Method for producing a battery tray of a traction battery for a mobile work machine

Abstract

The invention relates to a method for producing a battery tray (2) of a traction battery, in particular a lithium-ion traction battery, for a mobile work machine, in particular an industrial truck, wherein the battery tray (2) is at least partially filled with a ballast filling (15), wherein the ballast filling (15) comprises a ballast material (15a) and a bonding substance (15b). The method comprises the steps of: providing a battery tray (2), wherein the battery tray (2) has an outer casing (4) with a peripheral outer wall (3) and an intermediate base (5) secured to the outer wall (3), wherein a ballast filling space (7) is formed by the intermediate base (5) in the interior of the battery tray (2) and the battery tray (2) is open on the underside (US); positioning the battery tray (2) with the open underside (US) facing upwards on a filling device (1); filling the ballast filling space (7) with the ballast filling (15) by means of the filling device (1) via the open underside (US) of the battery tray (1); closing the open underside (US) of the battery tray (1) with a base plate (12); rotating the battery tray (2) provided with the base plate (12) by 180° about a horizontal axis of rotation (D); setting the ballast filling (15) to form a laminate material.

Description

[0001] 24323 / P24030-DEa / KBS= EM-KBS002

[0002] February 13, 2025 - Geirhos

[0003] 1

[0004] Description

[0005] Method for manufacturing a battery tray for a traction battery for a mobile work machine

[0006] The invention relates to a method for manufacturing a battery trough for a traction battery, in particular a lithium-ion traction battery, for a mobile working machine, in particular a forklift truck, wherein the battery trough is at least partially filled with a ballast filling, the ballast filling comprising a ballast material and a composite material.

[0007] A mobile work machine powered by a battery-electric drive, in particular a battery-electric industrial truck, for example a battery-electric counterbalance forklift, has a traction battery to provide the electrical drive energy. The traction battery has a battery tray in which one or more battery modules are installed. In known battery-electric industrial trucks, the traction battery is usually designed to be replaceable, so that a discharged traction battery can be easily replaced with a charged one during operation of the industrial truck.

[0008] Electrically powered industrial trucks, such as counterbalance forklifts, have a lifting mast with a load-handling device, such as a fork, on the front axle. The stability of such trucks with a load is crucially determined by the vehicle's overall center of gravity, which in turn depends on the position of the counterweight, as well as the position and weight of the traction battery.

[0009] Conventional traction batteries are relatively heavy lead-acid batteries that contribute significantly to the counter-torque against a load in the forklift. To prevent unstable conditions and the risk of the forklift tipping over, as well as during braking, the vehicle's weight and center of gravity are crucial. 24323 / P24030-DEa / KBS= EM-KBS002

[0010] February 13, 2025 - Geirhos

[0011] 2

[0012] Newer technologies now allow for the production and industrial use of batteries and accumulators that offer improved performance. These batteries can be described as high-performance batteries, characterized by a higher energy density relative to weight and / or volume compared to lead-acid batteries, and by the use of a different energy storage technology than a lead-acid reaction. Many high-performance batteries also feature the ability to deliver high power during discharge and / or charge at high power. The typical energy densities relative to weight and / or volume of a high-performance battery are higher than, and outside the range of, the corresponding parameters for lead-acid batteries, at least for one of these two values.

[0013] Lithium-ion batteries, which have achieved a level of reliability suitable for mass production, are increasingly being used on a larger scale than such high-performance batteries. They are characterized by high energy density, have only a low memory effect, and allow for high-power discharge and charging of the battery.

[0014] The use of such high-performance batteries is particularly advantageous in mobile machinery, for example industrial trucks, as traction batteries, because due to the high energy density in relation to the volume, a larger amount of electrical energy can be stored in the given installation space for the traction battery, thus increasing the range of a vehicle or the operating time of the industrial truck.

[0015] Battery-electric industrial trucks that use lithium-ion traction batteries as high-performance batteries, with lithium-ion battery modules installed in the battery tray, have the disadvantage that the lower weight of the lithium-ion traction battery compared to a lead-acid traction battery (with lead-acid battery modules installed in the battery tray) alters the center of gravity of the entire industrial truck, thus affecting its stability and load-bearing capacity. 24323 / P24030-DEa / KBS= EM-KBS002

[0016] February 13, 2025 - Geirhos

[0017] 3

[0018] Therefore, there is a need to align the weight of a lithium-ion traction battery with the weight of a lead-acid traction battery with the same external dimensions of the battery tray, so that a lead-acid traction battery can be replaced by a lithium-ion traction battery in the industrial truck without affecting the load-bearing capacity and stability of the industrial truck.

[0019] It is known from DE 102014 106644 B4 to attach a plate-shaped additional weight to the outside of the battery tray of a lithium-ion traction battery of a forklift truck using fasteners, in order to equalize the weight of the lithium-ion traction battery with that of a lead-acid traction battery with the same size battery tray. However, such a plate-shaped additional weight and the required fasteners result in a high degree of construction complexity.

[0020] To increase the weight of a lithium-ion traction battery for a mobile work machine, it is also possible to partially fill the battery tray with ballast. In the first process step of manufacturing the battery tray, a mixture of metal parts and a composite material is produced as ballast. This mixture is then poured into the battery tray in a second process step, where it hardens into a composite material. The battery tray has a double-walled structure with an outer and an inner wall, constructed from welded steel sheets. The ballast is filled into the space between the outer and inner walls.

[0021] However, a disadvantage here is that the battery tray with its double-walled construction causes high manufacturing costs.

[0022] The present invention is based on the objective of providing a method for manufacturing a battery tray of the aforementioned type, which is improved with regard to the aforementioned disadvantages. 24323 / P24030-DEa / KBS= EM-KBS002

[0023] February 13, 2025 - Geirhos

[0024] 4

[0025] This invention is solved in a method for manufacturing a battery tray for a traction battery, in particular a lithium-ion traction battery, for a mobile working machine, in particular a forklift truck, wherein the battery tray is at least partially filled with ballast, the ballast comprising a ballast material and a composite material, by the following steps:

[0026] • Providing a battery trough, wherein the battery trough has an outer shell with a circumferential outer wall and an intermediate floor attached to the outer wall, wherein the intermediate floor forms a ballast filling space in the interior of the battery trough and the battery trough is open at the bottom,

[0027] • Positioning the battery tray with the open bottom facing upwards on a filling device,

[0028] • Filling the ballast chamber with ballast using the filling device via the open underside of the battery tray,

[0029] • Closing the open underside of the battery tray with a base plate,

[0030] • Rotate the battery tray with the base plate 180° around a horizontal axis of rotation,

[0031] • Hardening of the ballast filling to form a composite material.

[0032] In the method according to the invention, a battery trough is provided, comprising an outer shell with a circumferential outer wall and an intermediate floor attached to the outer wall. Within the interior of the battery trough, the intermediate floor forms a ballast chamber, which is filled with ballast. The battery trough is open at the bottom. The ballast chamber is filled with ballast through the open bottom of the battery trough. After filling the ballast chamber, the open bottom of the battery trough is closed with a base plate. By rotating the battery trough, fitted with the base plate, by 180° about a horizontal axis and subsequently allowing the ballast to harden into a composite material, a permanent bond and fixation of the base plate to the composite material, and via the composite material to the battery trough, is achieved.The invention allows for a simple and cost-effective construction of the battery tray, as the base plate does not need to be laboriously welded to the outer wall. The invention further simplifies the construction of the battery tray, as the separation is described in 24323 / P24030-DEa / KBS = EM-KBS002.

[0033] February 13, 2025 - Geirhos

[0034] 5 of the ballast filling space in the interior of the battery trough only the intermediate floor attached to the outer wall is required and no elaborate double-walled construction of the battery trough with an outer wall and an inner wall is required for the provision of the ballast filling space.

[0035] According to an advantageous embodiment of the invention, the ballast is compacted during or immediately after filling the ballast chamber. This allows the ballast to be compacted and evenly distributed within the chamber in a simple manner. Preferably, the compaction of the ballast and the filling of the ballast chamber occur simultaneously. Alternatively, the compaction of the ballast can be carried out immediately after filling the ballast chamber and before closing the open underside of the battery tray with the base plate.

[0036] According to an advantageous embodiment of the invention, the battery trough is shaken to compact the ballast filling.

[0037] For this purpose, the ballast filling in the battery tray can be shaken using a shaker bottle.

[0038] According to an advantageous embodiment of the invention, a vibrating plate of the filling device, on which the battery trough stands, is used to vibrate the battery trough.

[0039] According to an advantageous embodiment of the invention, closing the open underside of the battery tray with the base plate creates a positive-locking connection between the base plate and the battery tray. This allows the base plate to be easily attached to the battery tray for subsequent rotation of the battery tray, with the base plate attached, by 180° about the horizontal axis of rotation.

[0040] According to an advantageous embodiment of the invention, to close the open underside of the battery tray with the base plate, the base plate is inserted into receiving grooves in the battery tray. With receiving grooves on the battery tray into which the base plate can be inserted like a drawer, 24323 / P24030-DEa / KBS= EM-KBS002

[0041] February 13, 2025 - Geirhos

[0042] 6. A form-fitting connection between the base plate and the battery tray can be achieved in a simple and cost-effective manner.

[0043] According to an advantageous embodiment of the invention, a vibration process is carried out on the battery trough, equipped with the base plate, immediately after it has been rotated 180° about the horizontal axis of rotation and before the ballast filling has hardened into the composite material. Such a vibration process allows for a simple bonding of the ballast filling in the ballast chamber with the base plate, so that, upon hardening of the ballast filling into the composite material, a permanent bond and fixation of the base plate to the composite material and, via the composite material, to the battery trough is achieved.

[0044] According to an advantageous embodiment of the invention, the vibration process is carried out with the vibrating plate of the filling device.

[0045] According to an advantageous embodiment of the invention, when positioning the battery tray with its open underside facing upwards on the filling device, the battery tray is lifted into a support frame. The battery tray, which during filling with ballast consists only of the outer wall and the intermediate floor, can be easily stabilized in the support frame against unwanted deformation in order to ensure the shape of the battery tray is maintained during the filling process.

[0046] According to an advantageous embodiment of the invention, when positioning the battery tray with the open underside facing upwards on the filling device, the battery tray is placed on the vibrating plate of the filling device.

[0047] According to an advantageous embodiment of the invention, metal parts and / or slag are used as ballast material. Preferably, metal scrap, steel scrap, or iron scrap is used as the metal parts, which can be crushed to a desired size before being filled into the battery trough. Alternatively or additionally, slag from the steel industry, in particular slag from iron or steel production, so-called blast furnace slag or steelworks slag, can be used as ballast material, which can be crushed to a desired size. 24323 / P24030-DEa / KBS= EM-KBS002

[0048] February 13, 2025 - Geirhos

[0049] 7. Crushed slag material, especially fine-grained granules, may be present. After the ballast filling has hardened into the composite material, the metal parts and / or the crushed slag material are bound in the hardened composite. A cost-effective ballast filling can be provided using such metal parts and / or crushed slag material.

[0050] According to an advantageous embodiment of the invention, a resin, in particular a polymer resin, is used as the composite material. Suitable resins include common types such as epoxy resin or polyester resin, which can be in the form of a one-component or multi-component resin. Preferably, the resin is in a liquid state.

[0051] According to an advantageous embodiment of the invention, the ballast material and the composite material are filled into the battery trough as a mixture.

[0052] The mixture consisting of the ballast material and the composite material can be easily produced in a mixing device, for example a mixing machine, which is preferably part of the filling device, before filling the battery trough.

[0053] According to an alternative and equally advantageous embodiment of the invention, the mixture is produced by spraying the ballast material with the composite material. The ballast material is advantageously sprayed with the composite material while it is being filled into the battery trough. This allows a uniform coating of the ballast material with the composite material to be achieved with a small amount of composite material sprayed onto the ballast material falling into the battery trough, ensuring that the ballast material hardens into the solid composite material. The spraying of the ballast material can be carried out, for example, with a spray device, which is preferably part of the filling device.

[0054] According to an alternative and equally advantageous embodiment of the invention, the ballast material and the composite material are filled into the battery tray sequentially, i.e., one after the other. With such a sequential filling of the battery tray with ballast material, i.e., one after the other, 24323 / P24030-DEa / KBS= EM-KBS002

[0055] February 13, 2025 - Geirhos

[0056] 8. The battery tray is filled with at least one layer of ballast material and one layer of composite material, whereby a desired quantity of ballast material is first added to the battery tray, followed by a desired quantity of composite material. This allows for uniform wetting of the ballast material with the composite material using a small quantity of composite material added to the ballast material in the battery tray, ensuring that the ballast material hardens into the solid composite material.

[0057] The invention further relates to a battery trough for use in the aforementioned method. The battery trough has an outer shell with a circumferential outer wall and an intermediate floor attached to the outer wall, which divides the interior of the battery trough into a ballast filling chamber, which can be filled with ballast, and a receiving chamber in which at least one battery module, in particular at least one lithium-ion battery module, can be installed, wherein the battery trough is open at the bottom, the open bottom forming a filling opening for filling the ballast filling chamber, and wherein the open bottom can be closed by means of a base plate that can be attached to the battery trough in a form-fitting or force-fitting manner.Such a battery trough has a simple and cost-effective design, since the intermediate floor allows the ballast filling space in the battery trough to be created in a simple and cost-effective manner, and the base plate does not need to be laboriously welded to the outer wall.

[0058] The invention further relates to a filling device for carrying out the above-mentioned method, wherein the filling device comprises a filling unit configured to dispense the ballast filling into the ballast filling chamber of the battery trough, and a vibrating plate configured to vibrate the battery trough standing on the vibrating plate. With such a filling device, the ballast filling chamber can be easily filled with the ballast filling by means of the filling unit, and the battery trough can be vibrated by means of the vibrating plate before and after rotation.

[0059] According to an advantageous embodiment of the invention, the filling device comprises a turning device configured to rotate the battery tray 180° about a horizontal axis of rotation. With such a turning device, 24323 / P24030-DEa / KBS= EM-KBS002 13.02.2025 - Geirhos

[0060] 9. Thus, after closing the open underside of the battery trough with the base plate, the battery tray can be easily rotated and placed on the vibrating plate with the base plate.

[0061] The invention further relates to a lithium-ion traction battery for a mobile work machine, in particular a forklift truck, using a battery trough produced according to the inventive method, wherein at least one lithium-ion battery module is installed in the battery trough provided with the hardened ballast filling.

[0062] The invention offers a number of advantages.

[0063] The base plate of the battery trough does not need to be welded to the outer wall of the battery trough, as the composite material ensures a permanent connection between the outer wall and the base plate. This results in a reduction in the manufacturing costs of the ballasted battery trough.

[0064] By closing the open underside of the battery trough with the base plate after the ballast filling chamber has been filled with ballast, a large filling area for the ballast filling is ensured with the open underside of the battery trough, which promotes the distribution of the ballast filling in the ballast filling chamber.

[0065] If the compaction of the ballast filling and the filling of the ballast filling chamber with the ballast filling take place simultaneously, thus compacting and filling the battery trough simultaneously, the distribution of the ballast filling in the ballast filling chamber of the battery trough to be filled can be improved and optimized.

[0066] Further advantages and details of the invention are explained in more detail with reference to the exemplary embodiment shown in the schematic figures. Here,

[0067] Figure 1 shows a battery trough produced according to the inventive method during the process step of filling the ballast filling chamber with ballast material, 24323 / P24030-DEa / KBS= EM-KBS002

[0068] February 13, 2025 - Geirhos

[0069] Figure 2 shows a battery tray produced according to the inventive method during the process step of closing the opened underside of the battery tray with a base plate.

[0070] Figure 3 shows a battery trough produced according to the inventive method during the process step of rotating the battery trough provided with the base plate by 180° about a horizontal axis of rotation,

[0071] Figure 4 shows a battery trough produced according to the inventive method during the process step of the vibration process of the battery trough provided with the base plate.

[0072] Figure 5 shows a battery trough intended for use in the method according to the invention in a perspective view from above,

[0073] Figure 6 shows the figure's battery trough in a perspective view from below.

[0074] Figure 7 shows the battery tray according to Figure 6 with the underside closed by the base plate,

[0075] Figure 8 shows the battery tray with the base plate in a longitudinal section along line L1 in Figure 1,

[0076] Figure 9 shows the battery trough with the base plate in a view along line L2 in Figure 1 and

[0077] Figure 10 shows a block diagram of the method according to the invention.

[0078] Figures 1 to 4 show a filling device 1 with which a battery tray 2 of a traction battery, for example a lithium-ion traction battery, for a mobile working machine, in particular a forklift truck, is filled in a 24323 / P24030-DEa / KBS= EM-KBS002 13.02.2025 - Geirhos

[0079] 11 according to the inventive method is at least partially filled with a ballast filling 15 to increase weight.

[0080] Figures 5 to 9 show in more detail the battery trough 2, which is filled with the ballast filling 15 in the method according to the invention.

[0081] Figure 10 shows a block diagram of the inventive method for producing the battery trough 2 provided with the ballast filling 15.

[0082] The battery trough 2 has – as shown in more detail in Figures 5 to 9 – an outer shell 4 which has a rectangular base and consists of a circumferential outer wall 3. The outer wall 3 comprises a left, end-facing outer wall 3a, a right, end-facing outer wall 3b, a front wall 3c and a rear wall 3d.

[0083] The left outer wall 3a, the right outer wall 3b, the front wall 3c and the rear wall 3d are preferably formed from sheets, in particular steel sheets, which are welded to the surrounding outer wall 3.

[0084] The battery tray 2 is provided with an intermediate shelf 5, which extends to the left outer wall 3a, the right outer wall 3b, the front wall 3c and the rear wall 3d. The intermediate shelf 5 is attached to the outer wall 3. The intermediate shelf 5 can preferably be attached to the left outer wall 3a, the right outer wall 3b, the front wall 3c and the rear wall 3d.

[0085] The intermediate floor 5 divides the outer shell 4 and thus the interior of the battery trough 2 into a ballast filling chamber 7, which is filled with the ballast material 15, and into a receiving chamber 8, in which, after the ballast filling chamber 7 has been filled with the ballast material 15, at least one battery module, in particular at least one lithium-ion battery module, can be installed to manufacture the traction battery.

[0086] Figure 5 shows the battery tray 2 in its normal installation position, i.e., the position in which the battery tray 2 is installed in a mobile work machine, for example, a forklift truck. 24323 / P24030-DEa / KBS= EM-KBS002

[0087] February 13, 2025 - Geirhos

[0088] 12

[0089] In Figure 5, the space above the intermediate floor 5 forms the receiving space 8, in which at least one battery module, in particular at least one lithium-ion battery module, can be installed to manufacture the traction battery. The receiving space 8 is completely open at the top surface OS of the outer wall 3 and thus of the battery tray 2, i.e., at the upper edge of the outer wall 3 formed by the walls 3a, 3b, 3c, 3d. In the illustrated embodiment, the walls 3a, 3b, 3c, 3d are provided at the top surface OS of the outer wall 3 with inwardly projecting flanges that form a mounting flange 10 for a cover (not shown) with which the receiving space 8 can be closed at the top surface OS after the battery modules have been installed in the receiving space 8.

[0090] In Figure 5, the space below the intermediate floor 5 forms the ballast filling space 7.

[0091] Figure 6 shows the battery trough 2 of Figure 1 in a position rotated by 180° about a horizontal axis of rotation, in which the battery trough 2 is upside down with the underside US of the outer wall 3 and thus of the battery trough 2 facing upwards.

[0092] The space between the underside US of the outer wall 3, i.e. the lower edge of the outer wall 3 formed by the walls 3a, 3b, 3c, 3d, and the intermediate floor 5 forms the ballast filling space 7 and thus a ballast filling chamber into which the ballast filling 15 is poured.

[0093] The battery trough 2, and thus the ballast chamber 7, is completely open on its underside US. The open underside US of the battery trough 2 is bounded by the inner edges IK of the walls 3a, 3b, 3c, 3d. The open underside US of the battery trough 2 forms a filling opening through which the ballast 15 is poured into the ballast chamber 7.

[0094] In the illustrated embodiment, the walls 3a, 3b, 3c, 3d are provided on the underside US of the outer wall 3 with inwardly projecting chamfers Aka, AKb, AKc, AKd, which, together with the end-face inner edges IK, define the open underside US. 24323 / P24030-DEa / KBS= EM-KBS002

[0095] February 13, 2025 - Geirhos

[0096] 13

[0097] A height offset is preferably formed between the bends Aka, AKb of the left outer wall 3a and the right outer wall 3b, as well as between the bends AKc, AKd of the front wall 3c and the rear wall 3d, so that receiving grooves AN1, AN2 are formed on the battery tray 2 between the bends Aka, AKb and the bend AKc, as well as between the bends Aka, AKb and the bend AKd, into which a base plate 12 can be inserted in a drawer-like manner, as shown in Figure 7.

[0098] In Figure 7, the battery trough 2 is shown in a representation according to Figure 6 with the base plate 12 fully inserted, in which the open underside US of the battery trough 2 is closed by the base plate 12.

[0099] The base plate 12 is inserted into the receiving grooves AN1 , AN2 formed by the bend Aka-AKd and is held in a form-fitting manner on the outer wall 3 by means of the receiving grooves AN1 , AN2.

[0100] Figure 8 shows the battery tray 2 in the installation position shown in Figure 5 in a longitudinal section, with a cover 11 attached to the mounting flange 10 on the upper surface OS of the battery tray 2 and the base plate 12 attached to the lower surface US of the battery tray 2. Figure 8 also shows the bends Aka and AKb of the left outer wall 3a and the right outer wall 3b in more detail.

[0101] The space between the outer wall 3, the intermediate floor 5 and the base plate 12 forms the ballast filling chamber 7. The space between the outer wall 3, the intermediate floor 5 and the lid 11 forms the receiving chamber 8.

[0102] In the installed position, the ballast chamber 7 is thus arranged below the intermediate floor 5, and the installation chamber 8 above the intermediate floor 5. The ballast 15 filled into the ballast chamber 7 is located in the lower region of the battery tray 2 in the installed position, resulting in a low center of gravity for the battery tray 2 and the traction battery manufactured from the battery tray. This results in a favorable center of gravity for a traction battery, which has the battery tray according to the invention, when installed in a mobile machine, for example, a forklift truck. 24323 / P24030-DEa / KBS= EM-KBS002

[0103] February 13, 2025 - Geirhos

[0104] 14

[0105] As can be seen in Figure 8, the intermediate floor 5 in the area of ​​the left outer wall 3a and the right outer wall 3b is extended upwards with vertical sections 5a, 5b, which run parallel to the outer wall 3a and 3b respectively, up to the area of ​​the mounting flange 10 and the cover 11, respectively, so that the areas between the vertical sections 5a, 5b of the intermediate floor 5 and the outer walls 3a, 3b also belong to the ballast chamber 7 and are filled with the ballast 15. This allows a high wall thickness to be achieved at the end wall 3a and at the end wall 3b of the battery tray 2 with the ballast 15, thereby providing effective protection against damage to the battery modules installed in the receiving space 8 when a traction battery, which has the battery tray 2 according to the invention, is installed in a mobile work machine, for example a forklift truck.

[0106] Figure 9 shows the battery tray 2 in the installed position of Figure 5, in a front view of the outer wall 3b in a half-section, with the base plate 12 attached to the underside US of the battery tray 2. Figure 9 also shows the chamfer Akc of the front wall 3c. The rear wall 3d, not shown in detail in Figure 9, is designed analogously.

[0107] In the following, a method for manufacturing a battery trough 2 is described with reference to Figure 10 and Figures 1 to 4, the structure of which corresponds to Figures 5 to 9 and whose ballast filling space 7 is supplied with the ballast filling 15.

[0108] In the inventive method, in a first step S1 a battery trough 2 is provided, which has an outer shell 4 with a circumferential outer wall 3 and an intermediate floor 5 attached to the outer wall 3, wherein the intermediate floor 5 forms a ballast filling space 7 in the interior of the battery trough 2 and the battery trough 2 is open at the bottom US.

[0109] In the first process step S1, a battery tray 2 according to Figures 5 to 9 is preferably provided, which is open at the bottom US and is not yet fitted with the base plate 12. 24323 / P24030-DEa / KBS= EM-KBS002 13.02.2025 - Geirhos

[0110] 15

[0111] In a subsequent second process step S2, the battery tray 2 is positioned on a filling device 1 with its open underside US facing upwards. If the battery tray 2 was provided in the installation position shown in Figure 5, it must be rotated 180° about a horizontal axis of rotation, in which the battery tray 2 is upside down with the open underside US of the outer wall 3 and thus of the battery tray 2 facing upwards, as shown in Figure 6.

[0112] The filling device 1 has a filling unit 20 which is designed to discharge the ballast filling 15 into the ballast filling chamber 7 of the battery trough 2.

[0113] The filling device 20 has an outlet opening 21.

[0114] In the second process step S2, the battery tray 2 is positioned with the open underside US facing upwards in a vertical direction V below the outlet opening 21 of the filling device 20.

[0115] In the second process step S2, the battery tray 2 can be lifted into a support frame 25.

[0116] In the second process step S2, the battery trough 2, optionally with the support frame 25, is placed on a vibrating plate 26 of the filling device 1.

[0117] In the subsequent third process step S3, the ballast chamber 7 is filled with the ballast 15 by means of the filling device 1 via the open underside US of the battery tray 2. This process step is shown in Figure 1. The open underside US of the battery tray 2 is thus used as a filling opening through which the ballast 15 is poured into the ballast chamber 7 from above.

[0118] The ballast filling 15 comprises a ballast material 15a and a composite material 15b, which are filled from above into the ballast filling chamber 7 of the battery trough 2 which is open at the bottom.

[0119] The ballast material 15a of the ballast filling 15 is preferably formed from crushed metal parts. The metal parts are preferably scrap metal or steel scrap. 24323 / P24030-DEa / KBS= EM-KBS002

[0120] February 13, 2025 - Geirhos

[0121] 16

[0122] Iron scrap is provided, which can be crushed to a desired size before being filled into the battery trough 2. Alternatively or additionally, slag from the steel industry, in particular slag from iron or steel production, so-called blast furnace slag or steelworks slag, can be used as ballast material 15a, which can be in the form of slag material crushed to a desired size, in particular fine-grained granules.

[0123] The composite material 15b is preferably a resin, in particular a synthetic resin. The resin is preferably in a liquid state. Suitable resins include common types such as epoxy resin or polyester resin, which can be in the form of a one-component or multi-component resin.

[0124] In the third process step S3, a mixture can be produced from the ballast material 15a and the composite material 15b, for example in a mixing device of the filling device 1, which is then filled into the battery trough 2 at the filling device 20.

[0125] Alternatively, in the third process step S3, the ballast material 15a can be filled into the battery trough 2 at the filling device 20 and the ballast material 15a falling into the battery trough 2 can be sprayed with the composite material 15b before impact in the battery trough 2, for example by means of a suitable spray device of the filling device 1, which is arranged in a vertical direction V below the outlet opening 21.

[0126] Alternatively, in the third process step S3, the ballast material 15a and the composite material 15b can be filled sequentially and thus one after the other into the ballast filling chamber 7, whereby first a desired quantity of ballast material 15a and then a desired quantity of composite material 15b is filled into the battery trough 2 by means of the filling device 20.

[0127] Preferably, in the third process step S3, the ballast filling 15 is compacted during the filling of the ballast filling chamber 7 with the ballast filling 15, and thus simultaneously with the filling of the ballast filling chamber 7 with the ballast filling 15. The filling of the ballast filling chamber 7 with the ballast filling 15 and the compaction of the ballast filling are therefore carried out simultaneously and thus in parallel. (See 24323 / P24030-DEa / KBS= EM-KBS002 13.02.2025 - Geirhos)

[0128] In step 17, the vibrating table 26 is used, which vibrates the battery trough 2 containing the ballast 15 during the third process step S3, thereby ensuring that the ballast 15 is evenly distributed in the ballast chamber 7. The vibrating movements of the vibrating table 26 are illustrated in Figure 1 by the arrows R1 and R2.

[0129] In the third process step S3, the ballast filling chamber 7 is filled with ballast filling 15 until a desired amount of ballast filling has been filled into the ballast filling chamber 7.

[0130] In a subsequent fourth process step S4, the opened underside US of the battery tray 2 is closed with the base plate 12.

[0131] For this purpose, the base plate 12 can be inserted into the receiving grooves AN1, AN2 of the battery trough 2 after the ballast filling chamber 7 has been filled with the ballast filling 15.

[0132] This process step is shown in Figure 2, where the insertion of the base plate 12 is indicated by the arrow P1.

[0133] In a subsequent fifth process step S5, the battery trough 2, equipped with the base plate 12, is rotated 180° around a horizontal axis of rotation D.

[0134] The filling device 1 may for this purpose include a turning device (not shown in detail) designed to rotate the battery trough 2, optionally together with the support frame 25, by 180° about the horizontal axis of rotation D. This process step S5 is shown in Figures 3 and 4, with the rotation of the battery trough 2, which is provided with the base plate 12, being illustrated in Figure 3 by arrow P2.

[0135] After the rotation process, the battery trough 2 rests on the base plate 12. This state is illustrated in Figure 4. Preferably, the battery trough 2, with its base plate 12, is placed on the vibrating plate 26 of the filling device 1.

[0136] In a subsequent sixth process step S6, a further vibration process takes place on the battery trough 2, which is equipped with the base plate 12. 24323 / P24030-DEa / KBS= EM-KBS002 13.02.2025 - Geirhos

[0137] 18

[0138] The vibration process is preferably carried out with the vibrating plate 26 of the filling device 1.

[0139] This process step is shown in Figure 4, where the shaking movements of the shaking table 26 in Figure 4 are illustrated by the arrows R1 , R2.

[0140] The vibration process of the sixth process step S6 ensures that a connection is created between the ballast filling 15 and the base plate 12.

[0141] In a subsequent seventh process step S7, the ballast filling 15 is hardened to form a solid composite material.

[0142] During curing, the ballast filling 15 forms a bond with the walls 3a, 3b, 3c, 3d of the battery trough 2, with the intermediate floor 5 of the battery trough 2 and with the base plate 12.

[0143] After the ballast filling 15 has hardened into a solid composite material, the base plate 12 is fixed to the battery trough 2 and its outer wall 3 via the hardened ballast filling 15, thus eliminating the need for a welded connection between the base plate 12 and the outer wall 3. In the battery trough 2 manufactured according to the invention, the composite material 15b of the ballast filling 15, preferably in the form of a resin, ensures the permanent connection between the outer wall 3 and the base plate 12.

[0144] After the ballast filling 15 has hardened to form the solid composite material, the battery trough 2 can be used for the production of a traction battery, for example a lithium-ion traction battery, for a mobile working machine, in particular a forklift truck, wherein at least one battery module, for example a lithium-ion battery module, is installed in the receiving space 8 of the battery trough 2.

[0145] The mass of the ballast filling 15 placed in the battery tray 2 is preferably selected such that the weight of the battery tray 2 according to the invention, provided with the ballast filling 15, in the lithium-ion battery modules 24323 / P24030-DEa / KBS= EM-KBS002

[0146] February 13, 2025 - Geirhos

[0147] 19 are installed, and thus the weight of a lithium-ion traction battery having the battery tray 2 produced according to the invention is adapted and adjusted to the weight of a lead-acid traction battery with the same external dimensions of the battery tray 2, so that in a forklift truck a replacement of a lead-acid traction battery by a lithium-ion traction battery which is provided with the battery tray 2 produced according to the invention is made possible without impairing the load-bearing capacity and stability of the forklift truck.

[0148] The ballast filling 15, consisting of the ballast material 15a and the composite material 15b, thus represents a balancing weight or additional weight of the battery trough 2 in order to equalize a lithium-ion traction battery designed with the battery trough 2 according to the invention to the weight of a semi-acid traction battery with the same dimensions of the battery trough 2.

Claims

24323 / P24030-DEa / KBS= EM-KBS002 02 / 13 / 2025 - Geirhos 20 Patent claims 1. Method for manufacturing a battery tray (2) of a traction battery, in particular a lithium-ion traction battery, for a mobile working machine, in particular a forklift truck, wherein the battery tray (2) is at least partially filled with a ballast filling (15), wherein the ballast filling (15) comprises a ballast material (15a) and a composite material (15b), characterized by the steps: • Providing a battery trough (2), wherein the battery trough (2) has an outer shell (4) with a circumferential outer wall (3) and an intermediate floor (5) attached to the outer wall (3), wherein the intermediate floor (5) forms a ballast filling space (7) in the interior of the battery trough (2) and the battery trough (2) is open at the bottom (US), • Positioning the battery tray (2) with the open bottom (US) facing upwards on a filling device (1), • Filling the ballast chamber (7) with the ballast filling (15) using the filling device (1) via the open underside (US) of the battery tray (1), • Closing the open underside (US) of the battery tray (1) with a base plate (12), • Rotating the battery tray (2) equipped with the base plate (12) by 180° about a horizontal axis of rotation (D), • Curing of the ballast filling (15) to form a composite material.

2. Method according to claim 1, characterized in that the ballast filling (7) is compacted during the filling of the ballast filling chamber (7) or subsequently after the filling of the ballast filling chamber (7).

3. Method according to claim 2, characterized in that the battery trough (2) is shaken to compact the ballast filling (15).

4. Method according to claim 3, characterized in that a vibrating plate (26) of the filling device (1) is used to vibrate the battery trough (2). 24323 / P24030-DEa / KBS= EM-KBS002 02 / 13 / 2025 - Geirhos 21 5. Method according to one of claims 1 to 4, characterized in that when closing the open underside (US) of the battery tray (2) with the base plate (12) a positive locking connection is made between the base plate (12) and the battery tray (2).

6. Method according to claim 5, characterized in that, in order to close the open underside (US) of the battery tray (2) with the base plate (12), the base plate (12) is inserted into receiving grooves (AN1 , AN2) of the battery tray (2).

7. Method according to one of claims 1 to 6, characterized in that a vibration process of the battery trough (2) provided with the base plate (12) is carried out after the rotation of the battery trough (2) provided with the base plate (12) by 180° about the horizontal axis of rotation (D) and before the hardening of the ballast filling (15) to the composite material.

8. Method according to claim 7, characterized in that the vibration process is carried out with the vibrating plate (26) of the filling device (1).

9. Method according to one of claims 1 to 8, characterized in that when positioning the battery tray (2) with the open underside (US) facing upwards on the filling device (1) the battery tray (2) is lifted into a support frame (25).

10. Method according to one of claims 1 to 9, characterized in that when positioning the battery tray (2) with the open underside (US) facing upwards on the filling device (1), the battery tray (2) is placed on the vibrating plate (26) of the filling device (1).

11. Method according to one of claims 1 to 10, characterized in that metal parts and / or slag are used as ballast material (15a).

12. Method according to one of claims 1 to 11, characterized in that a resin, in particular a plastic resin, is used as the composite material (15b). 24323 / P24030-DEa / KBS= EM-KBS002 February 13, 2025 - Geirhos 22 13. Method according to one of claims 1 to 12, characterized in that the ballast material (15a) and the composite material (15b) are placed as a mixture into the battery trough (1) be poured in.

14. Method according to claim 13, characterized in that the mixture is produced in a mixing device.

15. Method according to claim 13, characterized in that the mixture is produced by spraying the ballast material (15a) with the composite material (15b).

16. Method according to one of claims 1 to 12, characterized in that the ballast material (15a) and the composite material (15b) are sequentially filled into the battery trough (2).

17. Battery trough (2), in particular for use in a method according to any one of claims 1 to 16, characterized in that the battery trough (2) has an outer shell (4) with a circumferential outer wall (3) and an intermediate floor (5) attached to the outer wall (3), which divides the interior of the battery trough (2) into a ballast filling chamber (7), which can be filled with the ballast filling (15) comprising a ballast material (15a) and a composite material (15b), and a receiving chamber (8) in which at least one battery module, in particular at least one lithium-ion battery module, can be installed, wherein the battery trough (2) is open at the bottom (US), wherein the open bottom (US) forms a filling opening for filling the ballast filling (15) into the ballast filling chamber (7) and wherein the open bottom (US) can be attached to the battery trough (2) by means of a base plate that can be positively or force-fitted. (12) is lockable.

18. Filling device (1) for carrying out the method according to one of claims 1 to 16, characterized in that the filling device (1) has a filling device (20) configured to discharge the ballast filling (15) into the ballast filling chamber (7) of the battery trough (2), and a vibrating plate (26) configured to vibrate the battery trough standing on the vibrating plate (26). (2) to shake. 24323 / P24030-DEa / KBS= EM-KBS002 02 / 13 / 2025 - Geirhos 23 19. Filling device (1) according to claim 18, characterized in that the filling device (1) has a reversing device configured to rotate the battery tray 180° about a horizontal axis of rotation (D).

20. Lithium-ion traction battery for a mobile work machine, in particular a Industrial truck, using a battery trough (2) manufactured according to one of claims 1 to 16, wherein at least one lithium-ion battery module is installed in the battery trough (2) provided with the hardened ballast filling (15).

Images