Method for producing a battery
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- BAYERISCHE MOTOREN WERKE AG
- Filing Date
- 2025-12-19
- Publication Date
- 2026-07-30
Smart Images
Figure DE2025101213_30072026_PF_FP_ABST
Abstract
Description
[0001] 24-2570
[0002] METHOD FOR MANUFACTURING A BATTERY
[0003] The invention relates to a method for manufacturing a battery, in particular a vehicle battery or a traction battery of a vehicle.
[0004] Corresponding methods for manufacturing a battery are known in principle from the prior art. It is known, for example, to insert a cell assembly comprising a large number of energy storage cells into a housing and to encase it in a flowable or liquid foaming material. A disadvantage of this method is that the foaming / fixing process of the foaming material can lead to an undesirable change in the position of the cell assembly. Since the position of the cell assembly is particularly relevant to safety in a vehicle crash scenario, it is advantageous to achieve a reproducible and defined position of the cell assembly.
[0005] The invention is based on the objective of providing a method which, in particular with regard to a structurally and technically simple way, increases the safety of a battery with respect to external mechanical forces - e.g. a crash scenario - and / or increases manufacturing accuracy.
[0006] The problem is solved by a method for manufacturing a battery, in particular a vehicle battery, according to claim 1. The dependent claims relate to possible embodiments of the method. Furthermore, the problem is solved by a battery according to claim 14 and by a vehicle according to claim 15.
[0007] The invention relates to a method for manufacturing a battery, in particular a vehicle battery. The method provides for the provision of a housing body having a receiving recess and the provision of a plurality of energy storage cells, which are connected to one another via a connecting device to form a cell assembly. The cell assembly can form a rigid assembly or a pre-assembled assembly, which is inserted as a unit into the receiving recess. 24-2570
[0008] After the cell assembly has been inserted into the receiving recess of the housing body, and / or simultaneously with the insertion of the cell assembly into the receiving recess of the housing body, a foaming material is introduced into a cavity of the cell assembly and / or into a cavity located between the cell assembly and a housing wall of the housing body. In other words, the cell assembly itself and / or an area located between the cell assembly and the housing body has a cavity or free space into which the foaming material, preferably in a flowable or pourable form, and particularly preferably in liquid form, is introduced. This can be done, for example, by pouring or pouring the foaming material in liquid form above the cell assembly or above the at least one cavity. For example, application can be gravity-assisted.Optionally, an applicator can be used to apply the foaming material, which dispenses the foaming material via an outlet nozzle, whereby the applicator is moved over the cell assembly during the application of the foaming material and follows a predefined application path, in particular within a horizontal plane.
[0009] After and / or during the application of the foaming material, a molding tool with a shaping surface is positioned in close proximity to the cell assembly and / or the housing body in such a way that a surface section of the foaming material is formed during the foaming process. In this process, the foaming or foamed material comes into contact with a shaping surface of the molding tool, so that this surface determines or shapes the surface section of the foaming material.
[0010] During the introduction of the foaming material into a cavity and / or during the foaming process of the foaming material, the cell assembly can be supported by means of a support device, wherein the support device supports the cell assembly against the mold and / or against the housing body. By supporting the cell assembly during the introduction, in particular the pouring of the foaming material into the cavity and / or during the foaming process of the foaming material, 24-2570
[0011] If this occurs, forces arising from the foam material introduced into the cavity can be dissipated in a defined manner and / or act in a predefined way. For example, due to an increase in volume of the foaming material introduced into the cavities, deformation and / or bending and / or relative movement between sections of the cell assembly and the housing body can occur. This can, for example, change the position and / or orientation of the cell assembly, in particular at least one energy storage cell, relative to the housing body. For example, compressive forces can develop due to the foam material increasing in volume during the foaming process, leading to a displacement of the cell assembly relative to the housing body.By supporting the cell assembly, higher manufacturing accuracy and safety of the battery, and consequently also of the vehicle equipped with the battery, can be achieved.
[0012] It is possible for the cell assembly to have a planar shape and for the cell assembly to be supported along at least one of its narrow sides. The planar cell assembly has at least one narrow side. For example, the cell assembly can have a cuboid shape, where a principal extent surface corresponds to the largest area of the cell assembly or runs along the longitudinal axis, and the narrow sides form the cuboid's lateral faces, which are perpendicular to the principal extent surface. In other words, the principal extent surface of the cell assembly can correspond to a plane spanning along the X and Y axes (spatial directions), such that the narrow sides extend along a plane spanning the X and Z axes or Y and Z axes, or run parallel to this XZ or YZ plane.
[0013] In an advantageous embodiment, the support device can, for example, form an integral part of the finished or fully assembled battery. The support device can be connected to the cell assembly and / or the housing, for example, by means of the foam material, particularly by a material-fit and / or form-fit connection. In other words, the support device can remain attached to the battery as a component and thus forms part of the battery.24-2570
[0014] A manufacturing aid that remains attached to the battery. The support device, which initially rests loosely on the cell assembly and / or the housing, can be connected to the cell assembly or the housing, e.g., by gluing, using the foam material. Alternatively or additionally, the support device can be arranged and / or attached to the cell assembly and / or the housing body and / or to another insert placed in the cavity of the housing body before the foam material is introduced. For example, the support device is at least partially connected to the housing body and / or the cell assembly and / or an insert by force, form, and / or material bonding before the foam material is introduced into the cavity.The support device can thus be inserted into the receiving recess of the housing body together with the cell assembly and / or at a later time. This simplifies or reduces the assembly steps that must be carried out before the foam material is introduced into the at least one cavity.
[0015] Foaming material can be, for example, polyurethane (PU) foam. It is possible to use a foaming material that begins expanding immediately after application, i.e., "on its own." Alternatively, a foaming material can be used that is first applied to at least one cavity and then, simultaneously or at a later time, activated to expand its foaming properties. This activation can be achieved, for example, by supplying thermal energy to the foaming material, which initiates or significantly enhances the foaming process and expansion.
[0016] The support structure can be supported, for example, on the cell assembly side by contact with at least one energy storage cell and / or by contact with the connecting structure. The connecting structure can, for example, have a lattice structure, wherein a base structure extends along an outer edge on one side of the cell assembly, and connecting structures extend from this base structure at angles to the energy storage cells. The energy storage cells can, for example, be force- and / or material-24-2570
[0017] and / or be positively attached to the connecting structure and / or to the base structure, in particular glued or welded on.
[0018] It is possible that the cell assembly includes a cooling structure through which a cooling fluid flows, and that the support structure on the cell assembly side is supported by contact with the cooling structure. The cooling structure has, for example, walls that define a cooling channel structure within which a cooling fluid can flow. Starting from a base cooling channel structure, a distribution channel structure can extend towards the energy storage cells, so that a cooling fluid supplied via the base cooling channel structure is directed to the distribution channel structure, absorbs thermal energy from the energy storage cells there, and returns to the base cooling channel structure. In particular, an exchange of the fluid contained in the battery-side cooling structure takes place.The cooling channel structure consists of a flowing cooling fluid from a location outside the battery to a heat exchanger located outside the battery, part of a vehicle-side temperature management system, particularly a vehicle air conditioning system. The basic cooling channel structure can, for example, form a supply and discharge structure for a cooling fluid flowing to and from a distribution channel structure located near the energy storage cells.
[0019] In a first step, the cell assembly can, for example, be suspended in the receiving recess. In a subsequent step, the cell assembly can be fixed to the housing body, particularly exclusively, by means of the foam material. For this purpose, the cell assembly can be inserted into the housing body without any fixation and / or without a stop or contact in the XY direction and / or without experiencing any tension or jamming. In other words, the cell assembly inserted into the housing body is slidably positioned in the receiving recess with minimal force, so that a fixation preventing movement of the cell assembly relative to the housing body only occurs after the foam material has been introduced, and in particular after it has hardened.For example, during the foaming process, at least partial movement of the cell assembly relative to the housing body can be carried out, with this movement being controlled in a predefined manner by the support device.24-2570
[0020] is carried out, or guided in a predefined manner, by means of the support device.
[0021] The support of the cell assembly by means of the support device can, for example, be in a first support direction and in a second support direction perpendicular to the first support direction. Preferably, the first and second support directions run along or parallel to the main extension plane of the planar cell assembly. In other words, the cell assembly can be supported by the support device on at least two narrow sides, which are particularly not opposite each other. The opposite side, or the direction opposite to the support direction, has a clearance or mechanical play, so that at least partial movement of the cell assembly in a direction opposite to the support directions is allowed.
[0022] It is possible that the support of the cell assembly by means of the support device occurs only on one side within a support axis or within one support direction. This means that a clearance or mechanical play is maintained on one side of the cell assembly opposite the first. Preferably, the support of the cell assembly by means of the support device occurs on one side within a first support axis and on one side within a second support axis or support line that runs perpendicular to the first support axis or support line. A support axis is defined as a straight line along which a support force acts. The one-sided effect of the support means that the force is applied only on one side, i.e., only in one direction along the support line or support line.The support axis, support forces between the cell assembly and the housing and / or between the cell assembly and the mold are supported by the support device. For example, it is possible that no overdetermined support occurs, meaning that the cell assembly exhibits movement in the X and Y directions within its main extension plane, at least until the foam material has cured and / or the foam material has completed its foaming process. 24-2570.
[0023] The foaming material can be applied or dispensed, for example, by means of at least one applicator moving along an application path relative to the cell assembly, from above the cell assembly into a cavity of the cell assembly and / or into a cavity located between the cell assembly and the housing wall. The starting point of the application path must be located on the half of the cell assembly opposite at least one support element of the application device. Therefore, the starting point of the application path cannot be located in the center of the cell assembly when viewed from the X / Y plane. The starting point of the application path can thus be located in a central area, but in the half of the cell assembly opposite the support device.
[0024] In an optional advanced training, the application path can be configured to spiral radially outward from an inner region of the cell assembly in the direction of the applicator's movement. Viewed from above, the application path can have the form of a round and / or angular spiral. A spiral shape refers to an application path that moves from a radially inner region, which need not correspond to the exact center of the cell assembly, in a radially outward movement that simultaneously rotates at an angle around the center. The ratio of the radial component to the distance traveled can vary or remain constant along the application path.
[0025] For example, the starting point of the application path can be located away from an outer edge region of the cell assembly. Preferably, the starting point is located in a central third, more preferably in a central fifth, of the total length in the X and / or Y direction. The endpoint of the application path, i.e., the point at which the application of the foam material to the cell assembly ends, can, for example, be located at a radially outer edge region of the cell assembly. Alternatively or additionally, the endpoint of the application path can be located on a side facing the support device, particularly with regard to a consideration of the arrangement in the X and / or Y direction. In other words, the application path can be located in a region close to the support device in the X and / or Y direction. In particular, the endpoint of the application path is the 24-2570
[0026] Support device in X and / or Y direction closer than the starting point of the application path.
[0027] The starting point of the application path can, for example, be located in a surface section of the cell assembly that faces away from at least one first support element of the support device assigned to a first side of the cell structure and from at least one second support element of the support device assigned to a second side of the cell structure. For example, the surface section forms the shape of a quadrant of a cell assembly that has a rectangular base shape in plan view, wherein this quadrant does not adjoin or face away from the support elements of the support device.
[0028] It is possible that a support device is used which has a predetermined bending and / or breaking point designed to cause a defined bending and / or breaking of the support device in the event of an external force acting on the fully assembled battery. The external force could, for example, act on the battery during a crash scenario, such as a vehicle crash involving a battery used as a traction battery. For example, a planar battery, in particular a planar cell assembly of a battery, is installed horizontally within a vehicle, so that in the event of a side, frontal, and / or rear-end collision, an external force acts on the battery.
[0029] It can prove advantageous if, for example, after the foaming process has ended, a marking device arranged on the cell assembly and / or on the support device is detected by a sensing device, and sensing information describing the position and / or orientation of the cell assembly is generated. In other words, a sensing device can detect a marking device on the cell assembly side and / or on the support device side, and from this, the position and / or orientation of the cell assembly, in particular a relative position and / or orientation of the cell assembly to the housing body, can be determined. This allows, for example, monitoring of the foaming process so that any undesirable changes in the position and / or orientation can be detected.
[0030] The alignment of the cell assembly, resulting from the feeding or foaming process of the foaming material, can be detected. The marking device can, for example, have an elastic element that, when the mold is closed, rests against an inner surface of the mold, so that after the mold is opened, the marking device is at least partially not enclosed by the foaming material. In other words, a surface section of the cell assembly and / or a surface section of the support structure is protected or shielded from being covered by the foaming material by the marking device, so that a marking section of the marking device is exposed or optically detectable from the outside after the foaming process has been completed and the mold has been opened.
[0031] The detection device can be designed, for example, as an optical detection device, i.e., a camera, whereby the captured image and / or a captured sequence of images can be used to be evaluated by a person or by computer with regard to the position and / or orientation of the cell assembly.
[0032] For example, the marking device can include an elastic marking element that deforms elastically during the closing of the receiving recess of the housing body with the mold tool, so that no or minimal resistance forces oppose the closing force acting on the mold tool. Preferably, the elastic marking element can define an interior space, preferably ring-shaped, and most preferably circular. In the state of the mold tool being applied or closed, the interior space can form a sealed space from adjacent areas by the marking element and its sealing contact with the mold tool, preventing any foaming material from entering the interior. Consequently, the interior space is exposed or accessible from the outside after the foaming process is complete.This allows an exposed edge area of the marking element and / or an interior marking of the marking device to be optically detected by a detection device.24-2570.
[0033] The marking element can, for example, be made at least partially, preferably completely, of rubber and / or of an elastomer (e.g. elastic plastic) and / or silicone and / or have the shape of a ring, in particular a closed ring.
[0034] In addition to the method for manufacturing a battery, the invention also relates to a battery, in particular manufactured using a method described herein, comprising a housing body having a receiving recess and a cell assembly comprising a plurality of energy storage cells connected via a connecting device, wherein a foaming material is arranged in a cavity of the cell assembly and / or in a cavity arranged between the cell assembly and a housing wall of the housing body. The battery is further characterized in that it comprises a support device which is configured to support the cell assembly during a foaming process of the foaming material against a molding tool having a shaping surface, which forms a surface section of the foaming material during a foaming process, and / or against the housing body.
[0035] Furthermore, the invention relates to a vehicle, e.g., a motor vehicle, with a battery described herein, in particular a vehicle with a traction battery having the features of the battery described herein. The vehicle can thus be an electrically powered vehicle or an electric vehicle, wherein the energy source for providing the electrical energy for the vehicle's drive power is supplied from the battery described herein or from a traction battery corresponding thereto.
[0036] All advantages, details, designs and / or features of the method according to the invention are transferable or applicable to the battery according to the invention and to the vehicle according to the invention, and vice versa.
[0037] The invention is explained in more detail with reference to exemplary embodiments in the drawings. Figures 24-2570 show:
[0038] Fig. 1 shows a schematic side view of a battery according to an exemplary embodiment;
[0039] Fig. 2 shows a schematic top view of a cell assembly with a first application path of an application device for applying a foaming material according to an exemplary embodiment;
[0040] Fig. 3 shows a schematic top view of a cell assembly with an alternative application path of an application device for applying a foaming material according to an exemplary embodiment;
[0041] Fig. 4 shows a schematic representation of a support element of a support device according to an exemplary embodiment;
[0042] Fig. 5 shows a schematic representation of a support element equipped with a marking device, wherein a forming tool shaping the foam material is in the position closing a forming cavity, according to an exemplary embodiment.
[0043] The method for manufacturing a battery 1, in particular a vehicle battery, is described in the figures below. The method initially comprises the steps of providing a housing body 2 having a receiving recess 3 and providing a plurality of energy storage cells 4, which are connected to one another via a connecting device 5 to form a cell assembly 6. The cell assembly 6 is then inserted into the receiving recess 3, and a foaming material 25 is introduced into a cavity 7, 7' of the cell assembly 6 and / or into a cavity 7, 7' arranged between the cell assembly 6 and a housing wall of the housing body 2.
[0044] It is possible that the energy storage cells 4, which have, for example, a cylindrical, in particular a circular cylindrical, basic shape, are connected to each other via the connecting device 5 to form a rigid pre-assembly assembly. This pre-assembly assembly can optionally be mounted on a plate-like support body 29 on a base section of the receiving recess 24-2570.
[0045] of the housing body 2. Laterally, i.e., in the Y-direction and / or X-direction, a filler element 30 can be arranged at least on one side, preferably on two sides, which fills at least a lateral gap between the cell assembly 6 and the housing body 2, at least partially. The filler element 30 can, for example, have a lower stiffness than the support device 10. It is possible that the filler element 30 includes at least one receiving opening 31 for receiving the support device 10, at least partially, see Figure 1. Thus, it is possible that the support device 10 penetrates or bridges the filler element 30, particularly with respect to a horizontal extent or with respect to an extent in the main plane of extension, see Figure 1.Optionally, the receiving opening 31 can be open in a direction perpendicular to the main extension plane, so that the support device 10 can be inserted into the receiving opening 31 by a feeding movement perpendicular to the main extension plane of the cell assembly 6. For example, a plurality of receiving openings 31 of the filler body 30 form a crenellated structure, so that individual or composite support elements 26, 26', 27, 27' of the support device 10 can be inserted into the receiving openings 31 of the filler body 30 by a feeding movement, in particular a linear one. Alternatively or additionally, it can be provided that the support device 10 is at least partially, preferably predominantly, and particularly preferably completely, detachably or permanently attached to the filler body 30.Optionally, in a first step, the support device 10 can be at least partially, preferably predominantly, and particularly preferably completely, attached to the filler body 30 and then inserted together with the filler body 30 into the cell assembly 6, in particular into the receiving recess 3 of the housing body 2. For example, a receiving opening 31, which is passed through by the support device 10 during a feeding movement, is filled with foaming material 25 during the foaming process.
[0046] A forming tool 8, having a shaping surface 9, is positioned after and / or simultaneously with the application of the foaming material 25. This tool forms a surface section of the foaming material 25 during the foaming process. For this purpose, a space can be created by the housing body 2 and 24-2570.
[0047] The foaming material 25 is at least partially, preferably predominantly, and particularly preferably completely, enclosed or surrounded by the molding tool 8, and in particular is enclosed. Within this at least partially enclosed, and in particular enclosed, space, the foaming material 25 can expand and, due to the spatial limitation, undergo a defined expansion or be brought into a predefined shape.
[0048] During the introduction of the foam material 25 into a cavity 7, 7' and / or during the expansion of the foam material 25, the cell assembly 6 is supported by a support device 10. The support device 10 supports the cell assembly 6 against the mold 8 and / or against the housing body 2. In other words, the support device 10 can form a loose mechanical connection between the cell assembly 6 and the housing body 2 and / or between the cell assembly 6 and the mold 8, such that compressive forces can be transmitted via the connection, but tensile forces cannot. For example, the support device 10 can act as a stop, preventing the cell assembly 6 from shifting in at least one direction relative to the housing body 2.
[0049] In the figures, the foaming material 25 is only shown in figure 5; in the other figures, the foaming material 25 25 was not shown for the sake of clarity.
[0050] The cell assembly 6 can, for example, have a planar shape, with the support of the cell assembly 6 occurring in the direction of at least one narrow side 11, 12 of the cell assembly 6. As can be seen from a comparison of Figures 1 to 3, the cell assembly 6 can have a planar shape, the main plane of extension of which runs in or parallel to the XY plane. The support device 10 comprises a first group of first support elements 26, 26', which are arranged along a first narrow side 11 of the cell assembly 6, and a second group of second support elements 27, 27', which are arranged along a second narrow side 12 of the cell assembly 6. In other words, a first group of first support elements 26, 26' serves to support the cell assembly 6 along a first side, e.g., along the X-axis and / or 24-2570
[0051] along one longitudinal side of the cell assembly 6 and a second group of second support elements 27, 27' along a second side, e.g., along the Y-axis and / or along a transverse side, of the cell assembly 6. For example, the first and second sides are perpendicular to each other. It is possible that several support elements 26, 26' are connected to each other via a connecting section 32, so that several support elements 26, 26', each having a contact surface for contact with the cell assembly 6 and / or a second contact surface for contacting the housing body 2 and / or the mold 8, can be simultaneously attached to or fed into the cell assembly 6 and / or into the receiving recess 3 and / or into a filler body 30.
[0052] The support device 10 can, for example, form at least a portion, preferably predominantly, and particularly preferably completely, of the finished battery 1. Thus, the support device 10 can be at least a portion of the product housing the battery 1, e.g., a vehicle. For example, the support device 10 is connected to the cell assembly 6 and / or to the housing body 2 by the foam material 25, in particular by a material-fit and / or form-fit connection and / or in a permanent manner, i.e., not detachable without damage.
[0053] The support device 10 can, for example, be supported on the cell assembly side by contact with at least one energy storage cell 4 and / or by contact with the connecting device 5. Thus, the support device 10 can, for example, enable the cell assembly 6 to be supported by direct contact with at least one energy storage cell 4 and / or by direct contact with the connecting device 5. It is possible that the at least one energy storage cell 4 and / or the connecting device 5 has a contact surface that corresponds to a counter-contact surface of the support device 10. Preferably, the contact and counter-contact surfaces have a centering and / or guiding geometry, so that a relative target alignment and / or target positioning is easily achieved during the assembly of the cell assembly 6 and the support device 10.
[0054] The cell assembly 6 can, for example, include a cooling structure 13 through which a cooling fluid flows, and the support device 10 on the cell assembly side 24-2570
[0055] The cooling structure is supported by contact with it. For example, the cooling structure is at least partially, preferably predominantly, and particularly preferably completely, integrated into the connecting device 5 or forms a component thereof. In Figure 1, the cooling structure 13 is shown as a channel cross-section in the connecting device 5. Optionally, at least one connecting channel (not shown), for example, integrated into the connecting device 5, can supply and / or discharge the cooling fluid to and / or from the immediate vicinity of the energy storage cells 4. Thus, the connecting device 5 can optionally have a dual function: connecting the energy storage cells 4 to one another and guiding or conveying a cooling fluid.
[0056] In a preferred embodiment, the cell assembly 6 can be suspended in the receiving recess 3, with the subsequent fixation of the cell assembly 6 to the housing body 2 being effected, in particular exclusively, by means of the foam material 25. During the suspended mounting of the cell assembly 6 in the receiving recess 3, there is no positional fixation for movement within the XY plane between the cell assembly 6 and the housing body 2. Only after the foam material 25 has been introduced and cured does it act as, for example, a material-bonded connection between the cell assembly 6 and the housing body 2.
[0057] The support 105 of the cell assembly 6 can, for example, be provided by means of the support device 10 such that support can be provided in a first support direction 14 and in a second support direction 15, which forms an angle with the first support direction 14 and is in particular perpendicular to it. Preferably, the first and second support directions 14, 15 extend along or within the main extension plane XY-plane of the planar cell assembly 6. Optionally, the support 105 of the cell assembly 6 can be provided by means of the support device 10 only on one side within a support axis 16. Preferably, the support 105 of the cell assembly 6 is provided by means of the support device 10 only on one side within a first straight support axis 16 and within a second straight support axis 17, which is perpendicular to the first support axis 16.In other words, the support device 10 acts in such a way that its 24-2570.
[0058] Support within a force axis (support axis 16: X-axis and support axis 17: Y-axis) is only present on one side, so that there is no support in the opposite direction of the respective force axis, or movement of the cell assembly 6 relative to the housing body 2 is permitted. This allows, for example, non-jamming support or statically indeterminate support, since the cell assembly 6, with respect to its movement within the main extension plane XY-plane in the X and Y directions, is supported only on one side, i.e., in one direction of the X-axis and in one direction of the Y-axis, and thus exhibits mechanical play or clearance in the opposite direction.
[0059] The foam material 25 can, for example, be applied from above the cell assembly 6 into a cavity 7, 7' of the cell assembly 6 and / or into a cavity 7, 7' arranged between the cell assembly 6 and the housing wall by means of at least one applicator moving relative to the cell assembly 6 along an application path 18, wherein a starting point 19 of the application path 18 is located on a half 21 of the cell assembly 6 facing away from at least one of a first group of first support elements 26, 26' of the support device 10, cf. Figure 2. According to the embodiment shown in Figure 3, the starting point 19 can be located in a first half 21 of the main extension plane of the cell assembly 6, which faces away from at least one first support element 26, 26' and simultaneously in a second half 20 of the main extension plane of the cell assembly 6, which faces away from at least one second support element 27, 27' turned away.The starting point 19 can be located, in particular, at an intersection of the first and second halves 20, 21, see Figure 3. The endpoint 28 of the application path 18, along which the foam material 25 is applied to, in particular onto, the cell assembly 6, can be located on a side and / or half of the cell assembly 6 facing the support device 10. Preferably, the endpoint 28 is located in a region that forms an intersection of a half facing at least one first support element 26, 26' and a half facing at least one second support element 27, 27', see Figure 2.
[0060] Alternatively or additionally, the application path 18 can be chosen such that it originates from an inner area of the 24-2570 in the direction of movement of the applicator.
[0061] Cell assembly 6 spirals radially outwards. The spiral movement is illustrated in Figure 2 with a clockwise spiral movement and in Figure 3 with a counterclockwise spiral movement.
[0062] The starting point 19 of the application path 18 can, for example, be located at a distance from an outer edge region of the cell assembly 6. In other words, the starting point 19 can be located in a central region of the cell assembly 6 or in an intermediate region between a central region and an edge region or outer boundary region of the cell assembly 6. If the spiral path has three or more turns, the starting point 19 can be located at a position that does not correspond to the outermost turn, preferably to one of the radially innermost turns, see, for example, Figures 2 and 3.
[0063] It is possible that the starting point 19 of the application path 18 lies in a surface section of the cell assembly 6 that is opposite at least one first support element 26, 26' of the support device 10 assigned to a first side of the cell assembly 6 and at least one second support element 27, 27' of the support device 10 assigned to a second side of the cell assembly 6. In other words, the starting point 19 can lie in a surface section, e.g., a quarter or quadrant, that does not border the support device 10, in particular not the first and second support elements 26, 26', 27, 27' of the support device 10.
[0064] For example, a support device 10 is used which has a predetermined bending and / or breaking area 23, which is designed to cause a defined bending and / or breaking of the support device 10 in the event of an external force acting on the fully assembled battery 1. For example, the support device 10 has an accordion-like and / or bellows-like shape, such that a defined deformation and / or bending of at least one support element 20, 22 of the support device 10 occurs when the battery 1 is subjected to an external force acting or propagating within the X-Y plane. Likewise, the predetermined bending and / or breaking area 23 of the at least one support element 20, 22 of the support device 10 can have a different geometry.24-2570
[0065] For example, the predetermined bending and / or breaking area 23 can have a porous and / or sponge-like structure, at least in sections. Preferably, the predetermined bending and / or breaking area 23 has a recess that forms a substantially vertical channel. A material weakening to form the predetermined bending and / or breaking area 23, and simultaneously low-resistance penetration, filling, and / or permeation of the channel by a foam material 25 introduced vertically from above, can be achieved through a channel that is at least substantially vertical.
[0066] It is possible that, after the foaming process has ended, a marking device 24 arranged on the cell assembly 6 and / or on the support structure 10 is detected by a detection device, and detection information describing the position and / or orientation of the cell assembly 6 is generated. For this purpose, the marking device 24 can, as shown, for example, in Figure 5, form part of the support structure 10, e.g., be designed as a single-material and / or one-piece section of the support structure 10 (see Figure 5). Optionally, the marking device 24 can be at least partially a separate component from the support structure 10 and be connected to the support structure 10 by means of a force-fit, form-fit, and / or material-fit connection (not shown).Preferably, the marking device 24 can be designed to be at least partially elastic and / or bendable, so that in the closed state of the mold 8, the marking device 24 comes into a sealing contact with the mold surface 9 of the mold 8. For example, this prevents the ingress of foam material 25 into an interior 33 of the marking device 24, see Figure 5.
[0067] In general, the figures show a battery 1, which in particular was manufactured using a method described herein. The battery 1 comprises a housing body 2 having a receiving recess 3 and a cell assembly 6 comprising a plurality of energy storage cells 4 connected via a connecting device 5, wherein a foaming material 25 is arranged in a cavity 7, 7' of the cell assembly 6 and / or in a cavity 7, 7' arranged between the cell assembly 6 and a housing wall of the housing body 2. A support device 1024-2570 was used to manufacture the battery 1.
[0068] used, which is set up to support the cell assembly 6 during a foaming process of the foaming material 25 against a molding tool 8 having a shaping surface 9, which forms a surface section of the foaming material 25 during a foaming process of the foaming material 25, and / or against the housing body 2.24-2570
[0069] Reference symbol list
[0070] 1 battery
[0071] 2 Housing bodies
[0072] 3. Exclusion of 2
[0073] 4 Energy storage cells
[0074] 5 Connection device
[0075] 6 cell assembly
[0076] 7, 7' cavity
[0077] 8 Forming tool
[0078] 9 surface area of 8
[0079] 10 Support device
[0080] 11 first narrow side of 6
[0081] 12 more narrow sides of 6
[0082] 13 Cooling structure
[0083] 14 first support direction
[0084] 15 second support direction
[0085] 16 first support axle
[0086] 17 second support axle
[0087] 18 Application route
[0088] 19 Starting point of 18
[0089] 20 of 27, 27' opposite half of 6 21 of 26, 26' opposite half of 6
[0090] 23 Target bending and / or break point area 24 Marking
[0091] 25 Foam material
[0092] 26, 26' first support element of 10
[0093] 27, 27' wide support element of 10
[0094] 28 Endpoint of 18
[0095] 29 supporting structures
[0096] 30 filler particles
[0097] 31 Intake opening of 30
[0098] 32 connecting section of 10
[0099] 33 interior of 24
Claims
REQUIREMENTS 1. Method for manufacturing a battery (1), in particular a vehicle battery, comprising the process steps: - Providing a housing body (2) having a receiving recess (3), - Providing a plurality of energy storage cells (4) which are connected to each other via a connecting device (5) to form a cell assembly (6), - Inserting the cell assembly (6) into the receiving recess (3), - Introducing a foam material (25) into a cavity (7, 7') of the cell assembly (6) and / or into a cavity (7, 7') arranged between the cell assembly (6) and a housing wall of the housing body (2), - Arranging a forming tool (8) having a shaping surface (9) which forms a surface section of the foaming material (25) during a foaming process of the foaming material (25), characterized by - Supporting the cell assembly (6) during the introduction of the foaming material (25) into a cavity (7, 7') and / or during the foaming process of the foaming material (25) by means of a support device (10), wherein the support device (10) supports the cell assembly (6) against the molding tool (8) and / or against the housing body (2).
2. Method according to claim 1, characterized in that the cell assembly (6) has a planar shape and the support (105) of the cell assembly (6) is provided in the direction of at least one narrow side (11, 12) of the cell assembly (6).
3. Method according to claim 1 or 2, characterized in that the support device (10) forms a component of the finished battery (1), preferably the support device (10) is connected to the cell assembly (6) and / or to the housing by the foam material (25), in particular by a material-locking and / or form-locking connection.
4. Method according to one of the preceding claims, characterized in that the support device (10) is supported on the cell assembly side by contact with at least one energy storage cell (4) and / or by contact with the connecting device (5).
5. Method according to one of the preceding claims, characterized in that the cell assembly (6) comprises a cooling structure (13) through which a cooling fluid can flow and the support device (10) is supported on the cell assembly side by contact with the cooling structure.
6. Method according to one of the preceding claims, characterized in that the cell assembly (6) is received in the receiving recess (3) in a floating manner and the cell assembly (6) is subsequently fixed to the housing body (2), in particular exclusively, by means of the foam material (25).
7. A method according to any one of the preceding claims, characterized by supporting the cell assembly (6) by means of the support device (10) in a first support direction (14) and in a second support direction (15) which forms an angle with the first support direction (14) and is in particular perpendicular to it, preferably the first and second support directions (14, 15) extend along the main extension plane of the planar cell assembly (6).
8. A method according to any one of the preceding claims, characterized in that the support of the cell assembly (6) by means of the support device (10) within a support axis (16) is only carried out on one side, preferably the support of the cell assembly (6) by means of the support device (10) is carried out on one side only within a first support axis (16) and within a second support axis (17) which extends perpendicular to the first support axis (16).
9. Method according to one of the preceding claims, characterized in that the foaming material (25) is applied from above the cell assembly (6) into a cavity (7, 7') of the cell assembly (6) and / or into a cavity (7, 7') arranged between the cell assembly (6) and the housing wall by means of at least one applicator moving relative to the cell assembly (6) along an application path (18) and a starting point (19) of the application path (18) is located on a half (21) of the cell assembly (6) facing away from at least one support element (20) of the support device (10).
10. Method according to claim 9, characterized in that the application path (18) is selected such that it leads in a spiral manner from an inner area of the cell assembly (6) to the radial outside in the direction of movement of the applicator.
11. A method according to claim 9 or 10, characterized in that the starting point (19) of the application path (18) is located in a surface section of the cell assembly (6) that is facing away from at least one first support element (20) of the support device (10) associated with a first side of the cell assembly (6) and from at least one second support element (22) of the support device (10) associated with a second side of the cell assembly (6).
12. A method according to any one of the preceding claims, characterized in that a support device (10) is used which has a predetermined bending and / or breaking area (23) which is configured to cause a defined bending and / or breaking of the support device (10) in the event of an external force acting on the fully assembled battery (1).
13. Method according to one of the preceding claims, characterized in that after the foaming process has ended, a marking device (24) arranged on the cell assembly (6) and / or on the support device (10) is detected by a detection device and detection information describing the position and / or orientation of the cell assembly (6) is generated.
14. Battery (1), in particular manufactured in a method according to one of the preceding claims, comprising a housing body (2) having a receiving recess (3) and a cell assembly (6) having a plurality of energy storage cells (4) connected via a connecting device (5), wherein a foaming material (25) is arranged in a cavity (7, 7') of the cell assembly (6) and / or in a cavity (7, 7') arranged between the cell assembly (6) and a housing wall of the housing body (2), characterized by a support device (10) which is configured to support the cell assembly (6) during a foaming process of the foaming material (25) against a forming tool (8) having a shaping surface (9) which forms a surface section of the foaming material (25) during a foaming process of the foaming material (25), and / or against the housing body (2).
15. Vehicle comprising a battery (1), in particular a traction battery, according to claim 14.