Electrical energy storage device, electrical appliance system, and method for producing an electrical energy storage device

Abstract

The invention relates to an electrical energy storage device, in particular in the form of a rechargeable battery pack, comprising at least one electrical energy storage cell, in particular a plurality of electrical energy storage cells, in particular in the form of rechargeable battery cells, wherein: the electrical energy storage device comprises a housing; the at least one electrical energy storage cell is accommodated in an accommodating space defined by the housing; the housing comprises at least one first housing part and at least one second housing part; the electrical energy storage device comprises an open-loop and / or closed-loop control device for open-loop and / or closed-loop control of the charging and / or discharging of the at least one electrical energy storage cell; the open-loop and / or closed-loop control device is accommodated in the first housing part and is at least partially, in particular entirely, potted therein with a curing potting compound which forms a potting body; a housing sealing element is arranged or formed between the first housing part and the second housing part in order to seal off the accommodating space; and the housing sealing element is formed from the potting compound. The invention also relates to an improved electrical appliance system and to an improved method for producing an electrical energy storage device.

Description

[0001] A 501 263 z Applicant: Alfred Kärcher SE & Co. KG Alfred-Kärcher-Strasse 28 - 40

[0002] November 10, 2025 71364 Winnenden

[0003] Electrical energy storage device, electrical appliance system and method for manufacturing an electrical energy storage device

[0004] The invention relates to an electrical energy storage device, in particular in the form of a battery pack, comprising at least one electrical energy storage cell, in particular a plurality of electrical energy storage cells, in particular in the form of rechargeable battery cells, wherein the electrical energy storage device comprises a housing and wherein the at least one electrical energy storage cell is received in a receiving space defined by the housing, wherein the housing comprises at least a first housing part and at least a second housing part, wherein the electrical energy storage device comprises a control and / or regulating device for controlling and / or regulating the charging and / or discharging of the at least one electrical energy storage cell, wherein the control and / or regulating device is received in the first housing part and is at least partially, in particular completely, enclosed therein by a potting compound forming a potting body.is cast in a hardened potting compound, wherein a housing sealing element is arranged or formed between the first housing part and the second housing part for sealing the receiving space.

[0005] Furthermore, the invention relates to an electrical appliance system comprising at least one battery-operated electrical appliance, in particular in the form of a power tool, a household or garden appliance, and at least one electrical energy storage device for supplying the at least one electrical appliance with electrical energy.

[0006] Furthermore, the invention relates to a method for manufacturing an electrical energy storage device, in particular in the form of a battery pack, which comprises at least one electrical energy storage cell, in particular a plurality of electrical energy storage cells, in particular in the form of rechargeable battery cells, wherein the electrical energy storage device comprises a housing, in which method the at least one electrical energy storage cell is inserted into a receiving space defined by the housing, wherein at least a first housing part and at least a second housing part are provided for forming the housing, a control and / or regulating device for controlling and / or regulating the charging and / or discharging of the at least one electrical energy storage cell is inserted into the first housing part and is at least partially, in particular completely,is cast with a potting material forming a potting body, wherein a housing sealing element is arranged or formed between the first housing part and the second housing part to seal the receiving space.

[0007] Electrical energy storage devices for use in conjunction with battery-powered electrical appliances are known in various forms. Examples are disclosed in particular in EP 2 224 513 Bl. This publication also describes encapsulating a control and / or regulating device of the electrical energy storage device with a potting material which hardens after potting and thus forms a potting body protecting the control and / or regulating device.

[0008] To protect the electrical energy storage device and, in particular, the components thereof contained in the housing from environmental influences, the housing is preferably sealed.

[0009] US Patent 2020 / 0358055 A1 describes a battery pack, a processing system, and a method for manufacturing a battery pack. EP 2 212 942 B1 discloses a battery pack and a power tool incorporating a battery pack. An object of the present invention is to improve an electrical energy storage device, an electrical appliance system, and a method of the type described above in such a way that sealing the housing can be achieved in a simple manner.

[0010] This problem is solved according to the invention in an electrical energy storage device of the type described above by forming the housing sealing element from the potting material.

[0011] The proposed embodiment according to the invention makes it possible, in particular, to form not only the potting compound but also the housing sealing element in a single step. It is then no longer necessary, after potting the control and / or regulating device, to first place a sealing element, for example, on an edge of the first housing part before connecting the first housing part to the second housing part, especially by bringing the second housing part into contact with the sealing element and the first housing part. With the proposed embodiment, the housing of the electrical energy storage device can be designed to be non-openable, particularly as intended. Any separation of the two housing parts not intended by the design would irreversibly destroy the housing, and in particular the housing sealing element.

[0012] Preferably, the potting compound and the housing sealing element are monolithic. Such a design can particularly increase the stability of the electrical energy storage device. Furthermore, it is particularly possible to fill the potting material into the first housing part in such a way that, while still fluid, the potting material can flow into the area between the first and second housing parts, thus forming a complete seal between the two housing parts, especially after the potting material has fully cured.According to a further preferred embodiment of the invention, a sealing element receptacle can be formed between the first housing part and the second housing part, the first housing part comprises a first sealing element contact surface, the second housing part comprises a second sealing element contact surface, and the housing sealing element is in contact with both the first and second sealing element contact surfaces. In this way, a perfect seal between the two housing parts can be achieved. In particular, the sealing element receptacle can be formed circumferentially on both housing parts, so that the housing sealing element forms a self-contained, annular sealing element.

[0013] It is advantageous if the housing defines an inner surface that delimits the receiving space, if this inner surface is partially enclosed by the first housing part and partially by the second housing part, and if the inner surface is interrupted around its circumference by the sealing element receptacle. Such a design makes it particularly easy to manufacture the electrical energy storage device. The interruption of the inner surface by the sealing element receptacle creates a simple opening to the housing interior. The potting compound, while still fluid, can then flow into the sealing element receptacle through this opening. This can occur, for example, when the second housing part is at least partially covered with the still uncured, fluid potting compound.

[0014] To prevent the potting compound from leaking out of the housing during the formation of the housing sealing element, it is advantageous if the sealing element receptacle is open only towards the receiving space. The potting compound can then only flow from the receiving space into the sealing element receptacle. It is beneficial if the sealing element receptacle defines a sealing element receiving volume, if the housing sealing element defines a housing sealing element volume, and if the housing sealing element volume is smaller than the sealing element receiving volume. In this way, it can be ensured, in particular, that the housing sealing element has a smaller overall volume than the sealing element receptacle. This, in particular, prevents potting compound from leaking out of the housing when the housing parts are engaged.

[0015] Advantageously, the sealing element receptacle is only partially filled with the housing sealing element to form a sealing element receptacle cavity. In other words, the sealing element receptacle is designed to be large enough that it is not completely filled when the potting compound flows into it, but rather a sealing element receptacle cavity is formed. This serves, in particular, as a compensation volume to reliably prevent the potting compound from leaking out of the housing when the housing parts are assembled.

[0016] For a good seal of the housing, it is advantageous if the cavity volume of the sealing element receiving cavity is smaller than the housing sealing element volume.

[0017] Preferably, the ratio between the cavity volume and the housing sealing element volume is in the range of approximately 1:20 to approximately 1:2. In particular, it can be in the range of approximately 1:15 to 1:10. A ratio between the cavity volume and the housing sealing element volume in the specified ranges ensures, in particular, optimal sealing of the housing and prevents the leakage of the potting material from the housing during the manufacture of the electrical energy storage device.

[0018] Advantageously, the sealing element receiving cavity is bounded by the housing sealing element, the first housing part, and the second housing part. This ensures, in particular, that the housing sealing element can optimally seal the first and second housing parts against each other.

[0019] The electrical energy storage device can be easily designed if the sealing element receptacle is formed in the form of a gap. In particular, the gap can be designed such that the still-flowable potting material is drawn into the gap, and thus into the sealing element receptacle, by capillary action.

[0020] To facilitate the flow of the still fluid potting material into the gap, it is advantageous if the gap includes a first gap section extending transversely, in particular perpendicularly, to the inner surface of the housing.

[0021] It is advantageous if the first gap section defines a gap plane, if the potting compound defines a potting surface pointing towards the second housing part, and if the potting compound surface runs parallel or substantially parallel to the gap plane. This allows the potting material to reliably enter the gap. Furthermore, sufficient filling of the sealing element receptacle with the potting material can be ensured, for example, by appropriately filling the first housing part so that the potting compound level is high enough to ensure that the inner surface of both the first and second housing parts is in contact with the potting compound.In this way, a connection between the housing parts can be achieved not only in the area of ​​the sealing element receptacle, but also through a liquid-filled connection of the potting compound with the inner surface of the housing on both the first housing part and the second housing part.

[0022] Furthermore, it is advantageous if an end surface of the housing sealing element, which delimits the sealing element receiving cavity, defines an end surface plane, and if the end surface plane runs parallel or substantially parallel to the gap plane and / or parallel or substantially parallel to the potting compound surface. This ensures, in particular, that the sealing element receiving cavity is sufficiently filled with potting compound to form the housing sealing element.

[0023] For a reliable seal of the housing, it is advantageous if the potting compound surface lies between the gap plane and the end surface plane. This allows, in particular, the specification that the fill level of the potting material in the sealing element receptacle is higher than in the housing.

[0024] Preferably, the gap includes a second gap section extending parallel or substantially parallel to the inner surface of the housing. In particular, an L-shaped gap can be formed in cross-section. This further improves the fluid-filled connection between the housing parts in the area of ​​the sealing element receptacle. Furthermore, the potting compound can rise, especially in the sealing element receptacle in the area of ​​the second gap section, thus defining the end surface of the housing sealing element. The amount of potting compound used to form the housing sealing element is then selected such that the potting compound surface lies between the gap plane and the end surface plane.

[0025] Preferably, the second gap section extends in a direction away from the potting compound. This means, in particular, that the end surface of the housing sealing element defines the end surface plane, which runs at a distance from the potting compound surface.

[0026] For the potting compound to flow easily into the sealing element receptacle, it is advantageous if the gap has a defined width, ideally between approximately 0.2 mm and 7 mm. For example, the gap width could be between approximately 1 mm and 3 mm. In particular, the gap can be designed with a width that allows the potting compound to flow in with the aid of capillary action. For example, the gap could have a width of 1.5 mm. This is especially sufficient to allow highly viscous potting compounds, such as cyanoacrylates, to flow into the gap via capillary action.

[0027] In order to engage the housing parts in a defined manner in order to close the receiving space, it is advantageous if the first housing part includes a first stop surface, if the second housing part includes a second stop surface, and if the first stop surface is directly adjacent to the second stop surface.

[0028] The leakage of the potting compound from the sealing element receptacle can be easily prevented if the sealing element receptacle is closed by the second stop surface.

[0029] For the manufacture of the electrical energy storage device, it is advantageous if the potting material is a plastic or contains a plastic. Preferably, the plastic is a flowable, fully curing plastic. The plastic can then be poured, for example, into the first housing part in a flowable state, and subsequently cured to form the potting element.

[0030] The electrical energy storage device can be designed simply and cost-effectively if the plastic is or contains a resin, polyurethane, polyepoxide and / or silicone.

[0031] To reliably connect the two housing parts, it is advantageous for the first and second housing parts to engage by force-fit and / or positive locking. For this purpose, corresponding connecting elements, such as corresponding locking elements, can be provided on the two housing parts to form a snap-fit ​​or latching connection for coupling the two housing parts in a coupled position. The sealing element receptacle is also formed in this coupled position. Preferably, the first and second housing parts are connected without screws. While it is known to use screws to connect housing parts, these have the disadvantage that, for example, if they are tightened too much, the housing sealing element can be damaged. This cannot happen if the housing parts are connected without screws.

[0032] To be able to extract electrical energy from the electrical energy storage device, it is advantageous if the electrical energy storage device has at least two connection contacts and if these at least two connection contacts are sealed and lead out of the housing through at least one, and preferably only one, connection contact opening. In this way, the electrical energy storage device can then be effectively connected to, for example, a battery-operated electrical device to supply the device with electrical energy. Sealing the at least one connection contact opening prevents, in particular, fluids from entering the receiving space in an undesirable manner and damaging the components of the electrical energy storage device contained therein.

[0033] It is advantageous if the at least one terminal contact opening is bounded by a support element of the control and / or regulating device, and if a penetration sealing element, abutting the first housing part and the support element, is arranged or formed around the at least one terminal contact opening. The penetration sealing element can, in particular, be formed separately from the support element and the first housing part. To seal the support element relative to the first housing part, it can then be positioned between them. However, it is also possible to bond the penetration sealing element directly to the first housing part or the support element, for example, by injection molding a suitable plastic to form the penetration sealing element.

[0034] For optimal sealing of the housing, it is advantageous if the penetration sealing element is made of an elastic and / or flexible sealing element material. In particular, the sealing element material can be or contain an elastic polymer, for example, a natural or synthetic polymer such as rubber, polyvinyl acetate (PVA), polyvinyl chloride (PVC), polypropylene-based (PTFA), or linear low-density polyethylene (LLDPE).

[0035] According to a further preferred embodiment of the invention, at least one vent opening can be arranged or formed on the housing, particularly on the second housing part, and this vent opening can be fluid-tightly sealed by at least one sealing element. The vent opening can, in particular, be in the form of a perforation in the housing that fluidly connects the receiving chamber to the environment of the energy storage device. It serves, in particular, to allow gases to escape from the housing during the curing of the potting material. The vent opening can be fluid-tightly sealed by the sealing element, particularly after the potting material has cured, i.e., after the formation of the potted body. For example, the sealing element can be in the form of a label.Furthermore, at least one vent opening can be arranged or designed in the area of ​​a recess on the housing, in order to minimize in particular the risk of damaging the at least one closure element.

[0036] Preferably, the sealing element is designed in the form of a pressure relief valve. Gases produced during the curing of the potting material can thus escape automatically through the vent opening when the pressure relief valve at least partially releases it as soon as the gas pressure prevailing in the receiving chamber exceeds a pressure limit value specified by the pressure relief valve.

[0037] For a good and reliable seal of the housing, it is advantageous if the sealing element is connected to the housing by force, form, and / or material bonding. For example, it can be screwed on and optionally additionally secured with adhesive.

[0038] The problem set out at the beginning is further solved in an electrical appliance system of the type described at the beginning according to the invention in that the electrical energy storage device is designed in the form of one of the electrical energy storage devices described above.

[0039] The electrical device system thus also exhibits the advantages described above in connection with preferred embodiments of electrical energy storage devices. In particular, improved moisture resistance and, optionally, water resistance can be achieved while simultaneously optimizing the cost of the electrical device system. This also results in a longer service life for the electrical and electronic components housed within the electrical energy storage device, and consequently for the electrical energy storage device as a whole.

[0040] The electrical appliance system can, in particular, comprise two, three, four, or more electrical appliances. It can also include two, three, four, or more electrical energy storage devices. For example, the electrical appliance can also be in the form of a battery-powered vehicle, in particular a motor vehicle or an electric scooter, or a sweeper, in particular a ride-on sweeper. There are generally no restrictions on the use of the proposed energy storage devices. Preferably, the battery-powered household or garden appliance is in the form of a cleaning device. In particular, it can be in the form of a floor cleaner, a vacuum cleaner, a pressure washer, a steam cleaner, a sweeper, a saw, a blower, a lawnmower, or a hedge trimmer. The list of household and garden appliances mentioned is, of course, not exhaustive.Other devices are also conceivable that can be operated independently of the grid using electrical energy storage devices.

[0041] It is advantageous if the at least one battery-operated electrical device is designed to be operated with at least one, and in particular with only one, two, three, four, or more electrical energy storage devices. Depending on the power or voltage requirements of the battery-operated electrical device, a corresponding number of electrical energy storage devices can be used. In particular, with appropriate wiring, a desired operating voltage for an electrical device can be achieved not only with one electrical energy storage device, but also with two electrical energy storage devices connected in series, whose nominal voltages correspond to only half the operating voltage of the electrical device.

[0042] It is advantageous if at least one rechargeable battery can be connected to various battery-powered electrical devices. This allows a user to operate multiple devices while requiring only one electrical energy storage device, which can be connected to the specific device being used. This eliminates the need for all electrical devices to be equipped with energy storage devices, particularly rechargeable batteries. Users can thus optimally utilize one or more energy storage devices. Furthermore, this reduces the overall number of required energy storage devices, which is also beneficial from an environmental perspective.The problem set out at the beginning is further solved according to the invention in a method of the type described at the beginning by forming the housing sealing element from the potting material.

[0043] As already explained in detail, this allows for a particularly simple design of the electrical energy storage device. When potting the control and / or regulating unit of the electrical energy storage device, the housing sealing element can also be formed simultaneously. Therefore, it is not necessary to position a separate housing sealing element between the two housing parts to seal them. Instead, the potting material can be used for this purpose; it is introduced between the two housing parts during the potting process to seal and optionally join them.

[0044] To improve the stability of the electrical energy storage device and ensure optimal sealing of the housing, it is advantageous for the potting compound and the housing sealing element to be monolithic. They thus form a permanently bonded unit.

[0045] Furthermore, it is advantageous to form a receptacle for the sealing element between the first and second housing parts, provided that the first housing part includes a first sealing element contact surface, the second housing part includes a second sealing element contact surface, and the second housing part is placed onto the first housing part to form the receptacle, allowing the flowable potting compound to flow into it. This also allows the housing sealing element to be formed in such a way that it is in contact with both the first and second sealing element contact surfaces. The proposed procedure thus makes it possible, in particular, to form the receptacle only when the two housing parts are engaged with each other. This ensures, in particular, that the receptacle is bounded by both the first and second sealing element contact surfaces.

[0046] It is advantageous if the potting compound applied to the first housing part is at least partially cured, particularly by heat, IR radiation, UV radiation, and / or coherent radiation, before the second housing part is placed onto the first to form the sealing element receptacle. This approach has the particular advantage that the potting compound can be at least partially cured, for example, by direct irradiation. This is no longer possible once the two housing parts are engaged. This allows for simpler curing of the potting compound. However, it should be ensured, if possible, that the partially cured potting compound is still fluid enough to flow into the sealing element receptacle.

[0047] Preferably, the potting compound is fully cured after the second housing part is placed onto the first housing part. This process step, in particular, finalizes the formation of the potting element and also the formation of the housing sealing element.

[0048] Furthermore, the use of one of the advantageous methods described above for the manufacture of one of the advantageous electrical energy storage devices described above is proposed.

[0049] Furthermore, the use of one of the methods described above for the manufacture of one of the electrical energy storage devices described above is proposed.

[0050] The following description of preferred embodiments of the invention, in conjunction with the drawings, serves for further explanation. Figure 1 shows a schematic representation of an exemplary embodiment of an electrical appliance system;

[0051] Figure 2: a schematic representation of the first housing part, at least partially filled with potting material, before the second housing part is attached;

[0052] Figure 3: a schematic sectional view through an electrical energy storage device, wherein the first housing part is at least partially filled with a flowable potting material, before the second housing part is attached;

[0053] Figure 4: a view similar to Figure 3, but after placing the second housing part onto the first housing part;

[0054] Figure 5: an enlarged view of area A in Figure 4;

[0055] Figure 6: a schematic sectional view of the electrical energy storage device similar to Figure 4; and

[0056] Figure 7: a sectional view along line 7-7 in Figure 6.

[0057] Figure 1 schematically illustrates an embodiment of an electrical appliance system 10. It comprises one or more electrical energy storage devices 12 and one or more battery-operated electrical appliances 14.

[0058] The purely schematic embodiments of electrical appliances 14 shown in Figure 1 each comprise at least one electrical consumer 16.

[0059] The electrical energy storage device 12 is designed to be detachably connected to at least one of the electrical appliances 14. For this purpose, an energy storage device receptacle 18 may be provided on the electrical appliance 14. In a connected position in which the electrical appliance 14 and the electrical energy storage device 12 are operatively connected to each other, particularly mechanically and electrically, electrical energy stored in the electrical energy storage device 12 can be transferred to the electrical appliance 14 in a manner known to those skilled in the art.

[0060] The electrical appliance 14 comprises an appliance housing 20 in which the electrical consumer 16 is at least partially, in particular completely, enclosed.

[0061] The electrical energy storage device 12 and the device housing 20 can be mechanically and electrically coupled to and separated from each other.

[0062] The electrical consumer 16 can be designed in particular in the form of an electric motor 22.

[0063] In alternative embodiments, the electrical consumer 16 can also be designed in the form of a heating device, for example to heat water, in particular to evaporate it.

[0064] The electrical device 14 can also be designed to be optionally connected to a plurality of electrical energy storage devices 12. In particular, these can be electrical energy storage devices 12 of different sizes and storage capacities. Optionally, it is also possible to connect the electrical device 14 to more than one electrical energy storage device 12 simultaneously. In this way, higher operating voltages required when necessary can be achieved by connecting several electrical energy storage devices 12 in series. There are generally no restrictions on the type of electrical device 14. For example, it can be designed in the form of a battery-powered vehicle, in particular a motor vehicle or an electric scooter, or as a sweeper, in particular a ride-on sweeper.In particular, it can be designed in the form of a power tool, a household or garden appliance 24, for example, as a pushable, wheeled, or portable garden tool. Examples include, in particular, sweepers, saws, blowers, lawnmowers, or hedge trimmers. This list is not exhaustive. The electrical appliance 14 can also be designed in the form of a floor cleaning device, a vacuum cleaner, a high-pressure cleaner, or a steam cleaner. This list of examples of electrical appliances 14 in the form of household appliances is also not exhaustive.

[0065] In the embodiment shown in Figure 1, the electrical energy storage device 12 is designed in the form of a so-called battery pack 26. It comprises a housing 28 which defines a receiving space 30.

[0066] The housing 28 comprises a first housing part 38 and a second housing part 40. In the receiving space 30 defined by the housing 28, several electrical energy storage cells 32 are accommodated in the embodiments shown in the figures. These are connected to one another in the usual manner by electrically conductive cell connectors 42, for example, to realize a series connection of the five schematically depicted battery cells 34. In this case, the voltage provided by each battery cell 34 for the entire battery pack 26 is five times its individual value.

[0067] Furthermore, a control and / or regulating device 44 for controlling and / or regulating the charging or discharging or for monitoring the energy storage cells 32 is included in the receiving space 30. The control and / or regulating device 44 is mounted on a carrier element in the form of a conventional circuit board. Electrical and electronic components 100 of the control and / or regulating device 44 are positioned on the carrier element 46 in a conventional manner and are contacted accordingly.

[0068] As schematically shown in Figures 2 and 3, the control and / or regulating device 44 is essentially enclosed in the first housing part 38. To protect the electrical and electronic components 100 of the control and / or regulating device 44 from corrosion, it is encased in a curable potting material 50 forming a potting body 48.

[0069] A housing sealing element 52 is arranged or formed between the first housing part 38 and the second housing part 40 for sealing the receiving space 30. As will be explained in more detail below, the housing sealing element 52 is made of the potting material 50.

[0070] The first housing part 38 comprises a first stop surface 54. The second housing part 40 comprises a second stop surface 56. These are, as can be seen particularly well in Figure 5, directly adjacent to each other.

[0071] The first stop surface 54 is formed as a circumferential edge surface projecting from the first housing part 38 towards the second housing part 40. Parallel to the first stop surface 54, but set back, extends a first edge surface 58, also pointing towards the second housing part 40. Opposite the first edge surface 58, a front face 60 of the second housing part 40 is positioned, running parallel to it. The front face 60 runs parallel to the second stop surface 56.

[0072] The first edge surface 58 and the first stop surface 54 are connected to each other via a first gap surface 62. In this embodiment, the first gap surface 62 runs transversely, namely perpendicular to both the first edge surface 58 and the first stop surface 54. Opposite the first gap surface 62 is a second gap surface 64, which connects the end surface 60 and the second stop surface 56. The first gap surface 62 and the second gap surface 64 are spaced apart from each other.

[0073] A sealing element receptacle 66 is formed between the first housing part 38 and the second housing part 40. A first sealing element contact surface 68, encompassed by the first housing part 38, comprises the first edge surface 58 and the first gap surface 62. A second sealing element contact surface 70, encompassed by the second housing part 40, comprises the end face 60 and the second gap surface 64. As can be seen particularly well in Figure 5, the housing sealing element 52 is in contact with both the first sealing element contact surface 68 and the second sealing element contact surface 70.

[0074] The housing 28 comprises an inner housing surface 72 that defines the receiving space 30. This surface is formed partly by the first housing part 38 and partly by the second housing part 40. The inner housing surface 72 is interrupted by the sealing element receptacle 66, and this interruption extends around the entire circumference of the receiving space 30.

[0075] Due to the described design of the sealing element receptacle 66, which is bounded by the first edge surface 58, the first gap surface 62, the second stop surface 56, the second gap surface 64 and the end face 60, it is open only in the direction towards the receiving chamber 30. An end 74 of the sealing element receptacle 66 pointing away from the inner housing surface 72 is closed by, or formed by, the second stop surface 56.

[0076] The housing sealing element 52 extends from the inner housing surface 72 into the sealing element receptacle 66, but not to the end 74. Therefore, a sealing element receptacle cavity 76 is formed adjacent to the end 74 in the sealing element receptacle 66. The sealing element receptacle 66 defines a sealing element receptacle volume. The housing sealing element 52 defines a housing sealing element volume. The housing sealing element volume is smaller than the sealing element receptacle volume.

[0077] Furthermore, the sealing element receiving cavity 76 defines a cavity volume. This is smaller than the housing sealing element volume.

[0078] Furthermore, the ratio between cavity volume and housing sealing element volume is in the range of approximately 1:20 to approximately 1:2. In the embodiment shown in the figures, the ratio is in the range of approximately 1:15 to approximately 1:10.

[0079] As can be clearly seen in Figure 5, the sealing element cavity 76 is bounded by the housing sealing element 52 as well as by the first housing part 38 and the second housing part 40, namely by the second stop surface 56 and the second gap surface 64 of the second housing part 40 as well as by the first gap surface 62 of the first housing part 38.

[0080] The sealing element receptacle 66 is designed in the form of a gap 78. It extends transversely, namely perpendicular to the inner housing surface 72, along a first gap section 80. The gap 78 comprises a second gap section 82 extending parallel or nearly parallel to the inner housing surface 72. The second gap section 82 extends in one direction away from the first edge surface 58 and thus also in one direction away from the potting element 48.

[0081] The gap 78 defines a gap width 84, which has a value in the range of approximately 0.2 mm to approximately 7 mm. In the exemplary embodiment of the electrical energy storage device shown in the figures, the gap width 84 is approximately 1.5 mm. Such a gap width is particularly sufficient to allow highly viscous potting materials 50, such as cyanoacrylates, to flow into the gap 78 by means of capillary action.

[0082] The first gap section 80, together with its bounding first edge surface 58, defines a gap plane 86. The potting element 48 defines a potting surface 88 pointing towards the second housing part 40, which runs parallel or substantially parallel to the gap plane 86.

[0083] An end surface 90 of the housing sealing element 52, which delimits the sealing element receiving cavity 76, defines an end surface plane 92. The end surface plane 92 runs parallel or substantially parallel to the gap plane 86 and parallel or substantially parallel to the potting body surface 88. Furthermore, it can be clearly seen in Figure 5 that the potting body surface 88 extends between the gap plane 86 and the end surface plane 92.

[0084] The two housing parts 38 and 40 engage with each other by force and / or form locking. For this purpose, in particular, six pins 94 projecting from the first housing part 38 towards the second housing part 40 are formed on the first housing part 38, which engage in pin receptacles formed on the second housing part 40 (not shown in detail) when the second housing part 40 closes the first housing part 38.

[0085] Furthermore, housing parts 38 and 40 are connected to each other without screws, i.e., without screws.

[0086] The electrical energy storage device 12 further comprises at least two connection contacts 96. These are led out of the housing 28 in a sealed manner through a connection contact opening 98. The connection contacts 96 – in the embodiment shown in the figures, two are shown by way of example in Figure 2 and five by way of example in Figure 7 – are arranged on a lower side of the support element 46. The battery cells 34 are connected to a top side of the support element 56. Electrical or electronic components 100 comprising the control and / or regulating device 44, which are shown schematically in Figures 3, 4 and 6, are positioned on both the upper and lower sides of the support element 46.

[0087] The terminal contact opening 98 is formed on the first housing part 38. The support element 46 is arranged opposite the terminal contact opening 98. A sealing element 102 is arranged or formed between the support element 46 and an edge surrounding the terminal contact opening 98. The support element 46 thus limits or closes the terminal contact opening 98. The sealing element 102 surrounds the terminal contact opening 98 in an annular manner and is in contact with the first housing part 38 and the support element 46.

[0088] The penetration sealing element 102 is made of an elastic and / or flexible sealing element material. This material can be or contain an elastic polymer, for example, a natural or synthetic polymer such as rubber, polyvinyl acetate (PVA), polyvinyl chloride (PVC), polypropylene-based (PTFA), or linear low-density polyethylene (LLDPE).

[0089] The penetration sealing element 102 is either designed as a separate component or is integrally formed around the connection contact opening 98 on the first housing part 38 or bonded to it by means of a material connection, for example by gluing or injection molding. Alternatively, the penetration sealing element 102 is arranged or formed on the support element 46 corresponding to the connection contact opening 98. In particular, it can be bonded to the support element 46 by means of a material connection, for example by gluing or injection molding. Optionally, a vent opening 104 is formed on the housing 28 – this is shown schematically on the second housing part 40 in Figure 3 – which is realized as a penetration of a wall 106 of the housing, for example in the form of one or more bores.

[0090] The vent opening 104 is formed on the outside of the housing 28 in the area of ​​a recess 108. The vent opening 104 is closed in the area of ​​the recess 108 by a sealing element 110. This can be a self-adhesive label that is bonded to the housing 28 in the area of ​​the recess 108 and thus seals the vent opening 104 in a fluid-tight manner.

[0091] In alternative embodiments not shown, the closure element 110 is designed in the form of a pressure relief valve.

[0092] The sealing element 110 can optionally be connected to the housing 28 by force-fit and / or form-fit to seal the vent opening 104 fluid-tight. Optionally, such a sealing element 110 can also be materially bonded to the housing 28. For example, the sealing element 110 can be in the form of a threaded plug which, in a closed position where it fluidly seals the vent opening 104, is additionally materially bonded to the housing 28, for example by gluing or welding. Alternatively or additionally, a further sealing element can be provided to seal the sealing element relative to the housing 28.

[0093] The following procedure is used to manufacture the electrical energy storage device 12.

[0094] First, the two housing parts 38 and 40 are provided. The carrier element 46 with the control and / or regulating device 44 and the battery cells 34 arranged therein is inserted into the first housing part 38. It is placed on the penetration sealing element 102, which in this embodiment surrounds the connection contact penetration 98 and projects into the receiving space 30 and is integrally formed on the first housing part 38.

[0095] The potting compound 50, also referred to as casting material, is now poured into the first housing part 38 in a flowable state. Figure 2 shows the first housing part 38 filled with the potting compound 50 as described. Figure 3 clearly shows that enough potting compound 50 is poured into the first housing part 38 so that the fill level of the potting compound 50, and thus the surface area of ​​the potted body 88, is higher than the gap plane 86.

[0096] Now, as schematically shown in Figure 3, the second housing part 40 is placed onto the first housing part 38. The end face 60 is immersed in the potting compound 50. The second housing part 40 is moved towards the first housing part 38 until the second stop surface 56 abuts the first stop surface 54. This is clearly visible in Figures 4 to 6. When the stop surfaces 54 and 56 are in contact, the sealing element receptacle 66 is formed as described above.

[0097] The potting compound 50, filled in sufficient quantity into the first housing part 38, can flow into the sealing element receptacle 66, particularly aided by capillary action. With a suitable selection of the gap width 84, the end surface plane 92 then runs over or above the potting element surface 88 in the receiving space 30.

[0098] The described procedure results in the potting element 48 and the housing sealing element 52 being formed monolithically. In other words, they consist of one piece.

[0099] The potting compound can now be cured, for example, by heat, IR radiation, UV radiation, and / or coherent radiation. Optionally, the potting compound 50 can be partially cured before the second housing part 40 is placed onto the first housing part 38. This slightly reduces the flowability of the potting compound 50. Care should be taken to ensure that the flowability of the potting compound 50 is maintained sufficiently so that, after the second housing part 40 is placed onto the first housing part 38, the potting compound 50 can still flow into the sealing element receptacle 66 to form the housing sealing element 52.

[0100] In the manner described, the potting of the support element 46 not only protects it and the components 100 arranged on it, but also simultaneously seals the housing 28 by forming the housing sealing element 52 from the potting material 50. The housing parts 38 and 40 are then also materially bonded to each other in the area of ​​the sealing element receptacle 66.

[0101] The energy storage device 12, manufactured as described, is not designed for the user to open the housing 28. When separating the second housing part 40 from the first housing part 38, the forces exerted by the housing sealing element 52 must be overcome, resulting in irreversible damage to the housing sealing element 52 and / or the first housing part 38 and / or the second housing part 40 in the area of ​​the sealing element receptacle 66.

[0102] The housing sealing element 52 thus also serves as an indicator of whether the housing 28 has been opened improperly or not. In particular, the housing sealing element 52 forms a predetermined breaking point in the area of ​​the first gap section 18 if the housing parts 38 and 40 are forcibly separated.

[0103] The described embodiments of electrical energy storage devices 12 can be manufactured easily because the housing sealing element 52 does not need to be provided separately, but is automatically formed during the potting of the support element 46 and the closing of the receiving chamber 30 by engaging the first and second housing parts 38 and 40. This simplifies manufacturing and thus also reduces production costs. The potting material 50, which is required anyway for potting the support element 46, is thus also used for sealing the housing 28 and for joining the two housing parts 38 and 40.

[0104] Reference symbol list

[0105] Electrical appliance system electrical energy storage device

[0106] electrical appliance electrical consumer

[0107] Energy storage device intake

[0108] Device housing

[0109] electric motor

[0110] Household or garden equipment

[0111] Battery pack

[0112] Housing

[0113] Storage space for electrical energy storage cell

[0114] battery cell

[0115] Round cell, first housing part, second housing part

[0116] Cell connectors

[0117] Control and / or regulatory device

[0118] Support element

[0119] potting compound

[0120] Potting material

[0121] Housing sealing element first stop surface second stop surface first edge surface

[0122] End face first cleavage surface second cleavage surface

[0123] Sealing element receptacle first sealing element receptacle surface second sealing element receptacle surface housing inner surface

[0124] End

[0125] Sealing element receiving cavity

[0126] gap first gap section second gap section

[0127] Gap width

[0128] cleavage plane

[0129] Casting body surface

[0130] End surface

[0131] End surface plane

[0132] Pen

[0133] Connection contact

[0134] Connection contact interruption

[0135] component

[0136] Penetration sealing element

[0137] vent

[0138] Wall

[0139] Return

[0140] Locking element

Claims

Patent claims 1. Electrical energy storage device (12), in particular in the form of a battery pack (26), comprising at least one electrical energy storage cell (32), in particular a plurality of electrical energy storage cells (32), in particular in the form of rechargeable battery cells (34), wherein the electrical energy storage device (12) comprises a housing (28) and wherein the at least one electrical energy storage cell (32) is received in a receiving space (30) defined by the housing (28), wherein the housing (28) comprises at least a first housing part (38) and at least a second housing part (40), wherein the electrical energy storage device (12) comprises a control and / or regulating device (44) for controlling and / or regulating the charging and / or discharging of the at least one electrical energy storage cell (32), wherein the control and / or regulating device (44) is received in the first housing part (38) and is at least partially enclosed therein,in particular, is completely encased with a hardened potting material (50) forming a potting body (48), wherein a housing sealing element (52) is arranged or formed between the first housing part (38) and the second housing part (40) for sealing the receiving space (30), characterized in that the housing sealing element (52) is formed from the potting material (50).

2. Electrical energy storage device according to claim 1, characterized in that the potting body (48) and the housing sealing element (52) are monolithic.

3. Electrical energy storage device according to one of the preceding claims, characterized in that a sealing element receptacle (66) is formed between the first housing part (38) and the second housing part (40), that the first housing part (38) comprises a first sealing element contact surface (68), that the second housing part (40) comprises a second sealing element contact surface (70) and that the housing sealing element (52) is in contact with the first sealing element contact surface (68) and the second sealing element contact surface (70).

4. Electrical energy storage device according to claim 3, characterized in that the housing (28) defines an inner housing surface (72) limiting the receiving space (30), that the inner housing surface (72) is partially encompassed by the first housing part (38) and partially by the second housing part (40), and that the inner housing surface (72) is interrupted all around by the sealing element receptacle (66).

5. Electrical energy storage device according to claim 3 or 4, characterized in that the sealing element receptacle (66) a) is only open in the direction of the receiving space (30) and / or b) defines a sealing element receptacle volume, that the housing sealing element (52) defines a housing sealing element volume and that the housing sealing element volume is smaller than the sealing element receptacle volume.

6. Electrical energy storage device according to one of claims 3 to 5, characterized in that the sealing element receptacle (66) is only partially filled with the housing sealing element (52) to form a sealing element receptacle cavity (76), wherein in particular a cavity volume of the sealing element receptacle cavity (76) is smaller than the housing sealing element volume, wherein furthermore in particular a ratio between cavity volume and housing sealing element volume is in a range of about 1:20 to about 1:2, in particular in a range of about 1:15 to about 7. Electrical energy storage device according to claim 6, characterized in that the sealing element receiving cavity (76) is limited by the housing sealing element (52), by the first housing part (38) and by the second housing part (40).

8. Electrical energy storage device according to one of claims 3 to 7, characterized in that the sealing element receptacle (66) is designed in the form of a gap (78), wherein in particular the gap (78) comprises a first gap section (80) extending transversely, in particular perpendicularly, to the inner surface (72) of the housing.

9. Electrical energy storage device according to claim 8, characterized in that the first gap section (80) defines a gap plane (86), that the potting body (48) defines a potting body surface (88) pointing towards the second housing part (40), and that the potting body surface (88) extends parallel or substantially parallel to the gap plane (86), wherein in particular an end surface (90) of the housing sealing element (52) limiting the sealing element receiving cavity (76) defines an end surface plane (92), and that the end surface plane (92) extends parallel or substantially parallel to the gap plane (86) and / or parallel or substantially parallel to the potting body surface (88), wherein in particular the potting body surface (88) extends between the gap plane (86) and the end surface plane (92).

10. Electrical energy storage device according to claim 8 or 9, characterized in that the gap (78) comprises a second gap section (82) extending parallel or substantially parallel to the inner surface (72) of the housing, wherein in particular the second gap section (82) extends in a direction away from the potting body (48).

11. Electrical energy storage device according to one of claims 8 to 10, characterized in that the gap (78) defines a gap width (84) and that the gap width (84) has a value in a range of about 0.2 mm to about 7 mm.

12. Electrical energy storage device according to one of the preceding claims, characterized in that the first housing part (38) comprises a first stop surface (54), that the second housing part (40) comprises a second stop surface (56) and that the first stop surface (54) rests directly against the second stop surface (56), wherein in particular the sealing element receptacle (66) is closed by the second stop surface (56).

13. Electrical energy storage device according to one of the preceding claims, characterized in that the potting material is a plastic or contains a plastic, wherein in particular the plastic is a flowable, fully curing plastic for processing, wherein in particular the plastic is or contains a resin, polyurethane, polyepoxide and / or silicone.

14. Electrical energy storage device according to one of the preceding claims, characterized in that the first housing part (38) and the second housing part (40) a) engage by force and / or form locking and / or b) are connected to each other without screws.

15. Electrical energy storage device according to one of the preceding claims, characterized in that the electrical energy storage device (12) has at least two connection contacts (96) and that the at least two connection contacts (96) are made from the housing (28) are led out sealed through at least one, in particular only one, terminal contact opening (98), wherein in particular the at least one terminal contact opening (98) is limited by a support element (46) of the control and / or regulating device (44) and that the at least one terminal contact opening (98) is surrounded by a penetration sealing element (102) which abuts the first housing part (38) and the support element (46).

16. Electrical energy storage device according to claim 15, characterized in that the penetration sealing element (102) is formed from an elastic and / or flexible sealing element material, in particular an elastic polymer, further in particular from a natural or synthetic polymer, further in particular from rubber, polyvinyl acetate (PVA), polyvinyl chloride (PVC), polypropylene-based (PTFA) or linear low-density polyethylene (LLDPE) or containing such.

17. Electrical energy storage device according to one of the preceding claims, characterized in that at least one vent opening (104) is arranged or formed on the housing (28), in particular on the second housing part (40), and that the at least one vent opening (104) is closed fluid-tight with at least one closure element (110), wherein in particular the closure element (110) a) is designed in the form of a pressure relief valve and / or b) is connected to the housing (28) by force and / or form and / or material connection.

18. Electrical appliance system (10) comprising at least one battery-operated electrical appliance (14), in particular in the form of a power tool, a household or garden appliance (24), and at least one electrical Energy storage device (12) for supplying the at least one electrical device (14) with electrical energy, characterized in that the electrical energy storage device (12) is designed in the form of an electrical energy storage device (12) according to one of the preceding claims.

19. Electrical appliance system according to claim 18, characterized in that a) the battery-operated household or garden appliance (24) is designed in the form of a cleaning appliance, in particular in the form of a floor cleaning appliance, a vacuum cleaner, a high-pressure cleaner, a steam cleaner, a sweeper, a saw, a blower, a lawnmower or a hedge trimmer and / or b) the battery-operated electrical appliance (14) is designed to be operated with at least one, in particular with only one, with two, three, four or more electrical energy storage devices (12).

20. Electrical appliance system according to claim 18 or 19, characterized in that the at least one electrical energy storage device (12) can be optionally coupled with different battery-operated electrical appliances (14).

21. Method for manufacturing an electrical energy storage device (12), in particular in the form of a battery pack (26), which comprises at least one electrical energy storage cell (32), in particular a plurality of electrical energy storage cells (32), in particular in the form of rechargeable battery cells (34), wherein the electrical energy storage device (12) comprises a housing (28), in which method the at least one electrical energy storage cell (32) is inserted into a receiving space (30) defined by the housing (28). wherein at least one first housing part (38) and at least one second housing part (40) are provided for the formation of the housing (28), a control and / or regulating device (44) for controlling and / or regulating the charging and / or discharging of the at least one electrical energy storage cell (32) is inserted into the first housing part (38) and is at least partially, in particular completely, encased therein with a potting material (50) forming a potting body (48), wherein a housing sealing element (52) is arranged or formed between the first housing part (38) and the second housing part (40) for sealing the receiving space, characterized in that the housing sealing element (52) is formed from the potting material (50).

22. Method according to claim 21, characterized in that the potting body (48) and the housing sealing element (52) are formed monolithically.

23. Method according to claim 21 or 22, characterized in that a sealing element receptacle (66) is formed between the first housing part (38) and the second housing part (40), that the first housing part (38) comprises a first sealing element contact surface (68), that the second housing part (40) comprises a second sealing element contact surface (70), that the second housing part (40) is placed on the first housing part (38) to form the sealing element receptacle (66) so that the flowable potting compound (50) can flow into the sealing element receptacle (66) to form the housing sealing element (52) such that it is in contact with the first sealing element contact surface (68) and the second sealing element contact surface (70), wherein in particular a) the potting compound (50) introduced into the first housing part (38) is at least partially cured, in particular by heat, IR radiation, UV radiation and / or coherent radiation, before the second housing part (40) is placed on the first housing part (38) to form the sealing element receptacle (66) and / or b) the potting compound (50) is fully cured after the second housing part (40) has been placed on the first housing part (38).

24. Use of a method according to one of claims 21 to 23 for manufacturing an electrical energy storage device (12) according to one of claims 1 to 17.

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