribs would not be securely held due to the choice of material (particle foam). The battery component holder according to the invention also has the advantage of being particularly recyclable. This is achieved because, unlike the prior art method of completely embedding the battery components in a plastic, the battery components can be separated from the housing body without damage and with minimal effort, and thus processed separately.

[0019] The battery component holder is designed to accommodate battery components. The battery components are preferably designed as battery cells. The battery cells are preferably designed as cylindrical battery cells. Furthermore, it is also possible for the battery components to be designed as battery modules.

[0020] Preferably, the battery housing is designed as a traction battery housing for a traction battery of an electrically powered motor vehicle. Preferably, the traction battery housing is mountable on the body of a motor vehicle.

[0021] According to the invention, the housing body is designed to receive battery components. For this purpose, the housing body has receiving devices. A receiving device can be a cavity in the housing body. In particular, a receiving device can be a cavity that at least partially encloses a battery component in the assembled state of the battery component holder. The receiving device can essentially have the shape and dimensions of the battery component.

[0022] If the receiving device essentially has the shape and dimensions of the increasing battery component, this can be seen on page 5 / 39.

[0023] The P81032DE has the advantage that the battery component can be easily and compactly mounted and secured in the holder. This results in advantages regarding the weight and manufacturing costs of the battery component holder.

[0024] According to the invention, the housing body consists at least partially of a particle foam. A particle foam is a lightweight, closed-cell and / or open-cell foam material made up of pre-expanded polymer foam particles, which are shaped by heat and pressure, where they bond to form a solid material. Preferably, the housing body consists of EPP (expanded polypropylene), EPA (expanded polyamide), EPC (expanded polystyrene), mPPE (modified polyphenylene ether), or, more generally, a thermoplastic particle foam.

[0025] If the housing body is made of EPP, EPA, EPC or mPPE, it can be manufactured particularly easily and cost-effectively. Furthermore, there can be advantages in terms of recyclability.

[0026] The battery component holder has at least one retaining element. In one embodiment, the battery component holder has as many retaining elements as there are receiving devices. This can result in the advantage of particularly simple assembly and therefore lower manufacturing costs for the battery component holder.

[0027] In another embodiment, the battery component holder can also have multiple retaining elements per mounting device. This allows the individual retaining elements to be made smaller, resulting in the advantage of a lower weight for the battery component holder. Page 6 / 39

[0028] P81032DE

[0029] Preferably, the contact surface of the retaining element is planar. This can have the effect that the retaining element lies against the housing body in a particularly space-saving manner, resulting in advantages with regard to the installation space and thus the weight of the battery component holder.

[0030] The contact surface can be completely closed.

[0031] Preferably, in areas where no fasteners are located, the retaining element has a smaller thickness, measured in a direction perpendicular to the bearing surface, than its width and / or depth, measured in a direction parallel to the bearing surface. In particular, the width and / or depth can be at least three times, preferably at least five times, and more preferably at least seven times the thickness. Preferably, the retaining element is essentially disc-shaped.

[0032] This allows the volume of the holding element to be reduced, resulting in advantages in terms of the weight and manufacturing costs of the battery component holder.

[0033] Preferably, all connecting elements are arranged on the same side of the retaining element. This can result in a particularly space-saving design, which can offer advantages in terms of manufacturing costs and the weight of the battery component holder. However, designs are also conceivable in which connecting elements are arranged on both sides of the retaining element.

[0034] The connecting element can be formed in one piece, particularly monolithically, with the rest of the retaining element. This can result in advantages regarding the manufacturing costs of the battery component holder. Page 7 / 39

[0035] P81032DE

[0036] However, the connecting element can also be a separate component that is connected to the rest of the retaining element. This can result in advantages regarding the manufacturing costs of the battery component holder.

[0037] Preferably, the retaining element has more than one, more preferably at least three, more preferably at least six connecting elements.

[0038] The assembled state can refer to the state in which a battery component is installed in the battery component holder. Installation of the battery component holder in the battery housing may not be necessary for this. In particular, the assembled state can refer to the state in which the housing, battery, and retaining element are fixed to each other.

[0039] “To secure a battery component located in the receiving device” can mean that the retaining element is attached to the housing body in such a way that the battery component is not movable along the main axis of the receiving device. In particular, “to secure a battery component located in the receiving device” can mean that the retaining element is attached to the housing body in such a way that any lateral freedom of movement of the battery component is prevented.

[0040] The term "attachment" can mean that the retaining element makes full contact with the surface of the battery component.

[0041] The fact that the connecting element penetrates the housing body can mean that the connecting element occupies a space that was previously occupied by the housing body in a state where the battery component holder is not yet mounted, in particular where the retaining element is not yet connected to the housing body. Preferably, the connecting element displaces page 8 / 39

[0042] P81032DE displaces a portion of the housing body during penetration into the housing body. This displacement can occur both mechanically and as a result of at least partial melting of the housing body material. However, other displacement mechanisms are also conceivable.

[0043] If the connecting element displaces part of the housing body, a particularly space-saving design can result, which can have advantages in terms of manufacturing costs and the weight of the battery component holder.

[0044] A positive-locking connection between the connecting element of the retaining element and the housing body can be achieved by the housing body and / or the connecting element deforming during its penetration into the housing body in such a way that the housing body engages an undercut of the connecting element. This undercut can form during the penetration into the housing body. Furthermore, it is also possible that the connecting element already has an undercut before penetrating the housing body.

[0045] The connecting element and the housing body can be made of different materials. The materials of the connecting element and the housing body can have different melting points.

[0046] For example, the melting point of the fastener may be lower than the melting point of the housing body. This can, in particular, cause the fastener to deform as it penetrates the housing body and may form an undercut. Page 9 / 39

[0047] P81032DE

[0048] For example, the melting temperature of the fastener may be higher than the melting temperature of the housing body. This can, in particular, lead to the housing body being better able to adapt to and engage an undercut of the fastener during its penetration into the housing body.

[0049] A material-fit connection between the connecting element of the retaining element and the housing body can be achieved by welding the connecting element to the housing body during its penetration into the housing body. For example, the connecting element is driven into the housing body using an ultrasonic head and welded to it.

[0050] Alternatively, the materially sound connection between the connecting element of the retaining element and the housing body can also be achieved by bonding.

[0051] The connecting element and the housing body can be made of different materials. Preferably, the materials of the connecting element and the housing body are weldable.

[0052] The connecting element and the housing body can be made from the same materials.

[0053] According to an advantageous embodiment, the connecting element extends perpendicularly away from the bearing surface.

[0054] This allows the connecting element to penetrate the housing body particularly easily, resulting in advantages regarding the manufacturing costs of the battery component holder. Page 10 / 39

[0055] P81032DE

[0056] The term "perpendicular" in this context also encompasses all directions that deviate from a strictly mathematically perpendicular orientation within the scope of normal manufacturing tolerances. "Starting from the bearing surface" can mean that the connecting element is directly connected to the bearing surface.

[0057] According to an advantageous embodiment, the cross-section of the connecting element, which lies in a plane parallel to the bearing surface, decreases with increasing distance from the bearing surface or the cross-section is constant.

[0058] This prevents undercuts from forming in the housing body when the connecting element is inserted, which would reduce the effective contact area between the connecting element and the housing body. This can result in advantages regarding the manufacturing costs and weight of the battery component holder.

[0059] If the cross-section tapers, the connecting element can penetrate the housing body more easily. If the cross-section is constant, there may be advantages in terms of manufacturing costs.

[0060] If the cross-section decreases, it is preferable that the cross-section decreases uniformly. This allows the connecting element to penetrate the housing body particularly easily.

[0061] If the cross-section decreases, it may be provided in a further embodiment that the cross-section is at least partially composed of several partial surfaces. In particular, it may be provided that the connecting element has several toothed projections pointing in the direction of extension of the connecting element. (See page 11 / 39)

[0062] P81032DE

[0063] If the connecting element has several jagged protrusions, this can result in the advantage of reduced manufacturing costs for the battery component holder.

[0064] According to an advantageous embodiment, it is provided that a materially bonded connection between the at least one connecting element and the housing body was created by mechanical excitation, in particular by ultrasonic welding.

[0065] This eliminates the need for additional bonding agents and high thermal energy input, making it particularly easy to create a material-fit connection between the connecting element and the housing body. This can offer advantages in terms of manufacturing costs and the weight of the battery component holder. Furthermore, avoiding additional bonding agents can improve recyclability.

[0066] Mechanical excitation can be a method for initiating and maintaining periodic movements or oscillations in a physical system through the application of external mechanical forces or energy.

[0067] Ultrasonic welding can be a process used to join materials, especially plastics and metals, through the use of high-frequency vibrations.

[0068] According to an advantageous embodiment, it is provided that the at least one connecting element has at least one recess, preferably that the at least one recess extends perpendicularly to the bearing surface on a side surface of the at least one connecting element.

[0069] This increases the contact area between the connecting element and the housing body, so that the connecting elements page 12 / 39

[0070] The P81032DE can be designed smaller because an enlarged contact surface is implemented between the connecting element and the housing body. This can result in advantages regarding the manufacturing costs and weight of the battery component holder.

[0071] In this context, a side surface can be a surface of the connecting element that is essentially perpendicular to the bearing surface.

[0072] Preferably, the recess takes the form of an elongated groove extending over at least part of the connecting element. This allows the advantages mentioned above regarding manufacturing costs and weight to be achieved particularly efficiently.

[0073] Preferably, the connecting element has more than one, and more preferably at least three, recesses, each of which is designed as an elongated groove.

[0074] According to an advantageous embodiment, it is provided that the at least one connecting element has a taper in its cross-section, in particular a point, on its side facing away from the bearing surface.

[0075] This allows the connecting element to penetrate the housing body particularly easily. This can result in advantages regarding the manufacturing costs of the battery component holder.

[0076] The cross-section can preferably be measured in a plane parallel to the support surface.

[0077] The connecting element can have one point. However, the connecting element can also have multiple points. This can result in a more advantageous load distribution when the material penetrates (page 13 / 39).

[0078] P81032DE

[0079] Connecting element into the housing body, thus resulting in an advantage in terms of the manufacturing costs of the battery component holder.

[0080] In one embodiment, the connecting element has a taper only in its half facing away from the contact surface, preferably in its third facing away from the contact surface. This can result in an advantageous load distribution in the connecting element, which can have benefits with regard to the weight of the battery component holder.

[0081] According to an advantageous embodiment, it is provided that the at least one connecting element has the shape of a circular arc, in particular a full circle, in cross-section along a plane parallel to the bearing surface.

[0082] This results in a particularly even load distribution on the retaining element, allowing the retaining element to be made smaller. This can offer advantages in terms of manufacturing costs and the weight of the retaining element.

[0083] If at least one connecting element has the shape of a circular arc in cross-section along a plane parallel to the bearing surface, the overall shape of the connecting element can be that of a cylinder or hollow cylinder.

[0084] The cross-section along the extension of the connecting element can be constant, at least in sections, in a direction perpendicular to the bearing surface. However, the cross-section can also be variable, particularly tapering. In this case, the connecting element takes the form of a conical cylinder or a hollow cylinder.

[0085] The connecting element can form a complete circle in its cross-section. However, the connecting element can also simply be page 14 / 39

[0086] P81032DE forms a circular segment. In particular, the retaining element can then have several connecting elements, which are preferably arranged along a circular path on the bearing surface of the retaining element. If the connecting element forms only a circular segment in its cross-section, especially if the retaining element has several connecting elements arranged along a circular path, this can simplify the joining method of the retaining element to the housing body, which can result in advantages with regard to manufacturing costs.

[0087] According to an advantageous embodiment, it is provided that the largest dimension of the connecting element in a direction perpendicular to the bearing surface is larger than the smallest dimension of the connecting element in a direction parallel to the bearing surface, preferably that the largest dimension of the connecting element in a direction perpendicular to the bearing surface is at least twice as large as the smallest dimension of the connecting element in a direction parallel to the bearing surface.

[0088] This allows the connecting element to penetrate particularly deep into the housing body, enabling it to be made smaller. This can offer advantages in terms of manufacturing costs and the weight of the battery component holder.

[0089] The largest dimension of the connecting element in a direction perpendicular to the bearing surface can be the length of the longest perpendicular that can be dropped from a point on the surface of the connecting element to the bearing surface. The smallest dimension of the connecting element in a direction parallel to the bearing surface can be the shortest distance that can be formed in a plane parallel to the bearing surface between two points on the surface of the connecting element. Page 15 / 39

[0090] P81032DE

[0091] Preferably, the largest dimension of the connecting element in a direction perpendicular to the bearing surface is at least twice as large as the smallest dimension of the connecting element in a direction parallel to the bearing surface. More preferably, it can also be at least three times as large, and even more preferably at least four times as large.

[0092] According to an advantageous embodiment, the bearing surface is at least partially formed by an annular element, wherein either the at least one connecting element extends perpendicularly from this annular element, or the at least one connecting element extends from a projection laterally from the annular element, in particular perpendicular to the bearing surface, wherein the projection preferably lies in a plane with the bearing surface.

[0093] This can result in a particularly advantageous load distribution and thus benefits regarding the weight of the battery component holder.

[0094] The edges of the ring-shaped element can be smooth. However, the edges of the ring-shaped element can also be wavy, or the ring-shaped element can have one or more lateral indentations and / or projections. This can result in advantages regarding the manufacturing costs of the battery component holder.

[0095] If at least one connecting element extends from a projection extending laterally from the ring-shaped element, the area of ​​the projection can correspond to the base area of ​​the connecting element. Therefore, the connecting element can then be attached laterally to the ring-shaped element. Page 16 / 39

[0096] P81032DE

[0097] According to an advantageous embodiment, the retaining element and the housing body are made of weldable materials, preferably of the same material.

[0098] If the retaining element and the housing body are made of weldable materials, especially the same material, they are particularly easy to weld, which can result in advantages in terms of manufacturing costs.

[0099] However, it is also conceivable that the retaining element and the housing body are made of different materials. This allows the respective materials of the retaining element and the housing body to be best adapted to the specific requirements.

[0100] The at least one connecting element and the housing body can be made of polypropylene, polyamide, polycarbonate, polyphenyl ether or any combination of these materials, provided they are weldable, and in particular the respective material for the housing body can be designed as particle foam.

[0101] According to an advantageous embodiment, the holding element has an opening, preferably that the opening is smaller than the largest cross-section of the receiving device.

[0102] An opening inside the ring-shaped element allows access to the contact surfaces of the battery element. This can offer advantages in terms of the manufacturing costs of the battery component holder. Such an opening can also result in weight savings for the battery component holder. Furthermore, a battery component arranged in the receiving device can be connected to a page 17 / 39 via such an opening in the holding element.

[0103] P81032DE

[0104] The cooling fluid can be brought into contact with the battery, which is particularly advantageous for thermal management of the battery components.

[0105] If the opening is smaller than the largest cross-section of the receiving device, the retaining element can securely fix a battery component located in the receiving device, which can result in advantages regarding the manufacturing costs and weight of the battery component holder.

[0106] The opening can consist of several separate partial openings.

[0107] Preferably, the cross-section is measured here in a plane perpendicular to the main extension direction of the recording device.

[0108] According to an advantageous embodiment, the battery component holder has several retaining elements, and each retaining element has a side facing away from the support surface, wherein the respective surfaces of the facing sides of all retaining elements of the

[0109] The battery component holder lies in one plane when mounted.

[0110] If the surfaces of the multiple retaining elements facing away from the mounting surface are all in the same plane, they can be used for subsequent welding operations, particularly for welding to the base of the battery housing. This avoids the need for an additional element within the battery component holder, resulting in advantages in terms of manufacturing costs and the weight of the battery component assembly.

[0111] Preferably, the battery component holder has a retaining element for each receiving device. However, it is also conceivable, page 18 / 39

[0112] P81032DE that the battery component holder has multiple retaining elements for each receiving device.

[0113] Preferably, the housing body has sufficient elasticity so that the respective sides of all retaining elements facing away from the support surface can be brought into a plane by elastic deformation of the housing body in the assembled state to compensate for manufacturing-related geometric deviations of the housing body and the battery components, in particular taking into account the tolerance group TG7 according to DIN 16742.

[0114] Preferably, the sides facing away from the contact surface are parallel to the contact surface. This ensures a particularly space-saving installation of the retaining element, resulting in advantages in terms of manufacturing costs and the weight of the battery component.

[0115] Each retaining element can also have several surfaces facing away from the contact surface, which are preferably also aligned parallel to the contact surface. Preferably, each of these multiple contact surfaces lies in a plane. This can offer the advantage that manufacturing tolerances can be compensated for particularly easily, resulting in benefits regarding the manufacturing costs and weight of the battery components.

[0116] The present invention also aims to provide a battery housing that is particularly lightweight, can be produced at low manufacturing costs, has improved recyclability and enables secure fixing of battery components.

[0117] According to an advantageous embodiment, the battery component holder is provided to have at least two retaining elements and page 19 / 39

[0118] P81032DE the housing body shall have at least two receiving devices each for receiving a battery component, wherein the at least two retaining elements are connected to each other by means of a material bridge.

[0119] The appropriately designed battery component holder has the advantage that its assembly / construction is simplified.

[0120] The material bridge allows for a flexible distance between the retaining elements, so that the retaining elements can penetrate into the housing body to varying depths.

[0121] The material bridge is, for example, elastically designed and / or has a curved shape, so that the distance between the holding elements connected by means of the material bridge is changeable / variable.

[0122] Preferably, the battery component holder is designed such that the housing body has at least one material recess extending between a first housing body part and a second housing body part, and at least partially separating the first housing body part from the second housing body part, wherein the housing body has at least two receiving devices for receiving a number of battery components corresponding to the number of receiving devices, wherein a first receiving device is arranged in the first housing body part and a second receiving device is arranged in the second housing body part, wherein at least one retaining element has at least two connecting elements, and wherein the at least one retaining element is arranged in the assembled state of the battery component holder such thatthat a first connecting element penetrates the first housing body part and thereby forms a form-fit and / or material-fit connection with the first housing body part, and that a second connecting element penetrates the second housing body part and there- Page 20 / 39,

[0123] P81032DE enters into a form-fitting and / or material-fitting connection with the second housing body part.

[0124] The appropriately designed battery component holder offers the advantage that battery components held or arranged in the mounting devices can be better temperature controlled or cooled, while maintaining high rigidity of the battery component holder. This is because the material recess can be used to allow the passage of a cooling fluid, thus improving temperature control of the housing body and, consequently, of the battery components held in the respective mounting devices. Due to the penetration of the first connecting element of the at least one retaining element into the first housing body part and the penetration of the second connecting element of the at least one retaining element into the second housing body part, the at least one retaining element connects the first housing body part to the second housing body part, thereby increasing the stability of the battery component holder.

[0125] Preferably, the at least one material recess is arranged in the housing body such that the first receiving device and / or the second receiving device is / are open towards the material recess. Consequently, the material recess "intersects" the first receiving device and / or the second receiving device. Thus, the material recess is in direct fluid communication with the first receiving device and / or the second receiving device. A corresponding design of the battery component holder enables further improved cooling of the battery components that can be inserted into the receiving device.

[0126] The problem underlying the present invention is solved by a battery housing for accommodating a large number of battery components, comprising a first battery housing component. Page 21 / 39

[0127] P81032DE component, a second battery housing component and at least one previously described battery component holder, wherein the battery component holder is arranged sandwich-like between the first battery housing component and the second battery housing component, and wherein the battery component holder is connected to the first battery housing component and / or to the second battery housing component, preferably in a mechanically connected manner.

[0128] The battery housing according to the invention has the advantage of improved recyclability. Because a complex potting compound is not used in the battery housing, recycling is possible without the need for complex separation processes to separate the potting compound from the battery housing components. Furthermore, the battery housing according to the invention has the advantage of improved torsional and bending stiffness. Because the battery component holder is connected to the first battery housing component and / or to the second battery housing component, the battery housing can better withstand shear and bending forces.Finally, the battery housing according to the invention has the advantage that the battery housing has improved electrical and thermal insulation between the battery components, in particular battery cells, that can be accommodated in the battery housing.

[0129] The feature according to which the battery component holder is sandwiched between the first battery housing component and the second battery housing component can also be expressed as the battery component holder being arranged as a sandwich core between the first battery housing component and the second battery housing component. Consequently, the battery component holder can also be referred to as a sandwich core. Page 22 / 39

[0130] P81032DE

[0131] The first battery housing component is preferably designed as a battery housing shell. The first battery housing component can also be referred to as the battery housing lower shell or, more generally, as the lower shell.

[0132] The second battery housing component is preferably designed as a battery housing shell or a battery housing cover, the battery housing cover also being designed as a battery housing shell. The second battery housing component can also be referred to as the battery housing upper shell or, more generally, as the upper shell.

[0133] The first battery housing component and / or the second battery housing component are made of or comprised of a plastic, in particular a fiber-reinforced plastic. The plastic may be a thermoplastic. The material of the first battery housing component and / or the second battery housing component may be such that it is weldable with the material of the battery component holder.

[0134] The receiving devices of the battery component holder are designed as receiving recesses and / or as through-openings in the battery component holder.

[0135] A battery housing designed in this way has the advantage that the battery components can be more easily inserted into the receiving devices of the battery component holder of the battery housing.

[0136] Preferably, the receiving devices of the battery component holder have a first receiving opening and / or a second receiving opening. The first receiving opening is preferably opposite a base surface of the first battery housing component. Page 23 / 39

[0137] P81032DE is arranged superimposed. The second receiving opening is preferably arranged opposite a base surface of the second battery housing component. A battery component can be inserted into the receiving device through the first receiving opening or the second receiving opening.

[0138] The receiving devices of the battery component holder can also be referred to as receiving cavities.

[0139] Preferably, the battery housing is designed such that the height of the battery component holder is greater than or equal to the height of the battery components.

[0140] A battery housing designed in this way has the advantage that battery components, especially battery cells, can be positioned more effectively in the receiving devices of the battery component holder.

[0141] In the installed position of the battery housing, for example in a motor vehicle, the height extension of the battery components and the height extension of the battery component holder run in a vertical direction.

[0142] The present invention also aims to provide a battery which has a low weight and low manufacturing costs and at the same time has improved efficient recyclability.

[0143] The problem underlying the present invention is solved by a traction battery comprising at least one previously described battery component holder or battery housing and a plurality of battery components, each of which is received in a receiving device of the battery component holder. Page 24 / 39

[0144] P81032DE

[0145] The present invention also aims to provide a motor vehicle which has a battery with a low weight and improved efficient recyclability.

[0146] This problem underlying the present invention is solved by a motor vehicle, in particular an electric car, with a previously described traction battery which is energy-coupled with an electric motor of the motor vehicle.

[0147] The present invention also aims to provide a method for assembling a previously described battery component holder.

[0148] The problem underlying the present invention is solved by a method for assembling a previously described battery component holder, wherein a battery component is inserted into the receiving device such that an end face of the battery component is flush against an end face of the receiving device, a retaining element is brought towards the housing body with its bearing surface pointing towards the receiving device until the at least one connecting element contacts the housing body, the at least one connecting element is moved further towards the receiving device until the bearing surface is flush against the surface of the housing body or against the rear surface of the battery component, and thereby a mechanical excitation, in particular ultrasonic waves, is introduced into the retaining element and / or the housing body.where a materially sound connection is formed between the connecting elements and the housing body.

[0149] Further advantages, details and features of the invention will become apparent from the illustrated examples below. Page 25 / 39

[0150] P81032DE

[0151] Specifically, they show:

[0152] Figure 1: a sectional view of a battery component holder according to a first embodiment;

[0153] Figure 2: a sectional view of a battery component holder with two receiving devices according to a second embodiment;

[0154] Figure 3: a sectional view of a retaining element according to six different design forms in the image parts a) to f);

[0155] Figure 4: a top view of a retaining element according to a first embodiment in image part a), according to a second embodiment in image part b), according to a third embodiment in image part c) and according to a fourth embodiment in image part d);

[0156] Figure 5: a perspective view of a battery component holder according to a third embodiment;

[0157] Figure 6: a sectional view of a battery housing according to a first embodiment; and

[0158] Figure 7: a flow diagram of a method for assembling a battery component holder according to the invention.

[0159] In the following description, the same reference symbols denote the same components or the same features, so that a description given with respect to one figure regarding a component also applies to the other figures, so that a repetition- Page 26 / 39

[0160] P81032DE The description is avoided. Furthermore, individual features that have been described in connection with one version can also be used separately in other versions.

[0161] Figure 1 shows a sectional view of a battery component holder 1 for a battery housing for receiving battery components 2, the battery component holder 1 comprising a housing body 3, at least one retaining element 4, wherein the housing body 3 has at least one receiving device 5 for receiving at least one battery component 2, wherein the housing body 3 consists at least partially of a particle foam, wherein the retaining element 4 has at least one bearing surface 6 and at least one connecting element 7, wherein the retaining element 4 is configured to fix a battery component 2 located in the receiving device 5 when the battery component holder 1 is mounted.wherein the retaining element 4, in the assembled state of the battery component holder 1, at least partially rests with its bearing surface 6 on a surface of a battery component 2 located in the receiving device 5 and is connected to the housing body 3 in such a way that the at least one connecting element 7 penetrates at least partially into the housing body 3 and thereby forms a materially interlocking connection with the housing body 3.

[0162] In one embodiment, it is provided that the materially bonded connection between the at least one connecting element 7 and the housing body 3 was produced by mechanical excitation, in particular by ultrasonic welding.

[0163] The retaining element 4 shown here has an opening 11, where the opening 11 is smaller than the largest cross-section of the receiving device 5. Page 27 / 39

[0164] P81032DE

[0165] The battery component holder 1 can have one or more receiving devices 5 for receiving battery components 2. According to an embodiment shown in Figure 2, the battery component holder 1 has two receiving devices 5.

[0166] In the exemplary embodiment shown in Figure 1, the retaining element 4 and the housing body 3 are made of weldable materials, wherein the retaining element 4 and the housing body 3 are made of the same material.

[0167] In the embodiment shown in Figure 2, the battery component holder 1 has several retaining elements 4, each retaining element 4 having a side 12 facing away from the support surface 6, wherein the respective surfaces of the facing sides 12 of all retaining elements 4 of the battery component holder 1 lie in a plane A in the assembled state.

[0168] Figure 3 shows a sectional view of a total of six different embodiments of a retaining element 4. It can be seen that in the embodiments shown here, the connecting element 7 extends perpendicularly away from the support surface 6.

[0169] In the embodiments shown in Figure 3, it is evident that the cross-section of the connecting element 7, which lies in a plane parallel to the bearing surface 6, decreases with increasing distance from the bearing surface 6 or the cross-section is constant.

[0170] In the figure parts 3b) and 3c), embodiments of which are shown are shown, in which the at least one connecting element 7 has at least one recess 8, preferably that the at least one recess 8 is located on a side surface of the less-page 28 / 39

[0171] P81032DE tens a connecting element 7 extends perpendicularly to the support surface 6 .

[0172] In the figure parts 3c) to 3f), embodiments are disclosed in which the at least one connecting element 7 has a tapering of its cross-section, in particular at least one point, on its side facing away from the bearing surface 6.

[0173] In the embodiments shown in Figure 3, the largest dimension of the connecting element 7 in a direction perpendicular to the bearing surface 6 is larger than the smallest dimension of the connecting element 7 in a direction parallel to the bearing surface 6, wherein the largest dimension of the connecting element 7 in a direction perpendicular to the bearing surface 6 is at least twice as large as the smallest dimension of the connecting element 7 in a direction parallel to the bearing surface 6.

[0174] Figure 4 shows four different versions of the retaining element 4 in a top view, with the bearing surface 6 visible.

[0175] Figure 4a shows a section of a retaining element 4, wherein the bearing surface 6 is at least partially formed by an annular element 9, and wherein the at least one connecting element 7 extends perpendicularly from this annular element 9. The at least one connecting element 7 has the cross-sectional shape of a full circle along a plane parallel to the bearing surface 6. The connecting element 7 has three recesses 8.

[0176] Figure 4b shows a version in which the connecting element 7 takes the form of a broken circular arc. Page 29 / 39

[0177] P81032DE

[0178] Figure 4c also shows an embodiment of the connecting element, in which the bearing surface 6 is formed by a ring-shaped element 9, but there is no opening 11 inside the retaining element 4.

[0179] Figure part 4d) of fenbart shows an embodiment in which the bearing surface 6 is at least partially formed by an annular element 9, wherein the at least one connecting element 7 extends perpendicularly to the bearing surface 6 from a projection 10 laterally extending from the annular element 9, wherein the projection 10 lies in a plane with the bearing surface 6.

[0180] Figure 5 shows a perspective view of a battery component holder 1 according to a third embodiment. In the battery component holder 1 shown in Figure 5, the housing body 3 has a plurality of material recesses 3'. Reference is made below to the material recess 3' shown furthest to the right in Figure 5. The material recess 3' extends between a first housing body part 3_1 and a second housing body part 3_2 and at least partially separates the first housing body part 3_1 from the second housing body part 3_2. The housing body 3 has a plurality of receiving devices 5 for receiving a number of battery components 2 corresponding to the number of receiving devices 5. First receiving devices 5_1 are arranged in the first housing body part 3_1 and second receiving devices 5_2 are arranged in the second housing body part 3_2.

[0181] Figure 5 shows that the retaining elements 4 are designed as shown in Figure 4d. Consequently, the retaining elements 4 each have at least two connecting elements 7, which are not visible in Figure 5 because the connecting elements 7 are each arranged inside the housing body. Page 30 / 39

[0182] P81032DE

[0183] The following refers by way of example to the retaining element 4 shown in the lower right of Figure 5. In the illustrated assembled state of the battery component holder 1, the retaining element 4 is arranged such that a first connecting element 7 penetrates the first housing body part 3_1 and thereby forms a form-fit and / or material-fit connection with the first housing body part 3_1, and that a second connecting element 7 penetrates the second housing body part 3_2 and thereby forms a form-fit and / or material-fit connection with the second housing body part 3_2.

[0184] Figure 6 of fenbart shows a battery housing 13 for receiving a plurality of battery components 2, comprising a first battery housing component 14, a second battery housing component 15, and at least one previously disclosed battery component holder 1, wherein the battery component holder 1 is arranged sandwich-like between the first battery housing component 13 and the second battery housing component 14, and wherein the battery component holder 1 is connected to the first battery housing component 14 and / or to the second battery housing component 15, preferably by means of a butt joint.

[0185] Figure 7 of fenbart shows a flowchart for a method for assembling a battery component holder 1, wherein a battery component 2 is inserted into the receiving device 5 such that an end face of the battery component 2 is flush against an end face of the receiving device 5, a retaining element 4 with its bearing surface 6 pointing towards the receiving device 5 is brought towards the housing body 3 until the at least one connecting element 7 contacts the housing body 3, the at least one connecting element 7 is moved further towards the receiving device 5 until the bearing surface 6 is flush against the surface of the housing body 3 or against the rear surface of the battery component 2, page 31 / 39

[0186] P81032DE and thereby a mechanical excitation, in particular ultrasonic waves, is introduced into the retaining element 4 and / or the housing body 3, whereby a mechanically close connection is formed between the connecting elements 7 and the housing body 3.

[0187] Page 32 / 39

[0188] P81032DE

[0189] Reference symbol list

[0190] 1 Battery component holder

[0191] 2 Battery component

[0192] 3 Housing bodies

[0193] 3_1 first housing body part

[0194] 3_2 second housing body part

[0195] 3 ' Material recess

[0196] 4 retaining elements

[0197] 5 Receiving facility

[0198] 5_1 first reception facility

[0199] 5_2 second reception facility

[0200] 6 Support surface

[0201] 7 Connecting element

[0202] 8 In-depth study

[0203] 9 Ring-shaped element

[0204] 10 lead

[0205] 11 Opening

[0206] 12. Far-facing side

[0207] 13 Battery housings

[0208] 14 First battery housing component

[0209] 15 Second battery housing component

Claims

Page 33 / 39 Applicant: KAUTEX TEXTRON GmbH & Co. KG Our reference number: P81032DE Patent claims 1. Battery component holder (1) for a battery housing for receiving battery components (2), the battery component holder (1) comprising a housing body (3), at least one retaining element (4), wherein the housing body (3) has at least one receiving device (5) for receiving at least one battery component (2), wherein the housing body (3) consists at least partially of a particle foam, wherein the retaining element (4) has at least one bearing surface (6) and at least one connecting element (7), wherein the retaining element (4) is configured to fix a battery component (2) located in the receiving device (5) when the battery component holder (1) is mounted.wherein the retaining element (4) in the assembled state of the battery component holder (1) bears at least partially with its bearing surface (6) against a surface of a battery component (2) located in the receiving device (5) and is connected to the housing body (3) in such a way that the at least one connecting element (7) penetrates at least partially into the housing body (3) and thereby forms a form-fit and / or material-fit connection with the housing body (3).

2. Battery component holder (1) according to claim 1, characterized in that the at least one connecting element (7) extends perpendicularly from the support surface (6). Page 34 / 39 P81032DE extends away from the support surface (6).

3. Battery component holder (1) according to one of claims 1 or 2, characterized in that the cross-section of the at least one connecting element (7) which lies in a plane parallel to the support surface (6) decreases with increasing distance from the support surface (6) or the cross-section is constant.

4. Battery component holder (1) according to one of claims 1 to 3, characterized in that a materially bonded connection between the at least one connecting element (7) and the housing body (3) was produced by mechanical excitation, in particular by ultrasonic welding.

5. Battery component holder (1) according to one of claims 1 to 4, characterized in that the at least one connecting element (7) has at least one recess (8), preferably in that the at least one recess (8) extends perpendicularly to the bearing surface (6) on a side surface of the at least one connecting element (7).

6. Battery component holder (1) according to one of claims 1 to 5, characterized in that the at least one connecting element (7) has a tapering of its cross-section, in particular at least one tip, on its side facing away from the bearing surface (6).

7. Battery component holder (1) according to one of claims 1 to 6, characterized in that the at least one connecting element (7) has the shape of a circular arc, in particular a full circle, in cross-section along a plane parallel to the bearing surface (6). - 34- Page 35 / 39 P81032DE 8. Battery component holder (1) according to one of claims 1 to 7, characterized in that the largest dimension of the connecting element (7) in a direction perpendicular to the support surface (6) is larger than the smallest dimension of the connecting element (7) in a direction parallel to the support surface (6), preferably that the largest dimension of the connecting element (7) in a direction perpendicular to the support surface (6) is at least twice as large as the smallest dimension of the connecting element (7) in a direction parallel to the support surface (6).

9. Battery component holder (1) according to one of claims 1 to 8, characterized in that the bearing surface (6) is formed at least partially by an annular element (9), wherein either the at least one connecting element (7) extends perpendicularly from this annular element (9), or the at least one connecting element (7) extends from a projection (10) laterally projecting from the annular element (9), in particular perpendicular to the bearing surface (6), wherein the projection (10) preferably lies in a plane with the bearing surface (6).

10. Battery component holder (1) according to one of claims 1 to 9, characterized in that the retaining element (4) and the housing body (3) are made of weldable materials, preferably of the same material.

11. Battery component holder (1) according to one of claims 1 to 10, characterized in that the retaining element (4) has an opening (11), preferably that the opening (11) is smaller than the largest cross-section of the receiving device (5) .

12. Battery component holder (1) according to one of claims 1 to 11, characterized in that Page 36 / 39 P81032DE the battery component holder (1) has at least two retaining elements (4) and the housing body (3) has at least two receiving devices (5) each for receiving a battery component (2), wherein the at least two retaining elements (3) are connected to each other by means of a material bridge.

13. Battery component holder (1) according to one of claims 1 to 12, characterized in that the housing body (3) has at least one material recess (3') extending between a first housing body part (3_1) and a second housing body part (3_2) and at least partially separating the first housing body part (3_1) from the second housing body part (3_2), wherein the housing body (3) has at least two receiving devices (5) for receiving a number of battery components (2) corresponding to the number of receiving devices (5), wherein a first receiving device (5_1) is arranged in the first housing body part (3_1) and a second receiving device (5_2) is arranged in the second housing body part (3_2), wherein at least one retaining element (4) has at least two connecting elements (7), wherein the at least one retaining element (4) is arranged in the assembled state of the battery component holder (1) such thatthat a first connecting element (7) penetrates the first housing body part (3_1) and thereby forms a form-fit and / or material-fit connection with the first housing body part (3_1), and that a second connecting element (7) penetrates the second housing body part (3_2) and thereby forms a form-fit and / or material-fit connection with the second housing body part (3_2). Page 37 / 39 P81032DE 14. Battery housing (13) for receiving a plurality of battery components (2) , comprising a first battery housing component (14) ; a second battery housing component (15) ; and at least one battery component holder (1) according to any one of claims 1 to 13, wherein the battery component holder (1) is arranged sandwich-like between the first battery housing component (13) and the second battery housing component (14), and wherein the battery component holder (1) is connected to the first battery housing component (14) and / or to the second battery housing component (15), preferably by a material bond.

15. Traction battery comprising at least one battery component holder (1) according to any one of claims 1 to 13 or a battery housing according to claim 14; and a plurality of battery components (2) each being received into a receiving device (5) of the battery component holder (1).

16. Motor vehicle, in particular electric car, with a traction battery according to claim 15, which is energy-coupled with an electric motor of the motor vehicle.

17. Method for mounting a battery component holder (1) according to one of claims 1 to 13, characterized in that a battery component (2) is inserted into the receiving device (5) such that an end face of the battery component (2) is flush against an end face of the receiving device (5), - 37- Page 38 / 39 P81032DE a retaining element (4) with its support surface (6) pointing towards the receiving device (5) is brought towards the housing body (3) until the at least one connecting element (7) touches the housing body (3), - the at least one connecting element (7) further into direction of the receiving device (5) is moved until the contact surface (6) is flush with the surface of the housing body (3) or with the rear surface of the battery component (2), thereby introducing a mechanical excitation, in particular ultrasonic waves, into the retaining element (4) and / or the housing body (3), resulting in a materially bonded connection between the connecting elements (7) and the housing body (3). - 38-

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