DE102021125265A1 - Method for producing a housing part of a storage housing of an electrical energy storage device, housing part and storage housing - Google Patents

Abstract

The invention relates to a method for producing a housing part (3) of a storage housing (2) of an electrical energy storage device (1) for a motor vehicle drive, in which a component (4) designed as a fiber composite component (5) or as a sheet metal (6) is at least partially is encapsulated with a structure (23) formed from a plastic (22), wherein during the encapsulation (24) at least one receiving space (30) at least partially delimited by the structure (23) formed from the plastic (22) is formed, in which at least one battery cell (31) of the energy store (1) can be arranged.

Description

The invention relates to a method for producing a housing part of a storage housing of an electrical energy storage device for a motor vehicle drive according to the preamble of patent claim 1. The invention also relates to a housing part for a storage housing of an electrical energy storage device according to the preamble of patent claim 9 and a storage housing for a electrical energy storage.

The DE 10 2013 204 180 B4 discloses a housing for accommodating a cell stack for a battery, the housing having a side wall which is designed as a plastic component. The sidewall has a first receptacle and a second receptacle. The enclosure includes a metallic frame structure for prestressing the cell pack, the frame structure having a first rail secured in the first receptacle and a second rail secured in the second receptacle, the first rail and the second rail being aligned transversely to the sidewall.

The object of the invention is to create a method for producing a housing part of a storage housing of an electrical energy storage device for a motor vehicle drive, a housing part for a storage housing of an electrical energy storage device and a storage housing with such a housing part, so that the costs of the storage housing can be kept particularly low .

This object is achieved according to the invention by a method for producing a housing part of a storage housing of an electrical energy storage device for a motor vehicle drive having the features of patent claim 1, by a housing part for a storage housing of an electrical energy storage device having the features of patent claim 9 and by a storage housing for an electrical Energy storage solved with such a housing part with the features of claim 10. Advantageous configurations of the invention are the subject matter of the dependent patent claims and the description.

A first aspect of the invention relates to a method for producing a housing part of a storage housing of an electrical energy storage device for a motor vehicle drive. The motor vehicle is preferably designed as a passenger car, commercial vehicle or truck. The drive of the motor vehicle is preferably designed as an electric machine, by means of which the motor vehicle can be driven. The electrical energy store is preferably designed as an accumulator or as a battery.

In order to be able to achieve particularly high electrical power for the electrical, in particular purely electrical, driving of the motor vehicle, the energy store can have an electrical voltage, in particular an electrical operating or nominal voltage, which is preferably greater than 50 volts, in particular more than 60 volts and preferably several hundred volts. Accordingly, the energy store is preferably designed as a high-voltage component. The storage housing can thus be referred to in particular as a high-voltage storage housing.

The motor vehicle can, for example, be in the form of, in particular, a purely battery-electric vehicle. Alternatively, the motor vehicle can be designed as a hybrid vehicle, for example. In this case, the motor vehicle can have an internal combustion engine in addition to the electric machine, it being possible for the motor vehicle to be driven by means of the electric machine and/or the internal combustion engine.

The storage housing is designed as a housing or as an enclosure for the electrical energy storage device. The storage housing can at least partially, in particular completely, delimit an interior space of the electrical energy storage device. At least one battery cell of the electrical energy store can be arranged in the interior. A plurality of battery cells of the electrical energy store are preferably arranged in the interior.

The electrical machine has a stator connected to a machine housing and a rotor. Electrical power can be converted into mechanical power by means of the electrical machine, as a result of which the rotor can be driven by the stator and is therefore rotatable about a machine axis of rotation relative to the stator. The electrical power can be provided by the electrical energy store, in particular via an on-board network of the motor vehicle. The electric machine can provide at least one torque via the rotor, in particular for driving the motor vehicle.

The housing part is preferably designed in the shape of a shell. The housing part can thus be a housing shell. The housing part can be an upper housing part of the storage housing, referred to in particular as an upper part, or a lower housing part of the storage housing, referred to in particular as a lower part.

In the method, a component designed as a fiber composite component or as sheet metal is at least partially, in particular completely, encapsulated with a structure made of plastic. In other words, the component is connected by injection molding, in particular plastic injection molding, to the plastic sprayed onto the component, in particular in a materially bonded manner, such that the component is at least partially, in particular predominantly or completely, surrounded by the structure formed from the plastic. In other words, the structure formed from the plastic delimits the component, in particular directly, with the structure being produced by means of injection molding.

The component is preferably designed as the fiber composite component. Thus, it is preferably provided that the fiber composite component is at least partially, in particular predominantly or completely, encapsulated with the structure formed from the plastic.

The sheet metal is preferably a thin metal sheet. This can in particular be understood to mean that a thickness of the metal sheet is particularly small in relation to the longitudinal extent and/or transverse extent of the metal sheet.

The plastic can be a thermoplastic or a thermoset. For example, the plastic is polycaprolactam, which can be referred to in particular as polyamide 6 (PA6). Alternatively, the plastic can be a thermoplastic elastomer (TPE). The structure formed from the plastic can in particular be referred to as an overmolding or as an injection-molded structure.

In order to be able to keep the costs of the accumulator housing particularly low, it is provided according to the invention that during the encapsulation at least one receiving space, which is at least partially, in particular predominantly or completely, delimited by the structure formed from the plastic, is formed, in which at least one battery cell of the electrical energy accumulator at least can be arranged partially, in particular predominantly or completely. In other words, as a result of the component or the fiber composite component being overmolded with the structure formed from the plastic, the receiving space is formed or produced, which is at least partially, in particular directly, surrounded by the structure formed from the plastic. The at least one battery cell of the electrical energy store can be inserted into the receiving space. The battery cell is therefore at least partially arranged in the receiving space when the electrical energy store is in the fully manufactured state. The structure formed from the plastic is thus a functional element of the storage housing, it being possible for the receiving space to be provided as a positioning aid or as a fastening device for the battery cell.

A multiplicity of accommodation spaces are preferably provided in the structure formed from the plastic. In other words, during the encapsulation, a large number of receiving spaces are formed that are at least partially, in particular predominantly or completely, delimited by the structure formed from the plastic, with at least one battery cell of the energy storage device being able to be arranged or inserted at least partially, in particular completely, in each case .

Alternatively, multiple battery cells can be arranged in each receiving space. The battery cells can be present as a cell pack. This can in particular be understood to mean that at least one cell pack can be arranged at least partially in the respective receiving space of the electrical energy store, with the respective cell pack being able to comprise a plurality of battery cells.

The respective receiving space preferably has a receiving opening which is at least partially, in particular completely, delimited by the structure formed from the plastic. When arranging the respective battery cell in the respective receiving space, the respective battery cell can be inserted through the receiving opening.

The invention is based in particular on the following findings and considerations: battery-electric vehicles usually have the storage device, which is referred to in particular as a battery housing housing, which can be joined to form one or two shells by means of metal sheets or profiles, in order to accommodate and encapsulate cells, in particular battery cells, or modules, in particular battery modules. As a result, the cells or the modules can be protected against dynamic and/or static loads and external influences, such as electrically conductive or corrosive media. Furthermore, occupants of the motor vehicle can be protected by the storage housing from the electrical energy stored in the electrical energy storage device, in particular in the event of incorrect behavior. The misconduct can in particular be understood as misconduct by the occupants or a malfunction of the motor vehicle, in particular of the energy store. As a result, the safety of the motor vehicle can be particularly increased. Conventional storage housings can usually be assembled from a particularly large number of individual parts and fitted with modules or battery cells in a complex manner. As a result, the production outlay for producing the conventional storage housing can be particularly high, as a result of which the costs of the conventional storage housing can be particularly high. In addition, in principle, constructions made of steel and/or aluminum are conceivable for the accumulator housing. However, these are particularly complex to produce. In addition, a large number of joining partners or joining methods can result in a particularly great challenge or particularly great risk with regard to tolerances and the tightness of the accumulator housing. In order to still be able to maintain tolerances and tightness, particularly great effort and particularly high costs can arise. Furthermore, protection against corrosion of the storage housing or of the electrical energy storage device must be ensured over its service life. In the case of a conventional memory housing, which has a particularly large number of components and joining operations, particularly high costs and production risks can arise.

In contrast, the number of parts or joining partners can be kept particularly low in the method according to the invention. The storage housing can be implemented in a simple shell construction. Injection molding makes it particularly easy to produce complex geometries with particularly high rigidity. In addition, further functions can be realized through injection molding, for example the positioning aid or the holding device of the battery cells. In particular because the number of parts and joining partners can be kept particularly low in the method according to the invention, the risk with regard to tolerances and tightness can be kept particularly low. In addition, the corrosion protection of the accumulator housing can be guaranteed over the service life with particularly little effort. Furthermore, the effort involved in joining or assembling the storage housing can be kept particularly low. The method according to the invention can thus be used to keep expenditure and costs, in particular manufacturing costs, and production risks of the storage housing particularly low.

Preferably, the structure formed from the plastic is an outer layer of the storage enclosure. The structure or the outer layer can be directed inwards and/or outwards. The outer layer can thus be an outside, which delimits the storage housing to the outside, or the structure can be an inner layer, which delimits the interior of the electrical energy storage directly. The structure formed from the plastic can thus give the memory housing its final shape.

The structure formed from the plastic is preferably responsible for the rigidity of the storage housing. This can be understood in particular to mean that the mechanical rigidity of the accumulator housing is provided or achieved at least partially, in particular predominantly, by the structure formed from the plastic.

Provision is preferably made for an organic sheet to be used as the fiber composite component. In other words, the fiber composite component is preferably designed as an organic sheet. The organo sheet can be understood in particular as a fiber matrix semi-finished product. The organo sheet can have a fibrous fabric or a fibrous structure, with the fibrous fabric or the fibrous structure being embedded in a plastic matrix, in particular a thermoplastic. The storage housing can be produced particularly advantageously, in particular particularly easily, by means of the organo sheet. In addition, the weight of the accumulator housing can be kept particularly low by means of the organic sheet.

In a further embodiment, it is provided that the fiber composite component or the organic sheet comprises at least one layer formed from a fiber-reinforced plastic and at least one layer formed from a metal, the layers being connected to one another to produce the organic sheet. In other words, in the manufacture of the Organic sheet, the layer formed from the fiber-reinforced plastic and the layer formed from the metal arranged on one another, in particular one above the other, and connected to one another, in particular pressed. Due to the fact that the fiber composite component or the organic sheet comprises the layer formed from the metal, the strength of the fiber composite component or the organic sheet, which is referred to in particular as material strength, can be particularly increased.

The layer formed from the metal preferably serves as a barrier or as a blocking layer in order to particularly increase a protective function of the storage housing in the event of a thermal event in the electrical energy storage device. In other words, thermal compatibility of the memory housing can be particularly increased by the metallic layer. As a result, the safety of the electrical energy storage device or of the storage device housing can be particularly increased. The metallic layer is preferably a metallic foil.

The layer formed from the metal can be formed from steel, for example. For example, the layer formed from the metal is in the form of a lattice, as a result of which the layer formed from the metal can be referred to in particular as a metal lattice or as a steel lattice.

The fibre-reinforced plastic preferably comprises polycaprolactam (PA6), which is preferably designed in the form of a film or as a film. This can in particular be understood to mean that the fiber composite component or the organo sheet is produced from a PA6 film.

The fiber-reinforced plastic is preferably a glass-fiber-reinforced plastic (GRP) or a carbon-fiber-reinforced plastic (CFRP). The carbon fibers and/or the glass fibers are preferably present as a non-crimp fabric. The fibers, in particular glass fibers and/or carbon fibers, are in the form of mats. This can in particular be understood to mean that the fiber composite component or the organo sheet is produced from glass fiber mats or from carbon fiber mats. Because the fiber composite component has the glass fiber or carbon fiber reinforced plastic, the strength of the fiber composite component can be particularly increased.

The layer formed from the metal is preferably arranged directly on the layer formed from the fiber-reinforced plastic.

In a further embodiment, it is provided that the fiber composite component or the organic sheet comprises two layers formed from the fiber-reinforced plastic and spaced apart from one another, the layer formed from the metal being arranged between the layers formed from the fiber-reinforced plastic. In other words, the fiber composite component or the organic sheet is designed as a sandwich component or as a sandwich structure, with the layer formed from the metal being arranged between the two layers formed from the fiber-reinforced plastic. To produce the fiber composite component or the organic sheet, the layer formed from the metal is arranged between the layers formed from the fiber-reinforced plastic, the layer formed from the metal and the respective layer formed from the fiber-reinforced plastic being connected to one another, in particular pressed together. As a result, the stiffness or strength of the fiber composite component or the organic sheet can be particularly increased and at the same time the weight of the fiber composite component or the organic sheet can be kept particularly low.

The fiber composite component or the organic sheet can thus comprise a material mix which has, for example, the carbon fiber mat, the glass fiber mat and the metallic foil. The sandwich component can in particular be referred to as a stack or as a sandwich board. The fiber composite component or the organo sheet can be produced, for example, by means of a double belt press.

The battery cell is preferably designed as a round cell. This can in particular be understood to mean that the battery cell has a round cross section. Alternatively, the battery cell can be designed as a prismatic cell. This can in particular be understood to mean that the battery cell has a prismatic cross section. In the fully manufactured state of the electrical energy storage device, the battery cell is preferably connected to the structure formed from the plastic in a form-fitting and/or force-fitting manner. The injection-molded structure surrounding the organic sheet or the fiber composite component can thus accommodate the battery modules or the battery cells.

In a further embodiment, the component, in particular the fiber composite component or the organo sheet, is hot-formed before overmoulding. Hot forming can be referred to as thermoforming in particular. The component is first preheated. This can be done in particular by means of an infrared oven. During and/or after preheating, the component can be formed or drawn onto a press. The component can then be formed by means of the press, in particular by means of a heated tool.

In a further embodiment, it is provided that before the overmoulding, preferably after the thermoforming, a cell contacting system is arranged on the component, in particular the fiber composite component or the organo sheet or the sheet metal, which during the overmoulding together with the component at least partially, in particular completely, overmolded by the plastic. In other words, the cell contacting system is arranged between the structure formed from the plastic and the component. As a result, the cell contacting system can be integrated particularly advantageously into the housing part, as a result of which, for example, the costs and complexity of the housing part can be kept particularly low.

The battery cells or battery modules of the electrical energy store can be electrically connected to one another by means of the cell contacting system. In the fully manufactured state of the electrical energy store, the battery cells or the battery modules touch the cell contacting system directly.

Alternatively, the cell contacting system can be mounted afterwards. This can in particular be understood to mean that the cell contacting system is connected to the injection-molded structure and/or to the component after the overmolding. The connection can in particular be a plug-in connection.

The cell contacting system preferably touches the structure formed from the plastic and/or the component, in particular the fiber composite component or the organo sheet, directly.

The cell contacting system is preferably designed in the form of a grid. The cell contacting system can preferably be produced by stamping, as a result of which the cell contacting system can in particular be referred to as a stamped grid.

The cell contacting system can already be cut or stamped before it is arranged on the component. This can in particular be understood to mean that the cell contacting system already has a contour or geometry close to the final component before it is assembled, which is intended for the fully manufactured housing part. Furthermore, the cell contacting system can have predetermined breaking points or separation points, with the predetermined breaking points or the separation points being separated after the overmolding or assembly, as a result of which a desired interconnection of the respective battery cells can be achieved.

In a further embodiment, it is provided that the receiving space, in particular the receiving opening, is formed in a honeycomb manner during the overmolding. In other words, the respective receiving space, in particular the respective receiving opening, has a honeycomb cross section. As a result, the rigidity of the housing part can be particularly increased. The honeycombs can thus in particular be referred to as stiffness honeycombs. In the installation position of the accumulator housing in the motor vehicle, the rigidity of the accumulator housing can be particularly increased, in particular in the vertical direction of the vehicle.

In summary, the honeycombs can be referred to in particular as a honeycomb structure. The honeycomb structure is provided as a positioning aid or as a positioning geometry for the battery cells in the storage housing.

The respective honeycomb can preferably accommodate the respective battery cell in a positionally accurate manner, as a result of which the respective battery cell can be arranged particularly well, in particular particularly securely, in the respective receiving space. In this case, preferably no additional holding elements for the battery cells for holding the battery elements in their installed position on the component and/or the structure are to be introduced. In other words, the housing part is free of an additional holding element, which is provided in addition to the structure formed from the plastic or the honeycomb. As a result, the costs and complexity of the housing part or the storage housing can be kept particularly low.

In a further embodiment, it is provided that the respective receiving space is designed as a through-opening that penetrates the structure formed from the plastic, in particular completely. In other words, the respective receiving space has the receiving opening and a second receiving opening spaced apart from the receiving opening, in particular arranged opposite, wherein the two receiving openings are fluidically connected to one another. The receiving opening is delimited, in particular completely, by a first side of the layer formed from the plastic, and the second receiving opening is delimited, in particular completely, by a second side of the structure formed from the plastic, opposite the first side. As a result, the respective receiving space can be partially delimited by the cell contacting system, as a result of which the respective battery cell can be electrically connected to the cell contacting system in a particularly advantageous manner.

In a further refinement, it is provided that an installation direction in which the respective battery cell can be arranged in the respective receiving space runs in the vertical direction of the motor vehicle in relation to an installation position of the electrical energy store in the motor vehicle. In other words, when the respective battery cell is installed in the storage housing, the respective battery cell is arranged in the respective receiving space or inserted into the respective receiving space along the vertical direction of the vehicle. As a result, the respective battery cell can be installed particularly easily.

At least one connection element is preferably applied to the component and/or to the structure formed from the plastic, in particular by means of injection molding and/or by means of a MuCell process. The attachment element can in particular be referred to as an insert. The connection element is intended to enable at least one form-fitting and/or force-fitting connection to a component that is formed separately from the housing part. If the housing part is designed as a housing top part, the component can be the housing bottom part, for example. If the housing part is in the form of a lower housing part, the component can be in the form of an upper housing part, for example. The component can be, for example, a component of a body of the motor vehicle, in particular a floor element of a main floor. The respective connection can be implemented particularly advantageously by means of the connection element, as a result of which, for example, the weight of the housing part or the accumulator housing can be kept particularly low. The connection element can in particular be referred to as a connection point.

The storage housing preferably has at least one shielding element, which is referred to in particular as an EMC blocking element. The shielding element is preferably designed to at least partially shield electromagnetic radiation. The shielding element can thus be impermeable to the electromagnetic radiation. The shielding element can be designed as a shielding layer, which can in particular be referred to as an EMC barrier layer. As a result, electromagnetic compatibility (EMC) of the storage housing or of the electrical energy storage device can be particularly increased. As a result, interference with other devices due to unwanted electrical or electromagnetic effects of the electrical energy storage device can be avoided, and interference with the electrical energy storage device by the other devices can be avoided.

A second aspect of the invention relates to a housing part for a storage housing of an electrical energy storage device for a motor vehicle drive. Advantages and advantageous configurations of the first aspect of the invention are to be regarded as advantages and advantageous configurations of the second aspect of the invention and vice versa.

The housing part has at least one component designed as a fiber composite component or as a sheet metal, which is at least partially encapsulated by a structure made of plastic. In other words, the component is at least partially, in particular completely, surrounded by the structure formed from the plastic, which can be produced or is produced by means of injection molding.

The structure formed from the plastic is preferably arranged directly on the component.

In order to be able to keep the costs of the housing part particularly low, it is provided that the structure formed from the plastic at least partially, in particular predominantly or completely, delimits at least one receiving space of the housing part, which is at least partially, in particular predominantly or completely, formed by the encapsulation , wherein at least one battery cell of the energy storage device is at least partially, in particular completely, arranged in the at least one receiving space is bar or insertable. In other words, the structure formed from the plastic is designed as a wall that at least partially, in particular directly, delimits the receiving space, the wall being able to be produced or being produced by overmolding. The at least one battery cell of the electrical energy store can be at least partially accommodated in the accommodation space.

A third aspect of the invention relates to a storage housing of an electrical energy storage device for a drive of a motor vehicle, with a housing part according to the second aspect of the invention. Advantages and advantageous configurations of the first aspect and the second aspect of the invention are to be regarded as advantages and advantageous configurations of the third aspect of the invention and vice versa.

In order to be able to keep the costs of the accumulator housing or of the motor vehicle particularly low, it is provided that the housing part is designed as a housing lower part of the housing and the housing lower part is connected to a housing upper part which is separate from the housing lower part and which, in the installed position in the motor vehicle, is a floor element of a main floor a body of the motor vehicle. In other words, the motor vehicle has the floor element of the main floor of the body in its fully manufactured state, the floor element being designed as the upper housing part of the storage housing or serving as the upper housing part when the accumulator housing is in the installed position in the motor vehicle.

For example, due to vehicle architecture or body architecture in a vehicle crash of the motor vehicle, a force acting on the motor vehicle as a result of the accident, which acts on the housing part or the lower housing part, can be conducted, in particular diverted, or absorbed via the body. As a result, in the event of an accident, a force acting on the housing part or the housing lower part can be kept particularly low, as a result of which the accumulator housing, in particular the housing part or the housing lower part, can be implemented in a particularly simple shell construction. As a result, for example, the costs, complexity and weight of the storage housing can be kept particularly low.

The body of the motor vehicle can in particular be referred to as a shell. The body is preferably a self-supporting body.

A further aspect relates to an electrical energy store for a drive of a motor vehicle, with a store housing according to the third aspect of the invention. Advantages and advantageous configurations of the first aspect, the second aspect and the third aspect of the invention are to be regarded as advantages and advantageous configurations of the further aspect and vice versa.

Further features of the invention result from the claims, the figures and the description of the figures. The features and combinations of features mentioned above in the description and the features and combinations of features mentioned below in the description of the figures and/or shown alone in the figures can be used not only in the combination specified in each case, but also in other combinations or on their own.

• 1 eine schematische Teilansicht eines elektrischen Energiespeichers von oben, mit einem erfindungsgemäßen Gehäuseteil, welches mittels eines erfindungsgemäßen Verfahrens herstellbar ist; und
• 2 eine schematische Teilschnittansicht des elektrischen Energiespeichers aus 1; und
• 3 eine schematische Teilschnittansicht eines erfindungsgemäßen Gehäuseteils, welches mittels eines erfindungsgemäßen Verfahrens herstellbar ist; und
• 4 ein schematisches Verfahrensdiagramm eines erfindungsgemäßen Verfahrens zur Herstellung eines erfindungsgemäßen Gehäuseteils; und
• 5 eine schematische Teilschnittansicht eines erfindungsgemäßen Gehäuseteils gemäß einer weiteren Ausführungsform; und
• 6 Veranschaulichung eines Thermoformprozesses eines erfindungsgemäßen Verfahrens; und
• 7 Veranschaulichung eines Thermoformprozesses eines erfindungsgemäßen Verfahrens gemäß einer weiteren Ausführungsform; und
• 8 eine schematische Draufsicht und eine schematische Teilschnittansicht eines Bauteils und eines Zellkontaktiersystems eines erfindungsgemäßen Gehäuseteils; und
• 9 Veranschaulichung eines Umspritzprozesses eines Bauteils eines erfindungsgemäßen Gehäuseteils eines erfindungsgemäßen Verfahrens; und
• 10 eine schematische Perspektivansicht eines erfindungsgemäßen Gehäuseteils gemäß einer weiteren Ausführungsform; und
• 11 eine schematische Teilschnittansicht eines elektrischen Energiespeichers zur Veranschaulichung eines Fügeprozesses zum Fügen von Batteriezellen an ein erfindungsgemäßes Gehäuseteil; und
• 12 eine schematische Teilschnittansicht eines elektrischen Energiespeichers zur Veranschaulichung eines Fügeprozesses zum Fügen von Batteriezellen an ein erfindungsgemäßes Gehäuseteil mittels Induktionsschweißen; und
• 13 eine schematische Teilschnittansicht eines elektrischen Energiespeichers zur Veranschaulichung eines Fügeprozesses zum Fügen von Batteriezellen an ein erfindungsgemäßes Gehäuseteil mittels Ultraschallschweißen; und
• 14 eine schematische Teilschnittansicht eines elektrischen Energiespeichers zur Veranschaulichung eines Fügeprozesses zum Fügen von Batteriezellen an ein erfindungsgemäßes Gehäuseteil mittels Entladung; und
• 15 eine schematische Teilschnittansicht eines elektrischen Energiespeichers zur Veranschaulichung eines Fügeprozesses zum Fügen von Batteriezellen an ein erfindungsgemäßes Gehäuseteil mittels Laserschweißen; und
• 16 eine schematische und perspektivische Teilansicht einer Karosserie eines Kraftwagens und eine schematische Teilschnittansicht eines Gehäuseoberteils eines Speichergehäuses eines elektrischen Energiespeichers.

The invention will now be explained in more detail using a preferred exemplary embodiment and with reference to the drawings. Show it:

• 1 a schematic partial view of an electrical energy store from above, with a housing part according to the invention, which can be produced by means of a method according to the invention; and
• 2 a schematic partial sectional view of the electrical energy store 1 ; and
• 3 a schematic partial sectional view of a housing part according to the invention, which can be produced by means of a method according to the invention; and
• 4 a schematic process diagram of a method according to the invention for producing a housing part according to the invention; and
• 5 a schematic partial sectional view of a housing part according to the invention according to a further embodiment; and
• 6 Illustration of a thermoforming process of a method according to the invention; and
• 7 Illustration of a thermoforming process of a method according to the invention according to a further embodiment; and
• 8th a schematic top view and a schematic partial sectional view of a component and a cell contacting system of a housing part according to the invention; and
• 9 Illustration of an overmolding process of a component of a housing part according to the invention of a method according to the invention; and
• 10 a schematic perspective view of a housing part according to the invention according to a further embodiment; and
• 11 a schematic partial sectional view of an electrical energy store to illustrate a joining process for joining battery cells to a housing part according to the invention; and
• 12 a schematic partial sectional view of an electrical energy store to illustrate a joining process for joining battery cells to a housing part according to the invention by means of induction welding; and
• 13 a schematic partial sectional view of an electrical energy store to illustrate a joining process for joining battery cells to a housing part according to the invention by means of ultrasonic welding; and
• 14 a schematic partial sectional view of an electrical energy store to illustrate a joining process for joining battery cells to a housing part according to the invention by means of discharge; and
• 15 a schematic partial sectional view of an electrical energy store to illustrate a joining process for joining battery cells to a housing part according to the invention by means of laser welding; and
• 16 a schematic and perspective partial view of a body of a motor vehicle and a schematic partial sectional view of a housing upper part of a storage housing of an electrical energy storage device.

Elements that are the same or have the same function are provided with the same reference symbols in the figures.

1 shows a schematic partial view of an electrical energy store 1 for driving a motor vehicle. The electrical energy store 1 is shown in FIG 1 shown from above. The motor vehicle is preferably designed as a passenger car, commercial vehicle or truck. The drive of the motor vehicle is preferably an electric machine, by means of which the motor vehicle can be driven. The electrical machine of the motor vehicle can be supplied by means of electrical energy stored in the electrical energy store 1, so that the motor vehicle can be driven by means of the electrical machine. 2 shows a schematic partial sectional view of the electrical energy store 1, wherein in 2 a first section AA is shown, which runs between section reference points A, which are shown in 1 are sketched.

The electrical energy store 1 has a storage housing 2 in its fully manufactured state. The electrical energy storage device 1 is preferably designed as a high-voltage storage device, as a result of which the storage housing 2 can in particular be referred to as a high-voltage storage housing (HVS storage housing). The storage housing 2 comprises a housing part 3. 3 shows the housing part 3 in a schematic partial sectional view. The housing part 3 has a component 4 which is designed as a fiber composite component 5 or as a metal sheet 6 . In the exemplary embodiment, the component 4 is designed as the fiber composite component 5 .

4 shows a schematic process diagram of a process for producing the housing part 3. In a first step of the process, the component 4 or the fiber composite component 5 is produced, whereby the first step can be referred to as fiber composite component production 7 in particular. The fiber composite component 5 is preferably designed as an organic sheet 8 . In other words, the organic sheet 8 is used as the fiber composite component 5 .

5 shows a schematic partial sectional view of the housing part 3 with the fiber composite component 5, in particular the organic sheet 8. The fiber composite component 5 or the organic sheet 8 comprises at least one layer 10 formed from a fiber-reinforced plastic 9 and at least one layer 12 formed from a metal 11, the layers 10, 12 are connected to one another during the production of fiber composite components 7 or organo sheet production. The layer 10 formed from the plastic 9 can in particular be referred to as the first layer 10 . The one formed from the metal 11 In particular, layer 12 may be referred to as second layer 12 . The plastic 9 is preferably polycaprolactam (PA6). The fiber-reinforced plastic 9 preferably includes glass fibers and/or carbon fibers.

It is preferably provided that the fiber composite component 5 comprises two layers 10, 13 formed from the fiber-reinforced plastic 9 and spaced apart from one another, the layer 12 formed from the metal 11 being arranged between the layers 10, 13 formed from the fiber-reinforced plastic 9. In other words, the fiber composite component 5 or the organic sheet 8 is designed as a sandwich component, with the fiber composite component 5 or the organic sheet 8 having the first layer 10 formed from the fiber-reinforced plastic 9 and the third layer 13 formed from the fiber-reinforced plastic 9, which is spaced from the first layer 10, the second layer 12 formed from the metal 11 being arranged between the first and the third layer 10,13.

Thus, it is preferably provided in the fiber composite component production 7 that the layers 10, 13 formed from the fiber-reinforced plastic 9 are connected to one another with the interposition of the layer 12 formed from the metal 11, in particular pressed together. The fiber composite component production 7 is preferably carried out using a double belt press. The layers 10, 12, 13 in the double belt press can each be present as a film or in the form of a film and can be pressed together by means of the double belt press.

The double belt press can have several drive rollers. At least one of the drive rollers preferably has a heating device, referred to in particular as a heating register, which is provided for heating a film or films. At least one of the drive rollers preferably has a cooling device, referred to in particular as a cooling register, by means of which the fiber composite component 5 or the organic sheet 8 can be cooled. During the production of the fiber composite component 7, the layers 10, 12, 13 are preferably pressed together by means of a pneumatic surface pressure provided by the double belt press. Hydraulic belt tensioning is preferably provided in the double belt press. The fiber composite component production 7 can in particular be referred to as stacking. Possible process parameters of the fiber composite component production 7 using the double belt press are summarized in the following table. overall width [mm] 1100 1500 1900 Dimensions (length × width × height) [mm] 6300×2600×2350 6300×3000×2350 6300×3400×2350 height adjustment 0 to 150mm (5.90") 0 to 150mm (5.90") 0 to 150mm (5.90") maximum total pressing pressure [N/cm^2] 14.6 14.6 14.6 maximum pressure in all 4 zones [N/cm^2] 3.6 3.6 3.6 maximum pressing pressure 800 mm zone [N/cm^2] 10 10 10 Maximum surface pressure of rollers, rubberized [N/cm^2] (** maximum pressure when using double-walled press rollers) 260 (260) ** 260 (260) ** 170 (220) ** Maximum linear pressure of rollers, rubberized [N/cm^2] (** maximum pressure when using double-walled press rollers) 70 (70) ** 70 (70) ** 37 (55) ** Maximum temperature [°C] (Maximum working temperature for PTFE tapes: 250°C] 300 300 300 Heat output/module [kW] 96 131 166 Cooling module length [mm] 1500, expandable in 1500mm modules 1500, expandable in 1500mm modules 1500, expandable in 1500mm modules Heating module length [mm] 1500, expandable in 1500mm 1500, expandable in 1500mm 1500, expandable in 1500mm modules modules modules lamination width [mm] 1000 1400 1800 Weight approx. [kg] 19000 22000 25000

A second step, which takes place after the first step, of the method for producing the housing part 3 can in particular be referred to as thermoforming 14 . Thermoforming 14 can be understood in particular as hot forming.

The thermoforming 14 can include deep drawing of the fiber composite component 5 or the organic sheet 8 . this is in 6 illustrated. 6 shows the thermoforming of the fiber composite component 5 or the organic sheet 8 in schematic top views. A blank 15 of the fiber composite component 5 or the organic sheet 8 is formed by deep drawing with the supply of heat and thus brought to a final contour 16 of the fiber composite component 5 or the organic sheet 8. 6 also shows a schematic partial sectional view of the end contour 16 of a second section BB, which runs between section reference points B. The end contour 16 of the fiber composite component 5 or of the organo sheet 8 thus has a first surface 17 which is directly adjoined at both ends by a second surface 18 in each case, with the second surfaces 18 running perpendicular to the first surface 17 . The second surfaces 18 are spaced from each other. In addition, the end contour 16 of the fiber composite component 5 or of the organo sheet 8 has two third surfaces 19 . In each case one of the third surfaces 19 directly adjoins the respective second surface 18 , with the third surfaces 19 running perpendicularly to the second surfaces 18 . The third surfaces 19 run parallel to the first surface 17 and are spaced from the first surface 17 .

Alternatively or additionally, the thermoforming 14 can include bending the organo sheet 8 or the fiber composite component 5 . 7 shows in schematic top views the thermoforming 14 of the fiber composite component 5 or the organic sheet 8 according to a further embodiment, in which the blank 15 of the fiber composite component 5 or the organic sheet 8 is bent to its final contour 16 with the supply of heat. For this purpose, the blank 15 includes bending edges 20.

In a third step of the method for producing the housing part 3 that takes place after the second step, a cell contacting system 21 is arranged on the fiber composite component 5 or the organo sheet. The third step is an optional step of the method. The cell contacting system 21 is arranged on an upper side of the fiber composite component 5 or the organo sheet 8, the upper side being a surface pointing upwards in the vertical direction of the vehicle when the electrical energy store 1 is installed in the motor vehicle.

8th shows the cell contacting system 21 and the fiber composite component 5 or the organic sheet 8 in a schematic top view and in a schematic partial sectional view. The cell contacting system 21 is embodied in the form of a grid in the exemplary embodiment. In this case, the cell contacting system 21 is preferably a stamped grid, which can be understood in particular as meaning that the cell contacting system 21 is produced or can be produced by means of stamping.

In a fourth step of the method that takes place after the second step or the third step, the fiber composite component 5 or the organic sheet 8 is at least partially overmoulded with a structure 23 formed from a plastic 22 . The fourth step can in particular be referred to as overmoulding 24 . The plastic 22 is preferably polycaprolactam (PA6). Alternatively, the plastic 22 can be a thermoplastic elastomer (TPE), for example.

Overmolding 24 is in 9 illustrated, in which schematic top views of the fiber composite component 5 and the housing part 3 are shown. First, an insertion 25 of the fiber composite component 5 or the organo sheet 8 is carried out, in which the fiber composite component 5 or the organic sheet 8 is inserted into a tool half 26. The tool half 26 preferably has at least one spar 27, in which 9 shown embodiment, four bars 27 are provided. Then the fiber composite component 5 or organo sheet 8 inserted in the mold half 26 is at least partially, in particular completely, encapsulated with the structure 23 formed from the plastic 22 . It can be provided that the cell contacting system 21 can be arranged on the fiber composite component 5 or organic sheet 8 inserted in the mold half 26, whereby the cell contacting system 21 during the overmolding 24 together with the fiber composite component 5 or the organic sheet 8 at least partially, in particular completely the plastic 22 is encapsulated. The cell contacting system 21 is in 9 not shown. After the encapsulation 24, the housing part 3 is removed from the tool half 26, which can in particular be referred to as removal 28.

Preferably, at least one sealing element 29 is arranged or applied on the structure 23, in particular after the removal 28. The sealing element 29 is preferably designed as a peripheral seal. The sealing element 29 can be formed from a thermoplastic elastomer (TPE).

In order to be able to keep the costs of the storage housing 2 or the electrical energy storage device 1 particularly low, it is provided that during the overmoulding 24 at least one receiving space 30, which is at least partially delimited by the structure 23 formed from the plastic 22, is formed, in which at least one battery cell 31 of the electrical energy store 1 can be arranged or plugged in at least partially. In the in the 1 , 2 , 3 and 9 In the exemplary embodiment shown, several of the receiving spaces 30 are provided, with at least one of the battery cells 31 being able to be arranged or inserted at least partially in each of the receiving spaces 30 .

2 shows a detail section D, in which one of the battery cells 31 arranged in the receiving space 30 is illustrated. The respective receiving space 30 is partially delimited by walls 33 of the structure 23 formed from the plastic 22 . The respective receiving space 30 has a receiving opening 33 through which the respective battery cell 31 can be pushed when being arranged in the respective receiving space 30 . The respective receiving space 30 or the wall 32 is designed as a positioning aid or as a positioning geometry for the battery cell 31 in the storage housing 2 or the electrical energy storage device 1 . As a result, for example, the number of parts or joining operations of the housing part 3 can be kept particularly low, as a result of which the complexity and costs of the housing part 3 can be kept particularly low.

Alternatively, it can be provided that the cell contact 21 is not encapsulated by the plastic 22, but is arranged after the encapsulation 24 on the organo sheet 8 or the fiber composite component 5, in particular is plugged onto the organo sheet 8 or the fiber composite component 5. In other words, the cell contacting 21 can alternatively be arranged on the fiber composite component 5 after the fourth step instead of before the fourth step

Provision is preferably made for the respective receiving space 30 to be formed in a honeycomb manner during the overmolding 24 . In other words, the structure 23 formed from the plastic 22 forms a honeycomb structure 34 in which the battery cells 31 can be arranged. The respective receiving space 30 is thus designed as a honeycomb 35 . The rigidity of the structure 23 and thus of the housing part 3 can be particularly increased by means of the honeycomb structure 35 .

Provision is preferably made for the respective receiving space 30 to be in the form of a through-opening 37 penetrating, in particular completely, the structure 23 formed from the plastic 22 . this is in 2 shown.

The following table summarizes exemplary machine parameters of an injection molding machine, by means of which the fiber composite component 5 can be overmoulded with the structure formed from the plastic 22, or process parameters of the overmoulding 24. closing force 4000t 3200t 650t 125t Clamping plate, H × V 3315×2920mm 3240×2810mm 1530×1450mm 745×750mm Clear expanse 2440×1800mm 2250×1800mm 1000×930mm 470×470mm Maximum mold opening stroke 3100mm 3100mm 1150mm 600mm Mold installation height, minimum - maximum 1100 - 2000mm 1100 - 2200mm 600 - 1150mm 400 - 500mm opening width 4200mm 4200mm 1750mm 900mm screw diameter 135mm 135mm 90mm 40mm Shot weight per component (K), hp 1K: 0.5-12kg 1K: 1 - 8 kg 2K: up to 140 q 1K: 0.5 - 144kq 1K: 10 - 185q number of cascades 12 20 6 0 Tool heating circuits 64 64 12 8th removal robot With 6 axes + storage belt With 6 axes + storage belt Linear + storage belt Linear + storage belt

In a further refinement, it is provided that a mounting direction 38, in which the respective battery cell 31 can be arranged or inserted in the respective receiving space 30, runs in or along a vehicle vertical direction 39 of the motor vehicle in relation to an installation position of the electrical energy store 1 in the motor vehicle. The mounting direction 38 preferably runs downwards in the vertical direction 39 of the vehicle.

10 shows the housing part 3 according to a further embodiment in a schematic and perspective partial view, in which the fiber composite component 5 or the structure 23 has stiffening ribs 40 . As a result, the rigidity of the housing part 3, in particular of the fiber composite component 5 or of the structure 23, can be particularly increased. The stiffening ribs 40 can be arranged on the outside and/or inside of the fiber composite component 5 and/or the structure 23 .

The first, the second, the third and the fourth step of the process can be carried out in a common process step, ie in one plant, or in several process steps, ie in several, in particular two, three or four, different plants.

In a fifth step of the method, which takes place after the fourth step, the housing part 3 is post-processed by machining, which can in particular be referred to as post-machining 41 by machining. The fifth step is an optional step of the method. During the subsequent machining 41 of the housing part 3, the housing part 3 can be milled. In this case, for example, openings in the housing part 3 can be milled.

In a sixth step of the method, which takes place after the fourth step or the fifth step of the method, the housing part 3 is tested for leaks, which can be referred to as a leak test 42 in particular.

The respective battery cell 31 can be positively and/or non-positively connected to the structure 23 and/or the cell contacting system 21 . In other words, the respective battery cell 31 can be fixed to the structure 23 formed from the plastic 22 and/or to the cell contacting system 21 by means of a form fit 43 and/or by means of a force fit 44 . In this case, the positive connection 43 and/or the non-positive connection 44 can be implemented as a result of the respective battery cell 31 being inserted into the respective receiving space 30 . In other words, by inserting the respective battery cell 31 through the receiving opening 33 or the through-opening 37 , the form-fitting connection 43 or the force-fitting connection 44 can be implemented. this is in 2 and in 11 shown.

11 shows a schematic partial sectional view of the electrical energy store 1 to illustrate a joining process for joining the respective battery cell 31 to the housing part 3. In FIG 11 embodiment shown touch two adjacent battery cells 31 directly. Alternatively or additionally, the respective battery cell 31 can be materially connected to the cell contacting system 21 . The connection of the respective battery cell with the cell contacting system 21 can in particular as Cell contacting are referred to. For example, the respective battery cell 31 is connected to the cell contact 21 by means of welding.

12 shows the electrical energy store 1 in a schematic partial sectional view to illustrate an alternative joining process in which the cell contact is made by means of induction welding. In this case, heat is introduced into the cell contacting system 21 or induced electromagnetically by means of an inductor 45 . A force F is preferably applied to the respective battery cell 31 during induction welding. The force F preferably runs in the direction of the assembly direction 38. A solder is preferably used in the induction welding.

13 shows the electrical energy store 1 in a schematic partial sectional view to illustrate an alternative joining process in which the cell contacting is carried out by means of ultrasonic welding (US welding). In this case, a sonotrode 46 is arranged on the battery cell 31, by means of which high-frequency mechanical vibrations in the form of ultrasound are introduced into the battery cell 31 or the cell contacting system 21. As a result, the respective battery cell 31 can be caused to oscillate in resonance. This can be referred to as exciting the battery cell 31 in particular. A solder layer 47 can be arranged between the respective battery cell 31 and the cell contacting system 21 . The solder layer 47 is preferably arranged on a metal sheet or a coil product of the cell contacting system 21 .

14 shows the electrical energy store 1 in a schematic partial sectional view to illustrate an alternative joining process in which the cell contacting is carried out by discharging a pre-charged battery cell 31. For this purpose, a current collector 48 is arranged on the cell contacting system 21, by means of which the pre-charged battery cell 31 can be discharged. The solder layer 47 is preferably provided between the respective battery cell 31 and the cell contacting system 21 . The respective battery cell 31 is preferably acted upon by the force F during assembly.

15 shows the electrical energy store 1 in a schematic partial sectional view to illustrate an alternative joining process in which the cell contacting is carried out by means of laser welding. The laser welding is preferably remote welding. At least one opening 49 is provided in the fiber composite component 5 or the organic sheet 8, in particular a plurality of openings 49. The respective opening 49 is preferably punched into the fiber composite component 5 or the organic sheet 8 and can therefore preferably be referred to as a free punching. At least one laser beam 51 is generated or provided by means of a laser 50 , the laser beam 51 impinging on the cell contacting system 21 through the respective opening 49 . After the welding, the respective opening 49 can be closed. This can be done, for example, by overmoulding and/or sealing and/or filling the respective opening 49 .

In the exemplary embodiments shown in the figures, the housing part 3 is in the form of a lower housing part 52 of the storage housing 2 . The housing part 3 preferably has at least one attachment element 53 , via which the housing part 3 designed as a housing bottom part 52 can be fastened to a housing top part 54 of the accumulator housing 2 . The connection element 53 can be a connection point. in the in 1 until 3 shown embodiment, several of the connection elements 53 are provided. The respective connection element 53 can be or will be plugged onto the structure 23 . Alternatively, the respective connection element 53 can be applied to the structure 23 by means of injection molding.

16 shows in a schematic partial sectional view the housing upper part 54 of the storage housing 2, which is formed separately from the housing lower part 52. The housing upper part 54 has at least one socket 55, which can be provided for connections. The connections can be, for example, electrical connections of the respective battery cells 31 . The upper housing part 54 preferably has at least one second connection element 56, in particular two of the second connection elements 56. The upper housing part 54 can be connected to a body 57 of the motor vehicle by means of the respective second connection element. 16 also shows the body 57 in a schematic and perspective partial view.

In the fully manufactured state of the storage housing 2, the lower housing part 52 is connected to the upper housing part 54, in particular directly. Provision is preferably made for the upper housing part 54 to be a floor element 58 of a main floor of the body 57 of the motor vehicle in its installed position in the motor vehicle. this is in 16 illustrated, with the housing top 54 in 16 itself is not in its installation position in the motor vehicle. The base element 58 can be designed as a cooling plate, for example.

Reference List

1

energy storage

2

storage enclosure

3

housing part

4

fiber composite component

5

sheet

6

component

7

fiber composite component production

8th

organic sheet

9

plastic

10

first layer

11

metal

12

second layer

13

third layer

14

thermoforming

15

blank

16

final contour

17

first face

18

second faces

19

third faces

20

bending edges

21

cell contacting system

22

plastic

23

structure

24

overmoulding

25

insertion

26

tool half

27

spar

28

Remove

29

sealing element

30

recording room

31

battery cell

32

wall

33

intake opening

34

honeycomb structure

35

honeycomb

37

passage opening

38

mounting direction

39

vehicle elevation

40

stiffening ribs

41

post processing

42

leak testing

43

form fit

44

adhesion

45

inductor

46

sonotrode

47

solder layer

48

pantograph

49

opening

50

Laser

51

laser beam

52

housing base

53

connection element

54

housing top

55

Support

56

second connection element

57

body

58

floor element

A

section reference point

A-A

first cut

B

section reference point

B-B

second cut

C

section reference point

C-C

third cut

D

detail cutout

f

Power

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102013204180 B4 [0002]

Claims (10)

Method for producing a housing part (3) of a storage housing (2) of an electrical energy storage device (1) for a motor vehicle drive, in which a component (4) designed as a fiber composite component (5) or as a sheet metal (6) is at least partially equipped with a Plastic (22) formed structure (23) is encapsulated, characterized in that during the encapsulation (24) at least one of the structure (23) formed from the plastic (22) formed receiving space (30) is formed, in which at least a battery cell (31) of the energy store (1) can be arranged. procedure after claim 1 , characterized in that an organic sheet (8) is used as the fiber composite component (5). procedure after claim 1 or 2 , characterized in that the fiber composite component (5) comprises at least one layer (10) formed from a fiber-reinforced plastic (9) and at least one layer (12) formed from a metal (11), the layers (10, 12) being connected to one another become. procedure after claim 3 , characterized in that the fiber composite component (5) comprises two layers (10, 13) formed from the fiber-reinforced plastic (9), the layer (12) formed from the metal (11) between the layers formed from the fiber-reinforced plastic (9). Layers (10, 13) is arranged. Method according to one of the preceding claims, characterized in that before the encapsulation (24) on the component (4) a cell contacting system (21) is arranged, which during the encapsulation (24) together with the component (4) at least partially from the plastic (22) is overmoulded. Method according to one of the preceding claims, characterized in that the receiving space (30) is formed in a honeycomb shape during the overmolding (24). Method according to one of the preceding claims, characterized in that the receiving space (30) is designed as a through-opening (37) penetrating the structure (23) formed from the plastic (22). Method according to one of the preceding claims, characterized in that an assembly direction (38) in which the battery cell (31) can be arranged in the receiving space (30) in relation to an installation position of the electrical energy store (1) in the motor vehicle in the vehicle vertical direction (39 ) runs. Housing part (3) for a storage housing (2) of an electrical energy storage device (1) for a motor vehicle drive, with a component (4) designed as a fiber composite component (5) or as sheet metal (6), which is at least partially covered by a plastic ( 22) formed structure (23) is encapsulated, characterized in that the structure (23) formed from the plastic (22) at least partially delimits at least one receiving space (30) which is formed by the encapsulation (24), wherein in the at least at least one battery cell (31) of the energy store (1) can be arranged in a receiving space (30). Storage housing (2) for an electrical energy storage device (1) for a motor vehicle drive, with a housing part (3). claim 9 , wherein the housing part (3) is designed as a housing lower part (52) of the storage housing (2) and the housing lower part (52) is connected to a housing upper part (54) which is designed separately from the housing lower part (52) and which, in the installed position in the motor vehicle, is a floor element (58) of a main floor of a body (57) of the automobile.

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