Battery housing component having an electromagnetically insulating layer, traction battery housing, traction battery, motor vehicle, molding tool for producing a battery housing component, and method for producing a battery housing component

Abstract

The invention relates to a battery housing component (1) having a housing wall (10), which comprises a plastic, and an electromagnetically insulating layer (20), wherein the housing wall (10) has a first portion (11) in which the housing wall (10) surrounds the electromagnetically insulating layer (20) in such a way that the electromagnetically insulating layer (20) is not accessible in the first portion (11) of the housing wall (10), and the housing wall (10) has a second portion (12) in which the electromagnetically insulating layer (20) is provided on a first face (14) of the housing wall (10) such that the housing wall (10) has, in the second portion (12) thereof, an electrically conductive contact surface (16) at which the electromagnetically insulating layer (20) is directly accessible, a penetration protection (30) being provided between the housing wall (10) and the electromagnetically insulating layer (20) in the region of the second portion (12) of the housing wall (10).

Description

[0001] Page 1 of 35

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

[0003] Our reference number: P81092DE

[0004] September 25, 2024

[0005] Battery housing component having an electromagnetically insulating layer, traction battery housing, traction battery, motor vehicle, mold for manufacturing a battery housing component and method for manufacturing a battery housing component

[0006] The invention relates to a battery housing component comprising an electromagnetically insulating layer. Furthermore, the invention relates to a traction battery housing comprising a battery housing component, a traction battery comprising at least one battery component, and a motor vehicle comprising a traction battery. Finally, the invention relates to a mold for manufacturing a battery housing component and a method for manufacturing such a battery housing component.

[0007] In the prior art, battery housings for traction batteries in electric vehicles are known, consisting of at least two connected metallic components, typically made of aluminum or steel. These housings offer effective protection against electromagnetic radiation both emanating from and acting upon the battery, for example, from radiation sources within the vehicle. A disadvantage of these metallic housings is their high weight, which can impair the efficiency and range of the vehicle. A further disadvantage of these metallic housings is their long manufacturing time and high production costs. Page 2 of 35

[0008] P81092DE

[0009] Furthermore, battery housing components for traction batteries of electric vehicles are known from the prior art. These components consist of a housing body made of thermoplastic or thermoset plastic material and a planar element made of electrically conductive material. The planar element serves to shield the battery housing component and / or the traction battery from electromagnetic radiation. This electromagnetic radiation can originate from the battery components themselves or from the environment, for example, the vehicle, and act upon the battery housing component. The planar element can consist of a metal foil, a nonwoven fabric, a woven fabric, or a conductive / polymeric foam material, or it can be a layer applied to the housing body using sputtering, painting, vapor deposition, electroplating, or adhesion-based processes.

[0010] These battery housing components have in common that, following a shaping manufacturing process of the receiving body, a further processing step is required, for example, an assembly process to apply a flat element containing electrically conductive material. Particularly when such an element is mounted on an outer side of a battery housing component, the layers can be subject to environmental influences such as undercutting by media, for example, fluids, especially liquids, and thus detach from the battery housing component. Furthermore, external elements and layers are exposed to increased stress due to direct contact with the environment and are particularly susceptible to corrosion.

[0011] The invention is based on the objective of providing a battery housing component that ensures a reliable connection between the shielding layer and the rest of the housing wall, and secure electrical contact of electrically conductive components. Page 3 / 35

[0012] P81092DE enables the use of contact surfaces for multiple housing components and simultaneously allows for cost-effective manufacturing, preferably in a single manufacturing step.

[0013] According to a first aspect of the invention, the problem underlying the invention is solved by a battery housing component having the features of claim 1. Advantageous embodiments are described in the dependent claims.

[0014] More precisely, the problem underlying the invention is solved by a battery housing component comprising a housing wall made of plastic and an electromagnetically insulating layer, wherein the housing wall has a first section in which the housing wall surrounds the electromagnetically insulating layer in such a way that the electromagnetically insulating layer is not accessible in the first section of the housing wall, and wherein the housing wall has a second section in which the electromagnetically insulating layer is arranged on a first side of the housing wall, such that the housing wall in its second section has an electrically conductive contact surface at which the electromagnetically insulating layer is directly accessible, wherein in the region of the second section of the housing wall a penetration protection is arranged between the housing wall and the electromagnetically insulating layer.

[0015] A battery housing component designed in this way has the advantage of a particularly reliable connection between the electromagnetic insulating layer and the housing wall. This is achieved by the housing wall surrounding the electromagnetic insulating layer, at least in the first section of the housing wall. This also ensures electrical insulation in the first section of the housing wall, preventing unwanted discharges from components located within the housing components' receiving volume. (Page 4 / 35)

[0016] P81092DE

[0017] The battery component is formed by the electromagnetically insulating layer. A further advantage of such a battery housing component is that it can be manufactured using a tooling system and thus in a single production step. This significantly reduces manufacturing costs and time. By using a penetration protection layer in the area of ​​the second section of the housing wall, it is possible to prevent the molten plastic forming the housing wall from surrounding the electromagnetically insulating layer during the shaping process. This keeps the electromagnetically insulating layer in the area of ​​the second section of the housing wall directly accessible and allows it to be brought into electrically conductive contact with another battery housing component, such as a cover.This eliminates the need for a separate assembly step of the electromagnetically conductive layer or a subsequent processing step following the forming process of the battery housing shell to expose an electrically conductive contact surface.

[0018] The battery housing component preferably partially limits a receiving volume and is preferably designed to receive at least one battery component in the receiving volume.

[0019] The housing wall can be made of a thermoplastic and / or a thermosetting plastic. The plastic can be polypropylene or polyamide. The plastic can contain fibers, in particular glass fibers, carbon fibers and / or Aramid fibers.

[0020] Preferably, the electromagnetically insulating layer is electrically conductive. In the area of ​​the electrically conductive contact surface, the electromagnetically insulating layer can be designed to connect to another battery housing component. Page 5 / 35

[0021] P81092DE can be glued. This allows a material-fit connection to be achieved in addition to, or as an alternative to, an electrically conductive connection between two battery housing components when the two battery housing components are assembled. This avoids difficulties with material-fit connections, especially when bonding plastics such as polypropylene.

[0022] The feature that the housing wall surrounds the electromagnetically insulating layer in the first section can also be expressed as the electromagnetically insulating layer being arranged within the housing wall in the first section, preferably completely within the housing wall. This allows for a surface quality of the housing wall sufficient for a hermetic seal in the first section.

[0023] Preferably, the battery housing component is designed such that in the area of ​​the second section of the housing wall, the electromagnetically insulating layer lies on the first side of the housing wall.

[0024] A battery housing component designed in this way has the advantage that the electromagnetic insulating layer in the second area is more easily accessible, so that an electrically conductive connection with another battery housing component can be made even more effectively.

[0025] Preferably, the battery housing component is designed such that the penetration protection and the electromagnetic insulating layer are positively connected to each other.

[0026] A battery housing component designed in this way has the advantage that the electromagnetically insulating layer is... Page 6 / 35

[0027] The P81092DE can be fixed in position in the area of ​​the second section. This ensures that an electrically conductive connection with another battery housing component can be further improved.

[0028] Preferably, the penetration protection partially surrounds the electromagnetically insulating layer, preferably from a rear side of the electromagnetically insulating layer facing away from the receiving volume. During the forming process of the battery housing component, the electromagnetically insulating layer is preferably surrounded and / or partially or completely enclosed by a molten plastic forming the housing wall, and in these areas forms the first section of the housing wall. The penetration protection prevents the electromagnetically insulating layer from being penetrated by the molten plastic, so that the housing wall forms the second section in these areas.In this process, the penetration protection can be partially pushed through the openings in the electromagnetic insulating layer by the plastic melt, so that the penetration protection partially surrounds the electromagnetic insulating layer from a rear side of the electromagnetic insulating layer facing away from the receiving volume.

[0029] Preferably, in the area of ​​the second section of the housing wall, the housing wall and the electromagnetic insulating layer are positively connected to each other. Preferably, in the area of ​​the second section of the housing wall, the housing wall partially surrounds the electromagnetic insulating layer, particularly from a rear side of the electromagnetic insulating layer facing away from the receiving volume. Because a molten plastic forming the housing wall partially pushes the penetration protection through openings in the electromagnetic insulating layer, the housing wall also partially surrounds the electromagnetic insulating layer. Page 7 / 35

[0030] P81092DE indicates a rear side of the electromagnetically insulating layer facing away from the receiving volume.

[0031] Preferably, the penetration protection is in direct contact with the electromagnetic insulating layer and is preferably connected to the electromagnetic insulating layer.

[0032] Preferably, the battery housing component is designed such that the penetration protection has an organosheet and / or a crossply or is designed as such.

[0033] A battery housing component designed in this way has the advantage that, in the area of ​​the second section of the battery housing component, increased stability is achieved due to the penetration protection, and at the same time, an improved connection between the penetration protection and the housing wall is achieved. This allows a second battery housing component to be electrically contacted more effectively with the electrically conductive contact surface of the battery housing component.

[0034] An organosheet and / or a crossply may comprise a plastic, preferably a thermoplastic and / or a thermosetting plastic. Preferably, the housing wall and the organosheet and / or the crossply comprise an identical plastic.

[0035] An organosheet and / or a crossply comprises fibers, preferably continuous fibers. An organosheet comprises a woven fiber structure. A crossply comprises a laid fiber structure. A crossply may have more than one layer of fibers, wherein the fibers are arranged overlapping each other, and the fibers in one layer may form a 90° angle with each other relative to the fibers in a layer resting on top of that layer. Page 8 / 35

[0036] P81092DE

[0037] Preferably, the battery housing component is designed such that the penetration protection has a film containing a plastic material or is designed as such.

[0038] A battery housing component designed in this way has the advantage that, during the manufacturing process, a plastic melt forming the housing wall can deform the foil more easily and thereby at least partially deform it through openings in the electromagnetic insulating layer. This allows for an improved, positive-locking connection between the housing wall, the penetration protection, and the electromagnetic insulating layer.

[0039] The film can be designed as an adhesive film. The film can be bonded to the penetration protection and / or the housing wall. The film can comprise a foam material, preferably a plastic foam material.

[0040] The plastic of the foil is preferably weldable to the plastic of the housing wall. Preferably, the plastic of the foil is identical to the plastic of the housing wall. Particularly preferably, the penetration protection material is bonded to the housing wall, especially by welding. During the forming manufacturing process, the penetration protection material can be partially melted by the molten plastic, so that a bonded connection, in particular a welded connection, is formed between the penetration protection material and the housing wall. This further improves the connection between the penetration protection material and the housing wall.

[0041] The penetration protection may consist of a plastic foam. The plastic foam, in particular the plastic foam of page 9 / 35

[0042] P81092DE

[0043] Penetration protection can be in the form of a foam bead.

[0044] In a top view of the contact surface, the penetration protection can be arranged essentially congruent with and below the contact surface. This ensures that during the manufacturing process of the battery housing component, the electromagnetic insulating layer is not enclosed and / or penetrated by the molten plastic forming the housing wall, so that the electromagnetic insulating layer remains directly accessible in the area of ​​the second section of the housing wall.

[0045] Preferably, the electromagnetically insulating layer has a plurality of through-openings.

[0046] A battery housing component designed in this way has the advantage that the electromagnetic insulating layer can be better surrounded by the housing wall. For example, in a manufacturing process of the battery housing component, the electromagnetic insulating layer can be simplified by enclosing it within a molten plastic forming the housing wall and penetrating it in the area of ​​the openings in the electromagnetic insulating layer.

[0047] The electromagnetic insulating layer can be continuous. This allows for increased shielding against electromagnetic radiation. In particular, if the battery housing component is electrically connected to another battery housing component, such as a lid, a Faraday cage can be formed that completely encloses the storage volume. Page 10 / 35

[0048] P81092DE

[0049] "Continuous" here can mean that an area formed by the electromagnetic insulating layer is closed. For example, an area stretched across by the electromagnetic insulating layer, viewed from above, has no further openings or gaps apart from the openings in the electromagnetic insulating layer.

[0050] The electromagnetic insulating layer can comprise or be designed as a fabric, preferably a wire mesh, or a knitted fabric, preferably a wire mesh, or a perforated sheet, or an expanded metal mesh, or as such.

[0051] The electromagnetic insulating layer can have a wire, wherein the wire can have a diameter of > 0.2 mm, preferably > 0.3 mm, and / or wherein the wire can have a diameter of < 1 mm, preferably < 0.5 mm.

[0052] The electromagnetic insulating layer can have a mesh size between > 0.4 mm and < 12 mm, preferably between > 0.5 mm and < 10 mm, and particularly preferably 1.5 mm. Here, the mesh size can be the clear distance between two opposing wires of the electromagnetic insulating layer. If the openings of the electromagnetic insulating layer have, for example, a rectangular or square cross-section, the mesh size can be the distance between two opposing wires of a rectangular or square opening. If the openings have, for example, a circular cross-section, the mesh size can be the diameter of the openings.

[0053] The electromagnetic insulating layer can be made of or composed of a metal, preferably aluminum and / or steel. Page 11 of 35

[0054] P81092DE

[0055] Preferably, the battery housing component is designed such that the housing wall has a circumferential connecting device designed for connection with another battery housing component, wherein the first section and the second section of the housing wall are arranged in the area of ​​the connecting device.

[0056] A battery housing component designed in this way has the advantage that it can be easily connected to another battery housing component, and in particular, electrically conductively connected. In an assembled state, this ensures improved, and especially continuous, shielding against electromagnetic radiation.

[0057] The connection device can be designed as a connecting flange. The battery housing component can be shell-shaped, and the connection device can extend away from the receiving volume.

[0058] The housing wall is preferably designed as a monolithic component. A monolithic component is manufactured from a single piece and is particularly seamless, especially without joints.

[0059] The connecting device can have a sealing surface arranged on the first side of the housing wall in the area of ​​the connecting device. Preferably, the sealing surface is formed in the area of ​​the first section of the housing wall on the first side of the housing wall. The sealing surface is preferably configured to form a sealed connection with another battery housing component or a sealing element. Preferably, the sealed connection can be a butt-fit connection, page 12 / 35

[0060] P81092DE must be designed in particular as an adhesive bond or as a welded joint.

[0061] The sealing element can be designed as an elastomer seal or as a foam seal. The foam seal can be applied using a Foamed in Place (FIP) process.

[0062] Preferably, the battery housing component is designed such that the contact surface extends around the entire housing wall along the connecting device.

[0063] A battery housing component designed in this way has the advantage that, if the battery housing component is electrically connected to another battery housing component, a further improved, and in particular continuous, shielding of the intake volume is made possible.

[0064] The penetration protection can extend around the entire housing wall along the connection point. This ensures that the electromagnetic insulating layer is directly accessible all around the entire housing wall, thus improving the establishment of an electrically conductive connection with the contact surface.

[0065] The penetration protection can only be arranged in the area of ​​the second section of the housing wall. In other words, the penetration protection is preferably not arranged in the first section of the housing wall and / or not in a third section of the housing wall.

[0066] The contact surface can be ribbon-shaped. The penetration protection can be ribbon-shaped. Page 13 / 35

[0067] P81092DE

[0068] Preferably, the battery housing component is designed such that the battery housing component at least partially limits a receiving volume for receiving at least one battery component, wherein the first section of the housing wall is arranged behind the second section of the housing wall, starting from the receiving volume.

[0069] A battery housing component designed in this way has the advantage of better preventing the penetration of the electromagnetic insulating layer and reducing the risk of corrosion of the electromagnetic insulating layer. For example, if the battery housing component is connected to another battery housing component, the electromagnetic insulating layer is not directly accessible to the environment and is therefore better protected against corrosion.

[0070] The penetration protection can extend around the entire receiving volume. The contact surface can extend around the entire receiving volume. The electromagnetically insulating layer can extend around the entire receiving volume.

[0071] The electromagnetic insulating layer can terminate from a receiving volume in front of the first section of the housing wall, and in particular in front of the sealing surface. This ensures that a sealed connection against the environment is achieved through the sealing surface. Alternatively, the electromagnetic insulating layer can extend into the first section of the housing wall. The electromagnetic insulating layer can terminate within the housing wall in front of one end. This prevents the electromagnetic insulating layer from coming into direct contact with the environment, thus further improving protection against corrosion and penetration of the electromagnetic insulating layer. Page 14 / 35

[0072] P81092DE

[0073] Preferably, the battery housing component is designed such that the battery housing component at least partially limits a receiving volume for receiving at least one battery component, wherein the first side of the housing wall faces the receiving volume.

[0074] A battery housing component designed in this way has the advantage that the electromagnetic insulating layer arranged in the area of ​​the second section of the housing wall on the first side of the housing wall is better protected against environmental influences, especially against corrosion.

[0075] The housing wall can have a second side, arranged opposite the first side and facing away from the receiving volume. The second side can be an outer surface of the housing wall and preferably facing an environment.

[0076] The electromagnetic insulating layer can be located further away from the first side of the housing wall in the area of ​​the first section than in the area of ​​the second section of the housing wall along a thickness extension of the housing wall.

[0077] The first section of the housing wall can be arranged directly adjacent to the second section of the housing wall. Preferably, the first section of the housing wall can transition continuously into the second section of the housing wall. In particular, the electromagnetically insulating layer between a first section and a second section can run continuously and be surrounded by the housing wall in the first section, preferably completely surrounded, and arranged on the first side of the housing wall in the second section, preferably resting on the first side. Page 15 / 35

[0078] P81092DE

[0079] Preferably, the battery housing component is designed such that the housing wall has a third section in which the housing wall partially surrounds the electromagnetic insulating layer, and in the area of ​​the first section, the electromagnetic insulating layer is arranged further away from the first side of the housing wall along a thickness extension of the housing wall than in the area of ​​the third section of the housing wall.

[0080] A battery housing component designed in this way offers the advantage that electrically conductive contact surfaces can be produced more precisely. During the manufacturing process, the electromagnetically insulating layer is pressed against a mold half by the melting pressure of the plastic forming the housing wall. There, it is deformed by the molten plastic, at least partially penetrated, and at least partially enclosed. After the housing wall has formed, the electromagnetically insulating layer protrudes partially from the housing wall in the third section due to restoring forces, so that the housing wall only partially surrounds the electromagnetically insulating layer. In areas with penetration protection, the electromagnetically insulating layer is neither penetrated nor enclosed by the molten plastic.By only providing penetration protection to selected areas, electrically conductive contact surfaces can be created in a more targeted manner.

[0081] The housing wall can have more than one third section, in particular two, three, four, or five. The housing wall can have more than one first section, in particular two, three, four, or five. According to a preferred embodiment, the second section can be arranged between the first section and a third section on the first side of the housing wall. Page 16 / 35

[0082] P81092DE, wherein the first section is arranged from the receiving volume behind the second section and the second section is arranged from the receiving volume behind the third section.

[0083] According to a preferred embodiment, the third section can be arranged between the first section and the second section on the first side of the housing wall, wherein the first section is arranged behind the second section starting from the receiving volume and the second section is arranged in front of the third section starting from the receiving volume.

[0084] The first section of the housing wall can be arranged directly adjacent to the third section of the housing wall. Preferably, the first section of the housing wall can transition continuously into the third section of the housing wall. In particular, the electromagnetic insulating layer between a first section and a third section can be continuous and, in the first section, be surrounded by the housing wall, preferably completely surrounded, and in the third section, be partially surrounded by the housing wall.

[0085] The third section can be located in a receiving area of ​​the battery housing component on the first side of the housing wall. The receiving area of ​​the battery housing component is the area in which one or more battery components are received within the receiving volume.

[0086] Preferably, the battery housing component is designed such that the housing wall has a recess, wherein the third section of the housing wall is arranged in the recess.

[0087] A battery housing component designed in this way has the advantage that the electromagnetic insulating layer is... Page 17 / 35

[0088] P81092DE can be improved by allowing the electromagnetic insulating layer to be incorporated and positioned within the housing wall. During the manufacturing process of the battery housing component, positioning elements of a mold can hold the electromagnetic insulating layer in a defined position, specifically spaced away from a mold surface of the mold, so that the electromagnetic insulating layer is only pressed against the positioning elements by a plastic melt forming the housing wall in the immediate contact areas of the positioning elements. In these contact areas, which form a bottom surface of the recess in the housing wall, a third section of the housing wall can be formed.

[0089] The recess can have a circular free cross-section. The recess can be band-shaped. The recess can extend around the entire receiving volume of the battery housing component.

[0090] The recess can be formed in the first side of the housing wall. The recess can be formed in a receiving area of ​​the battery housing component in the housing wall. The recess can be formed in the area of ​​the connection device in the housing wall.

[0091] The recess is preferably formed originating from a receiving volume behind the contact surface in the housing wall. The recess is preferably formed originating from a receiving volume behind the sealing surface in the housing wall. This allows the electromagnetic insulating layer to be positioned and arranged more effectively in the housing wall during the manufacturing process of the battery housing component. Furthermore, this prevents the electromagnetic insulating layer from being undermined. Page 18 / 35

[0092] P81092DE

[0093] According to a preferred embodiment, a recess is formed between the sealing surface and the contact surface in the housing wall.

[0094] The battery housing component can have more than one recess. The recesses can be formed in a receiving area of ​​the battery housing component in the housing wall and arranged at intervals from each other. A first section of the housing wall can be formed between each pair of recesses. With a battery housing component designed in this way, the electromagnetic insulating layer can be positioned more effectively during the manufacturing process of the battery housing component.

[0095] The recesses can be arranged in the area of ​​the connecting device. A first section of the housing wall can be formed between two recesses, with the first section forming the sealing surface of the housing wall.

[0096] The battery housing component can be manufactured using an injection molding process or a flow pressing process.

[0097] Preferably, the battery housing component is designed such that the battery housing component was manufactured using a method according to the sixth aspect of the invention.

[0098] A battery housing component designed in this way has the advantage that the battery housing component can be manufactured without tooling and therefore particularly cost-effectively and quickly.

[0099] The problem underlying the invention is further solved according to a second aspect of the invention by a traction battery housing comprising at least a first page 19 / 35

[0100] P81092DE

[0101] A battery housing component according to the first aspect of the invention and a second battery housing component connectable to the first battery housing component, wherein the first battery housing component and the second battery housing component together form a receiving volume for receiving at least one battery component, wherein the second battery housing component has an electrically conductive contact surface, and wherein, in the assembled state, an electrically conductive contact is established between the two contact surfaces of the first battery housing component and the second battery housing component.

[0102] A traction battery housing designed in this way offers the advantage of particularly good shielding against electromagnetic radiation. Furthermore, because the electromagnetically insulating layer does not come into direct contact with the environment, such a traction battery housing exhibits significantly increased corrosion resistance.

[0103] The electrically conductive contact between the two contact surfaces of the battery housing components in the assembled state can be established using an electrically conductive sealing element. Alternatively, the two contact surfaces of the battery housing components can be in direct surface contact with each other in the assembled state, thus creating an electrically conductive connection. The two contact surfaces of the two battery housing components can also be bonded together in the assembled state.

[0104] Preferably, the traction battery housing is designed such that the second battery housing component is designed according to the first aspect of the invention. Page 20 / 35

[0105] P81092DE

[0106] According to a further embodiment, the traction battery housing comprises a first battery housing component according to the first aspect of the invention and a second battery housing component connectable to the first battery housing component, wherein the first battery housing component and the second battery housing component together form a receiving volume for receiving at least one battery component, wherein the second battery housing component has a contact surface, and wherein, in the assembled state, the two contact surfaces of the first battery housing component and the second battery housing component are materially connected to each other, preferably bonded.According to the further embodiment, the contact surface of the second battery housing component can be designed as an electrically conductive contact surface, whereby in the assembled state an electrically conductive contact can be established between the two contact surfaces of the first battery housing component and the second battery housing component.

[0107] The problem underlying the invention is further solved according to a third aspect of the invention by a traction battery for a motor vehicle, comprising a traction battery housing according to the second aspect of the invention and at least one battery component which is arranged in the receiving volume of the traction battery housing.

[0108] A battery component can be a battery cell and / or a battery module. A battery component can also be a cooling device.

[0109] The problem underlying the invention is further solved according to a fourth aspect of the invention by a motor vehicle comprising a traction battery according to the third aspect of the invention. Page 21 / 35

[0110] P81092DE

[0111] The problem underlying the invention is further solved according to a fifth aspect of the invention by a mold for manufacturing a battery housing component according to the first aspect of the invention, wherein the mold has a first mold half and a second mold half, wherein the mold can be moved between an open position and a closed position by a relative movement between the first mold half and the second mold half, wherein the first mold half has a positioning element extending away from a mold surface of the first mold half, and wherein the positioning element is configured to receive an electromagnetically insulating layer introduced into the first mold half and to hold it positioned at least sectionally spaced away from the mold surface during the manufacture of the battery housing component.

[0112] A forming tool designed in this way has the advantage that a battery housing component according to the first aspect of the invention can be manufactured using such a tool in a die-casting process, thereby reducing manufacturing time and costs. The positioning elements create the recess in the battery housing component during the manufacturing process. This allows the electromagnetic insulating layer to be positioned precisely within the battery housing component, so that the housing wall has a first section and a second section.

[0113] A forming surface of a tool half is preferably the surface of the tool half that gives shape to a component produced by means of the forming tool. Page 22 / 35

[0114] P81092DE

[0115] The positioning element can have a height of greater than or equal to 0.3 mm, preferably greater than or equal to 0.4 mm, and particularly preferably greater than or equal to 0.5 mm. The positioning element can also have a height of less than or equal to 5 mm, preferably less than or equal to 4 mm, and particularly preferably less than or equal to 3 mm. The height of the positioning element is the extension of the positioning element away from the mold surface of the tool half.

[0116] The positioning element can have a width of greater than or equal to 0.5 mm, preferably greater than or equal to 0.8 mm, and particularly preferably greater than or equal to 1 mm. The positioning element can also have a width of less than or equal to 8 mm, preferably less than or equal to 6 mm, and particularly preferably less than or equal to 5 mm. The width of the positioning element is a dimension perpendicular to its height.

[0117] A positioning element can be designed as a positioning pin, preferably a cylindrical positioning pin. A cylindrical positioning pin has a circular cross-section and can have a diameter greater than or equal to 0.5 mm, preferably greater than or equal to 0.8 mm, and particularly preferably greater than or equal to 1 mm. The positioning pin can have a diameter less than or equal to 8 mm, preferably less than or equal to 6 mm, and particularly preferably less than or equal to 5 mm.

[0118] The positioning element can be designed as a web or a rib and, in a top view of the mold surface of the tool half, have a linear, in particular closed, contour. For example, the positioning element can be formed in an area of ​​the tool half where the... (page 23 / 35)

[0119] P81092DE binding device of the battery housing component is manufactured and is arranged around a region of the mold surface forming the receiving volume of the battery housing component.

[0120] Preferably, the first half of the tool has a plurality of positioning elements. The positioning elements can be spaced apart from one another. The spacing of the positioning elements can be determined depending on the melt viscosity of a plastic melt forming the housing wall of the battery housing component and / or the stiffness of the electromagnetic insulating layer. For example, a smaller spacing between the positioning elements is required with a high melt viscosity than with a low melt viscosity, while a larger spacing of the positioning elements is sufficient with a high stiffness of the electromagnetic insulating layer than with a low stiffness.

[0121] Preferably, the molding tool is designed as a flow forming tool or as an injection molding tool.

[0122] The problem underlying the invention is further solved according to a sixth aspect of the invention by a method for manufacturing a battery housing component according to the first aspect of the invention, preferably using a mold according to the fifth aspect of the invention, wherein the method comprises the following steps:

[0123] Introducing an electromagnetically insulating layer into a mold;

[0124] Applying a penetration protection layer to the electromagnetic insulating layer;

[0125] Introducing a heated plastic compound into the mold; page 24 / 35

[0126] P81092DE

[0127] Forming the heated plastic mass, thereby forming a housing wall that surrounds the electromagnetically insulating layer in the area of ​​a first section of the housing wall, and wherein the electromagnetically insulating layer is arranged on a first side of the housing wall in the area of ​​a second section of the housing wall, so that the housing wall has an electrically conductive contact surface on which the electromagnetically insulating layer is directly accessible.

[0128] Such a process has the advantage that the battery housing component can be manufactured using a tool and thus, in particular, in a single production step. This reduces both costs and time during manufacturing.

[0129] The process can be designed as a primary forming process, preferably as an injection molding process. Alternatively, the process can be designed as a flow forming process.

[0130] The penetration protection can be bonded to the electromagnetic insulating layer. Alternatively, it can be applied to the electromagnetic insulating layer using a foamed-in-place (FIP) process. In an FIP process, a foam, preferably a plastic foam, can be applied directly to the electromagnetic insulating layer. This simplifies the production of any desired penetration protection contour.

[0131] Further advantages, details and features of the invention will become apparent from the illustrated examples below.

[0132] Specifically, see pages 25 / 35

[0133] P81092DE

[0134] Figure 1: a schematic sectional view of a battery housing component according to a first embodiment;

[0135] Figure 2: a schematic sectional view of an area of ​​a traction battery housing according to a second embodiment; and

[0136] Figure 3: a schematic sectional view of an area of ​​a traction battery housing according to a third embodiment.

[0137] In the following description, identical reference symbols denote identical components or identical features, so that a description given for one component in relation to one figure also applies to the other figures, thus avoiding repetitive descriptions. Furthermore, individual features described in connection with one embodiment can also be used separately in other embodiments.

[0138] Figure 1 shows a schematic sectional view of a battery housing component 1 according to a first embodiment. The battery housing component 1 has a housing wall 10 made of plastic and an electromagnetically insulating layer 20. The housing wall 10 has a first section 11 in which the housing wall 10 surrounds the electromagnetically insulating layer 20 such that the electromagnetically insulating layer 20 is not accessible in the first section 11 of the housing wall 10. Furthermore, the housing wall 10 has a second section 12 in which the electromagnetically insulating layer 20 is arranged on a first side 14 of the housing wall 10, such that the housing wall 10 has an electrically conductive contact surface 16 in its second section 12, at which the electromagnetically insulating layer 20 is directly accessible, wherein in the region of the second section 12 of the housing wall 10 a side 26 / 35

[0139] P81092DE

[0140] Penetration protection 30 is arranged between the housing wall 10 and the electromagnetically insulating layer 20.

[0141] The electromagnetically insulating layer 20 is arranged to rest on the first side 14 in the region of the second section 12. The first side 14 faces a receiving volume 2, which is partially bounded by the battery housing component 1. The housing wall 10 has a third section 13, wherein the electromagnetically insulating layer 20 is partially surrounded by the housing wall 10 in the region of the third section 13. Furthermore, the battery housing component has a second side 15, which is arranged opposite the first side 14 and faces away from the receiving volume 2. The second side 15 of the battery housing component 1 forms an outer surface of the battery housing component 1.

[0142] The housing wall 10 has a circumferential connecting element 17, which is designed for connection with a further battery housing component 3, wherein the first section 11 and the second section 12 of the housing wall 10 are arranged in the area of ​​the connecting element 17. The contact surface 16 extends along the connecting element 17 circumferentially around the entire housing wall 10 and the receiving volume 2. The first section 11 is arranged behind the second section 12 of the battery housing component 1, starting from the receiving volume 2. The connecting element 17 is designed as a connecting flange. The housing wall 10 is designed as a monolithic component.

[0143] Figure 2 shows a schematic sectional view of a region of a traction battery housing 4 according to a second embodiment. The traction battery housing 4 has a first battery housing component 1 and a second battery housing component 3, wherein the battery housing components are shown on page 27 / 35.

[0144] The components 1 and 3 of the P81092DE battery housing form a receiving volume 2 (not shown in Figure 2). The second battery housing component 3 has an electrically conductive contact surface 19. The two battery housing components 1 and 3 are electrically connected to each other via their two contact surfaces 16 and 19 by means of an electrically conductive seal 50.

[0145] The first battery housing component 1 has two recesses 18, each of which contains a third section 13. One recess 18 is formed between the first section 11 and the second section 12 of the housing wall 10 on the first side 14 of the housing wall 10. Starting from a receiving volume 2 (not shown in Figure 2), this recess 18 is located behind the second section 12. The first section 11 is located behind this recess 18. The other recess 18 is formed behind the first section 11, starting from the receiving volume 2 (not shown in Figure 2).

[0146] In the region of the third section 13, the housing wall 10 partially surrounds the electromagnetically insulating layer 20. In the region of the first section 11 of the housing wall 10, the electromagnetically insulating layer 20 is located further away from the first side 14 of the housing wall 10 along a thickness extension of the housing wall 10 than in the region of the third section 13 of the housing wall 10. The electromagnetically insulating layer 20 is located further away from the first side 14 of the housing wall 10 along the thickness extension of the housing wall 10 in the region of the first section 11 than in the region of the second section 12 of the housing wall 10.

[0147] The first section 11 of the housing wall 10 is arranged directly adjacent to the two third sections 13 of the housing wall 10 located in the recesses 18 and transitions continuously into them. The electromagnetic field runs along page 28 / 35.

[0148] P81092DE The electromagnetic insulating layer 20 extends continuously between the first section 11 and the third sections 13 and is partially surrounded by the housing wall 10 in the third sections 13 and completely surrounded by the housing wall 10 in the first section 11. The second section 12 is arranged immediately adjacent to one of the third sections 13 and transitions continuously into it. The electromagnetic insulating layer 20 extends between the second section

[0149] 12 and the third section 13 continuously and is partially surrounded by the housing wall 10 in the third section 13, and is arranged lying on the first side 14 of the housing wall 10 in the second section 12 .

[0150] The first section 11 forms a sealing surface, wherein the first battery housing component 1 is connected to the second battery housing component 3 in the area of ​​the sealing surface by means of a sealing element 40 designed as an environmental seal.

[0151] Figure 3 shows a schematic sectional view of an area of ​​a traction battery housing 4 according to a third embodiment.

[0152] The casing wall 10 of the first battery casing component 1 has five third sections 13, each of the third sections being

[0153] 13 each is arranged in a separate recess 18. Three of the recesses 18 are arranged in a receiving area 60 of the traction battery housing 4. Page 29 / 35

[0154] P81092DE

[0155] Reference symbol list

[0156] 1 (First) Battery Housing Component

[0157] 2. Recording volume

[0158] 3 Second battery housing component

[0159] 4 traction battery housings

[0160] 10 Housing wall

[0161] 11 First Section

[0162] 12 Second Section

[0163] 13 Third Section

[0164] 14 First page

[0165] 15 Second page

[0166] 16 Contact surface (of the first battery housing component)

[0167] 17 Connection device

[0168] 18 In-depth study

[0169] 19 Contact surface (of the second battery housing component)

[0170] 20 Electromagnetically insulating layer

[0171] 30 penetration protection

[0172] 40 sealing element

[0173] 50 Electrically conductive seals

Claims

Page 30 / 35 Applicant: KAUTEX TEXTRON GmbH & Co. KG Our reference number: P81092DE Patent claims 1. Battery housing component (1) comprising a housing wall (10) comprising a plastic; an electromagnetic insulating layer (20); wherein the housing wall (10) has a first section (11) in which the housing wall (10) surrounds the electromagnetic insulating layer (20) in such a way that the electromagnetic insulating layer (20) is not accessible in the first section (11) of the housing wall (10);and wherein the housing wall (10) has a second section (12) in which the electromagnetically insulating layer (20) is arranged on a first side (14) of the housing wall (10), such that the housing wall (10) has an electrically conductive contact surface (16) in its second section (12) at which the electromagnetically insulating layer (20) is directly accessible, characterized in that a penetration protection (30) is arranged between the housing wall (10) and the electromagnetically insulating layer (20) in the area of ​​the second section (12) of the housing wall (10).

2. Battery housing component (1) according to claim 1, characterized in that in the area of ​​the second section (12) of the housing wall (10) the electromagnetically insulating layer (20) rests on the first side (12) of the housing wall (10).

3. Battery housing component (1) according to one of the preceding claims, characterized in that the penetration protection (30) and the electromagnetic insulating layer (20) are positively connected to each other. Page 31 / 35 P81092DE 4. Battery housing component (1) according to one of the preceding claims, characterized in that the penetration protection (30) comprises an organosheet and / or a crossply or is designed as such.

5. Battery housing component (1) according to one of the preceding claims, characterized in that the penetration protection (30) has or is designed to be a film containing plastic.

6. Battery housing component (1) according to one of the preceding claims, characterized in that the electromagnetically insulating layer (20) has a plurality of through-openings .

7. Battery housing component (1) according to one of the preceding claims, characterized in that the housing wall (10) has a circumferential connecting device (17) which is designed for connection with a further battery housing component (3), wherein the first section (11) and the second section (12) of the housing wall (10) are arranged in the area of ​​the connecting device (17).

8. Battery housing component (1) according to claim 7, characterized in that the contact surface (16) extends around the entire housing wall (10) along the connecting device (17).

9. Battery housing component (1) according to one of the preceding claims, characterized in that the battery housing component (1) at least partially limits a receiving volume (2) for receiving at least one battery component, wherein the first section (11) of the housing wall (10) is arranged behind the second section (12) of the housing wall (10) starting from the receiving volume (2). Page 32 / 35 P81092DE 10. Battery housing component (1) according to one of the preceding claims, characterized in that the battery housing component (1) at least partially limits a receiving volume (2) for receiving at least one battery component, wherein the first side (11) of the housing wall (10) faces the receiving volume (2).

11. Battery housing component (1) according to one of the preceding claims characterized by the following features: the housing wall (10) has a third section (13) in which the housing wall (10) partially surrounds the electromagnetic insulating layer (20); in the region of the first section (11) the electromagnetic insulating layer (20) is arranged further away from the first side (11) of the housing wall (10) along a thickness extension of the housing wall (10) than in the region of the third section (13) of the housing wall (10).

12. Battery housing component (1) according to claim 11, characterized in that the housing wall (10) has a recess (18), wherein the third section (13) of the housing wall (10) is arranged in the recess (18).

13. Battery housing component (1) according to one of the preceding claims, characterized in that the battery housing component (1) was manufactured using a method according to claim 18.

14. Traction battery housing (4) , comprising at least a first battery housing component (1) according to one of the preceding claims and a second battery housing component (3) connectable to the first battery housing component (1) ; Page 33 / 35 P81092DE wherein the first battery housing component (1) and the second battery housing component (3) together form a receiving volume (2) for receiving at least one battery component; wherein the second battery housing component (3) has an electrically conductive contact surface (19); and wherein, in the assembled state, an electrically conductive contact is established between the two contact surfaces (16, 19) of the first battery housing component (1) and the second battery housing component (3).

15. Traction battery for a motor vehicle, comprising a traction battery housing (4) according to claim 14 and at least one battery component arranged in the receiving volume (2) of the traction battery housing (4).

16. Motor vehicle comprising a traction battery according to claim 15.

17. Mold for manufacturing a battery housing component (1) according to one of claims 1 to 13, characterized by the following features: the mold has a first mold half and a second mold half, wherein the mold can be moved between an open position and a closed position by a relative movement between the first mold half and the second mold half; the first mold half has a positioning element extending away from a mold surface of the first mold half; and wherein the positioning element is configured to receive an electromagnetically insulating layer (20) introduced into the first mold half and to at least partially retain the layer during the manufacture of the battery housing component (1). Page 34 / 35 P81092DE should be positioned at a distance from the mold surface in sections.

18. Method for manufacturing a battery housing component (1) according to one of claims 1-13, preferably using a mold according to claim 17, characterized in that the method comprises the following steps: Introducing an electromagnetically insulating layer (20) into a mold tool; Applying a penetration protection layer (30) to the electromagnetic insulating layer (20) ; Introducing a heated plastic mass into the mold; Forming the heated plastic mass, thereby forming a housing wall (10) that surrounds the electromagnetically insulating layer (20) in the area of ​​a first section (11) of the housing wall (10) and wherein the electromagnetically insulating layer (20) is arranged on a first side (14) of the housing wall (10) in the area of ​​a second section (12) of the housing wall (10), so that the housing wall (10) has an electrically conductive contact surface (16) at which the electromagnetically insulating layer (20) is directly accessible.

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