DE102021203549A1 - Method for manufacturing a battery module, battery module and device for manufacturing a battery module - Google Patents

Abstract

In order to provide a method for producing a battery module, with which a battery module, which preferably has an increased durability, can be produced easily and inexpensively, it is proposed according to the invention that the method comprises the following: - providing a plurality of battery cells, which are preferably designed as round cells; Potting the battery cells with a potting material, the potting material preferably hardening and/or crosslinking after the potting and a potting body being formed by curing and/or crosslinking the potting material.

Description

The present invention relates to a method for manufacturing a battery module.

The object of the present invention is to provide a method for producing a battery module with which a battery module, which preferably has increased durability, can be produced simply and inexpensively.

According to the invention, this object is achieved by a method for producing a battery module having the features of claim 1 .

• - Bereitstellen mehrerer Batteriezellen, welche vorzugsweise als Rundzellen ausgebildet sind;
• - Vergießen der Batteriezellen mit einem Vergussmaterial,

wobei das Vergussmaterial nach dem Vergießen vorzugsweise aushärtet und/oder vernetzt und durch Aushärten und/oder Vernetzen des Vergussmaterials ein Vergusskörper gebildet wird.The method for manufacturing a battery module preferably includes the following:

• - Providing several battery cells, which are preferably designed as round cells;
• - encapsulation of the battery cells with an encapsulation material,

wherein the potting material preferably hardens and/or crosslinks after the potting and a potting body is formed by curing and/or crosslinking of the potting material.

The potting material comprises or is formed from, for example, a polyurethane material or an epoxy resin material.

For example, it is conceivable that the potting material is a one-component material, a two-component material or a multi-component material.

For example, it can be favorable if the casting material is a two-component material with a hardener, in particular a crosslinking agent.

The term "in particular" is preferably used in the context of this description and the appended claims to describe optional features.

In particular, it can be favorable if the potting material is heat-curing and/or moisture-curing.

The potting material preferably has high thermal conductivity.

A thermal conductivity of the potting material is preferably greater than approximately 0.5 W/m*K, for example greater than approximately 0.7 W/m*K.

The battery cells are preferably circular-cylindrical battery cells, in particular circular-cylindrical round cells.

The battery cells are preferably at least approximately rotationally symmetrical to a longitudinal axis thereof.

For electrical contacting, each of the battery cells preferably comprises two cell poles, which are arranged in the area of a cell head of the battery cells.

The battery cells preferably each comprise a cell head and a cell base.

The cell head and the cell base of a respective battery cell are preferably arranged at opposite ends of the battery cells.

It can be favorable if the battery cells each include a cell housing in which a cell coil is arranged.

The cell housing of a battery cell preferably includes a cell head cover, a cell floor and a cell jacket.

The cell housing of a battery cell is preferably formed from a metallic material, for example steel.

The cell housing preferably has corrosion protection.

In one configuration of the method, it is provided that the battery cells are positioned relative to one another, in particular essentially parallel to one another, and/or relative to the holding device before they are cast by means of a holding device.

The battery cells are preferably positioned relative to one another by means of the holding device in such a way that the longitudinal axes of the battery cells are arranged essentially parallel to one another.

In particular, the battery cells are arranged parallel to one another in such a way that the battery cells are arranged as densely as possible.

It can be favorable if the battery cells are arranged with a packing density in the range from approximately 60% to approximately 90%, for example with a packing density in the range from approximately 70% to approximately 80%.

In one configuration of the method, it is provided that the battery cells are guided in a direction running parallel to the longitudinal axes of the battery cells in order to position them in the holding device.

In this case, the battery cells are guided in particular by means of a guiding and/or aligning device of the holding device.

In one configuration of the method, it is provided that the battery cells are positioned by means of the holding device in such a way that the cell heads of the battery cells are arranged essentially in one positioning plane.

The battery cells can have length tolerances in a direction running parallel to their longitudinal axes.

It is possible, for example, for the battery cells to have length tolerances of approximately 0.5 mm in the direction running parallel to their longitudinal axes.

Arranging the cell heads of the battery cells in a positioning plane can preferably facilitate and/or accelerate electrical connection of the battery cells by means of cell connectors, in particular bonding of the battery cells.

A compensation of length tolerances of the battery cells in the area of the cell heads of the battery cells can thus preferably be achieved.

A length tolerance of the battery cells preferably only has an effect in the area of the cell bases of the battery cells.

In particular, the battery cells are positioned by means of the holding device in such a way that the cell head covers of the cell housings of the battery cells are arranged essentially in one positioning plane.

A deviation of the cell heads of the battery cells and/or the cell head covers of the cell housings of the battery cells from the positioning plane is preferably at most approximately 0.2 mm, in particular at most approximately 0.1 mm.

The battery cells of a battery module are preferably electrically connected to one another in parallel and/or in series by means of cell connectors.

A cell connector includes, for example, a bonded connection and/or a welded connection or is formed by these.

For this electrical interconnection by means of the cell connectors, it is advantageous if the distance between the cell poles of adjacent battery cells is constant and/or if the cell heads of the battery cells deviate from the positioning plane by the smallest possible amount.

In one configuration of the method, it is provided that the battery cells are held and/or gripped by their cell heads by means of the holding device.

It can be favorable if the battery cells are only held and/or gripped by the holding device at an upper end region of their cell housing.

Within the scope of this description and the appended claims, an upper end area of the cell housing of the battery cells is understood to mean, in particular, an end area which encompasses the cell head of the battery cells or is adjacent to it.

In particular, the battery cells are held and/or gripped by the holding device only on the cell head cover and/or only on an upper end area of the cell casing of a respective cell housing, for example on at most approximately 25% of a surface of the cell casing on the upper end area of the cell housing.

In particular, it can be favorable if the battery cells are only held and/or gripped by the holding device on the cell head cover of a respective cell housing.

The holding device preferably comprises a plurality of holding elements, with each holding element being designed in such a way that one battery cell can be held and/or gripped on the cell head cover of the cell housing of the battery cell.

A surface of a holding element of the holding device, which is brought into contact with a cell head of the battery cell and/or with a cell head cover of a cell housing of the battery cell when holding and/or gripping a battery cell, is preferably essentially complementary to a surface of the battery cell on the cell head and/or or a surface of the cell head cover of the cell case of the battery cell.

In one configuration of the method, it is provided that the battery cells are held and/or gripped magnetically, electromagnetically, pneumatically or mechanically by means of the holding device.

In one configuration of the method, it is provided that the battery cells are held by the holding device until the potting material is crosslinked in such a way that a position of the battery cells is fixed relative to one another and/or relative to a casting mold.

For example, it can be favorable if the battery cells are held by the holding device for at least approximately 5 minutes, for example at least approximately 10 minutes, while the potting material hardens and/or crosslinks.

The battery cells are held by the holding device, for example, until at least approximately 60%, for example at least approximately 70%, preferably at least approximately 80%, of the potting material is crosslinked and/or cured.

An alignment of the battery cells relative to each other and/or relative to the casting mold is preferably fixed by the curing and/or crosslinking of the casting material.

1. a) die Batteriezellen und der Vergusskörper nach dem Aushärten und/oder Vernetzen des Vergussmaterials aus der Gießform entnommen werden; oder
2. b) die Batteriezellen und der Vergusskörper nach dem Aushärten und/oder Vernetzen des Vergussmaterials in der Gießform verbleiben und mit dieser ein Verbundbauteil bilden.

In one embodiment of the method, it is provided that

1. a) the battery cells and the cast body are removed from the casting mold after the casting material has hardened and/or crosslinked; or
2. b) the battery cells and the cast body remain in the casting mold after the casting material has hardened and/or crosslinked and form a composite component with it.

The casting mold is in particular removed from the battery module.

If the battery cells and the cast body are removed from the casting mold after the casting material has crosslinked and/or cured, it can be provided that the casting mold is lined with a separating material, for example with a film material, before the casting material is introduced.

It can be advantageous, for example, if the casting mold is lined with a deep-drawn foil before the casting material is introduced, which remains on the battery module after the casting mold has been removed.

The separating material, in particular the foil material, for example the thermoforming foil, preferably forms part of the battery module.

If the battery cells and the potting body remain in the mold after the potting material has been crosslinked and/or cured, the mold preferably forms part of the battery module.

In one configuration of the method, it is provided that the battery cells are positioned relative to a casting mold before they are cast by means of the holding device in such a way that the battery cells are spaced apart from a base of the casting mold.

In particular, it can be favorable if the battery cells are positioned relative to the casting mold by means of the holding device before casting in such a way that a cell foot of the battery cells and/or a cell floor of the cell housing of the battery cells is at a distance from the bottom of the casting mold.

The casting mold is preferably formed by a trough, for example a metallic trough.

The trough comprises, for example, a base and/or a side wall that is closed in the form of a ring.

The bottom of the trough comprises, for example, a metallic material or is formed from this.

As an alternative to this, it is conceivable that the trough comprises a metallic material or is formed from this.

In one embodiment of the method, it is provided that the holding device is directly or indirectly attached to a casting mold by means of a stop device in such a way that the holding device can be positioned in a predetermined position relative to the casting mold.

The stop device is preferably set in such a way that with a maximum length of the battery cells, in particular at an upper length tolerance range, a minimum distance of the battery cells from the bottom of the mold is maintained, in particular a minimum distance of a cell base of the battery cells and/or a cell base of the cell housing of the battery cells from the bottom of the mold.

To set a predetermined distance, the holding device is placed against an edge of the casting mold, for example, in particular by means of the stop device.

It can be favorable if the casting mold includes a stop on which the stop device can be struck.

Alternatively or additionally, it can be provided that the holding device is positioned relative to the casting mold by means of a positioning device.

The minimum distance of the battery cells from the bottom of the mold, in particular the minimum distance of a cell base of the battery cells and/or a cell bottom of the cell housing of the battery cells from the bottom of the mold, preferably corresponds to a minimum thickness of the potting material which is arranged between the bottom of the mold and the battery cells is.

The minimum distance of the battery cells from the bottom of the mold, in particular the minimum distance of a cell foot of the battery cells and/or a cell bottom of the cell housing of the battery cells from the bottom of the mold, is preferably at least approximately 0.3 mm, for example at least approximately 0.4 mm.

A maximum distance of the battery cells from the bottom of the mold, in particular a maximum distance of a cell foot of the battery cells and/or a cell bottom of the cell housing of the battery cells from the bottom of the mold, is preferably at most approximately 1.5 mm, for example at most approximately 1.0 mm.

The maximum distance of the battery cells from the bottom of the mold, in particular the maximum distance of a cell foot of the battery cells and/or a cell bottom of the cell housing of the battery cells from the bottom of the mold, preferably corresponds to a maximum thickness of the potting material which is arranged between the bottom of the mold and the battery cells is.

A thickness of the potting material, which is arranged between the bottom of the casting mold and the battery cells, is for example in a range from approximately 0.3 mm to approximately 1.5 mm, preferably in the range from approximately 0.4 mm to approximately 1.0 mm .

In one configuration of the method, it is provided that the battery cells are positioned using the holding device before they are cast in such a way that a minimum cell spacing between adjacent battery cells, in particular a minimum spacing between the cell casings of the cell housings of adjacent battery cells, is at least approximately 0.3 mm, preferably at least approximately 0 .7 mm, and/or at most about 2.0 mm, preferably at most about 1.3 mm.

A particularly high energy density of the battery module can preferably be achieved by such a minimum cell distance.

The minimum cell spacing between adjacent battery cells is preferably adapted to a capillary behavior of the potting material. For example, it can be provided that a minimum cell spacing between adjacent battery cells and/or a viscosity of the potting material are matched to one another in such a way that the potting material between the battery cells rises to the desired height before it hardens.

It can be favorable, for example, if the potting material has a viscosity, in particular a mixed viscosity, of at most approximately 5000 mPas, preferably at most approximately 2000 mPas.

A closer arrangement of the battery cells and thus a higher energy density of a battery module can preferably be achieved by a small cell spacing.

Due to the small distances between adjacent battery cells, in particular the cell casings of the cell housings of adjacent battery cells, forces acting on the battery module, for example bending forces acting on the battery module, can preferably be transmitted from a cell housing of a battery cell to the cell housing of an adjacent battery cell.

In this case, the flexural rigidity of a battery module can preferably be increased by a factor of approximately 2 to approximately 10 compared to the prior art.

Natural resonance frequencies of a battery module are preferably also increased by a factor of approximately 2 to approximately 10 compared to the prior art.

In particular, the reliability and/or service life of bonded connections and/or welded connections, by means of which the battery cells of the battery module are electrically connected to one another, can be increased.

1. a) die Batteriezellen mittels der Haltevorrichtung elektrisch voneinander isoliert sind, während die Batteriezellen mittels der Haltevorrichtung gehalten und/oder gegriffen werden; und/oder
2. b) die Haltevorrichtung gegenüber den Batteriezellen elektrisch isoliert ist, während die Batteriezellen mittels der Haltevorrichtung gehalten und/oder gegriffen werden.

In one embodiment of the method, it is provided that

1. a) the battery cells are electrically insulated from one another by means of the holding device, while the battery cells are held and/or gripped by means of the holding device; and or
2. b) the holding device is electrically isolated from the battery cells, while the batte ry cells are held and/or gripped by means of the holding device.

The holding device preferably comprises an electrical insulation device for electrically isolating the holding device from the battery cells.

The holding device and/or the electrical insulation device are preferably designed in such a way that the battery cells are electrically insulated from one another while the battery cells are held and/or gripped by means of the holding device.

In one configuration of the method, it is provided that the battery cells are encapsulated using the encapsulation material with one, preferably with several, for example two, mounting elements, which are preferably designed to fix a battery module to a housing of a battery device.

The battery cells are encapsulated in particular with the assembly elements when the battery cells and the encapsulation body are removed from the casting mold after the encapsulation material has been crosslinked and/or cured.

For example, it is conceivable that a battery module can be fixed to a housing of a battery device only by means of the mounting elements.

It can be favorable if the mounting elements include a potting section, by means of which the mounting elements are potted with the potting material, and/or if the mounting elements include a mounting section, with which the mounting elements can be fixed to a housing of a battery device, for example to a mounting rail of the housing .

The encapsulated section of an assembly element preferably comprises a plurality of undercut elements which are designed in such a way that the encapsulated section of the assembly element and the encapsulated body undercut each other after the battery cells have been encapsulated.

The cast section of the mounting element and the cast body are preferably connected to one another in a form-fitting manner by means of the undercut elements.

A secure hold of the cast section in the cast body can preferably be made possible in this case.

It can be favorable, for example, if the undercut elements are passage openings in the cast section of the assembly element.

The assembly section of an assembly element preferably comprises one or more form-fitting elements which can be connected to a fastening rail of a housing of a battery device in a form-fitting manner, for example in the manner of a jigsaw puzzle.

As an alternative or in addition to this, it can be provided that the mounting section of a mounting element comprises one or more fastening elements, which are designed, for example, as through-openings in the mounting section.

For example, the mounting section of a mounting element can be screwed to a mounting rail of a housing of a battery device.

The assembly elements are, for example, profile elements, for example sheet metal angles.

For reasons of space, it can be provided that the material thickness of the profile elements, in particular the metal angles, is at most approximately 2 mm.

During the encapsulation of the battery cells, the assembly elements are preferably fixed to the casting mold, for example by means of one or more hold-down devices.

As an alternative or in addition to this, it is possible for the assembly elements to be screwed to the casting mold in order to fix them to the casting mold.

By fixing the mounting elements on the casting mold, a spacing of the mounting elements relative to the casting mold, for example relative to a side wall of the casting mold and/or relative to a bottom of the casting mold, can preferably be fixed.

Precisely fitting installation of a battery module can preferably be made possible in this way.

It can be favorable if a mounting element includes or forms a temperature control device for temperature control of the battery cells.

In particular, it can be provided that a mounting element comprises a temperature control channel structure through which a temperature control medium can be conducted.

1. a) zunächst das Vergussmaterial in die Gießform eingebracht wird und anschließend die Batteriezellen in das Vergussmaterial hineingedrückt werden; oder
2. b) zunächst die Batteriezellen zumindest teilweise in der Gießform angeordnet werden und anschließend das Vergussmaterial in die Gießform eingebracht wird.

In one embodiment of the method, it is provided that the casting material for casting the battery cells is introduced into a mold, preferably

1. a) first the casting material is introduced into the casting mold and then the battery cells are pressed into the casting material; or
2. b) first the battery cells are at least partially arranged in the casting mold and then the casting material is introduced into the casting mold.

The battery cells are preferably pressed into the potting material or arranged in the casting mold in a direction running parallel to the longitudinal axes of the battery cells by means of the holding device.

For introduction into the casting mold, the casting material is poured into the casting mold, preferably in liquid form.

When the potting material is introduced into the casting mold and the battery cells are then introduced into the potting material, the battery cells are preferably pressed into the potting material which is still liquid.

When first the battery cells are at least partially arranged in the mold, the potting material in liquid form is preferably poured into the mold so that it flows around the battery cells.

In one configuration of the method, it is provided that the casting material is subjected to a negative pressure after it has been introduced into the casting mold, in particular after the battery cells have been brought into contact with the casting material.

Within the scope of this description and the appended claims, a negative pressure is understood to mean, in particular, a pressure below the ambient pressure.

A negative pressure is preferably applied to the potting material while the potting material is still liquid and/or flowable.

Gas bubbles are preferably removed from the casting material by applying a negative pressure to the casting material.

In one configuration of the method, it is provided that the battery cells, when cast, are at least approximately 10%, preferably at least approximately 25%, and/or at most approximately 90%, preferably at most approximately 75%, based on their length in the casting material be introduced.

A length of a battery cell is preferably a length taken parallel to the longitudinal axis of the battery cell.

• - Gesamtmasse des Batteriemoduls; und/oder
• - thermische Kopplung der Zellköpfe der Batteriezellen mit dem Vergussmaterial; und/oder
• - zu erzielende mechanische Steifigkeit des Batteriemoduls.

A potting height of the potting material is preferably selected by considering the following optimization parameters:

• - total mass of the battery module; and or
• - Thermal coupling of the cell heads of the battery cells with the potting material; and or
• - the mechanical rigidity of the battery module to be achieved.

A mechanical rigidity of the battery module can preferably be increased by increasing the encapsulation height.

Improved thermal coupling of the cell heads of the battery cells to the potting material means that heat can preferably be dissipated more effectively from the cell heads.

The present invention also relates to a battery module.

The present invention is based on the further object of providing a battery module which preferably has increased durability and can be produced easily and inexpensively.

According to the invention, this object is achieved by a battery module having the features of claim 17 .

The battery module is in particular a battery module which is produced according to the method according to the invention for producing a battery module.

• - mehrere Batteriezellen, welche vorzugsweise als Rundzellen ausgebildet sind;
• - einen Vergusskörper aus einem Vergussmaterial, mittels welchem die Batteriezellen vergossen sind,

wobei Zellköpfe der Batteriezellen im Wesentlichen in einer Ebene angeordnet sind.The battery module preferably includes the following:

• - Several battery cells, which are preferably designed as round cells;
• - a casting body made of a casting material, by means of which the battery cells are cast,

wherein cell heads of the battery cells are arranged essentially in one plane.

The battery module according to the invention preferably has one or more of the components associated with the method according to the invention for producing a battery module described features and / or advantages.

Furthermore, the method according to the invention for producing a battery module preferably has one or more of the features and/or advantages described in connection with the battery module according to the invention.

The potting material and/or the potting body are preferably used to mechanically fix the battery cells and/or to electrically insulate the battery cells.

It can also be favorable if the potting material is designed to dissipate heat from the battery cells.

Battery cells of the battery module are preferably electrically connected to one another by means of a number of cell connectors, for example by means of a number of bonded connections and/or welded connections.

A battery module produced according to the invention is preferably designed to be rigid.

Increased reliability of the bonded connections and/or welded connections can preferably be achieved through a high flexural rigidity of the battery module.

The battery module includes, for example, a trough in which the cast body is arranged and/or which covers the cast body on multiple sides, preferably five sides.

As an alternative to this, it can be provided that the potting body is covered on several sides, preferably on five sides, by a foil material, for example by a thermoforming foil.

In one configuration of the battery module, it is provided that the cast body of the battery module is arranged in a mold and forms a composite component with the mold.

In one configuration of the battery module, it is provided that the potting body is positively connected to one or more, for example two, assembly elements.

For example, it is conceivable that a battery module can be fixed to a housing of a battery device only by means of the mounting elements.

It can be favorable if the mounting elements include a potting section, by means of which the mounting elements are potted with the potting material, and/or if the mounting elements include a mounting section, by means of which the mounting elements can be fixed to a housing of a battery device, for example to a fastening rail of the housing .

The encapsulation section of a mounting element is embedded in particular in the encapsulation material of the encapsulation body.

For example, it is conceivable that one mounting element is arranged parallel to a long secondary side of the battery module.

The encapsulated section of an assembly element preferably comprises a plurality of undercut elements which are designed in such a way that the encapsulated section of the assembly element and the encapsulated body undercut one another after the battery cells have been encapsulated.

The present invention also relates to a device for producing a battery module.

The present invention is based on the further object of providing a device for producing a battery module, by means of which a battery module, which preferably has increased durability, can be produced simply and inexpensively.

According to the invention, this object is achieved by a device for producing a battery module having the features of claim 20 .

The device according to the invention for producing a battery module serves in particular to carry out the method according to the invention for producing a battery module.

• - eine Haltevorrichtung, welche ein oder mehrere Halteelemente zum Halten und/oder Greifen jeweils einer Batteriezelle umfasst,

wobei ein jeweiliges Halteelement derart ausgebildet ist, dass jeweils eine Batteriezelle an einem Zellkopf derselben gehalten und/oder gegriffen werden kann, beispielsweise magnetisch, elektromagnetisch, pneumatisch oder mechanisch.The device for manufacturing a battery module preferably includes the following:

• - a holding device which comprises one or more holding elements for holding and/or gripping one battery cell each,

a respective holding element being designed in such a way that a battery cell can be held and/or gripped at a cell head of the same, for example magnetically, electromagnetically, pneumatically or mechanically.

It can be favorable if the holding elements are magnetic holding elements or electromagnetic holding elements.

If the holding elements are magnetic holding elements or electromagnetic holding elements, the potting material can preferably be subjected to a negative pressure, in particular other without the battery cells falling off the holding elements of the holding device.

In one configuration of the device, it is provided that a surface of a holding element of the holding device, which is brought into contact with the cell head of the battery cell and/or with a cell head cover of a cell housing of the battery cell when holding and/or gripping a battery cell, is essentially complementary to a Surface of the battery cell is formed on the cell head and / or a surface of the cell head cover of the cell housing of the battery cell.

In one configuration of the device, it is provided that the holding device is designed in such a way that the holding device switches between a switching state in which battery cells are held and/or gripped by means of a respective holding element and a release state in which battery cells are not held and/or gripped , is switchable.

For example, it is conceivable that the holding device comprises electromagnetic holding elements, with a holding force of the electromagnetic holding elements being switchable.

Alternatively or additionally, it is conceivable that the holding device comprises magnetic holding elements which comprise a switchable permanent magnet, for example a mechanically switchable permanent magnet or an electrically switchable permanent magnet.

In one configuration of the device, it is provided that the device comprises a testing device, by means of which a holding state of the one or more holding elements can be checked.

If the holding device comprises electromagnetic holding elements, it can be provided, for example, that a change in a holding state of the one or more holding elements can be detected by measuring a change in inductance using the testing device.

By measuring a change in inductance, it is possible in particular to detect a change in a gap between a battery cell, in particular between a cell head cover of the battery cell, and a respective holding element.

In order to detect a change in inductance, an alternating current component is preferably applied to the holding current of a respective electromagnetic holding element.

The holding current is formed, for example, by a first holding current component and by a superimposed second holding current component, with the second holding current component preferably being in the form of a periodic alternating current component.

The first holding current component is preferably used essentially to apply the holding force of a respective electromagnetic holding element. In contrast, the second holding current component is preferably used as a measurement or signal variable, with an inductance of a coil of the electromagnetic holding element changing as a result of a change in the air gap between a respective electromagnetic holding element and a battery cell.

The change in inductance changes, in particular, a phase shift between the alternating current component and the alternating voltage component of the second holding current component.

This phase shift can preferably be detected and used to check a holding state of a respective holding element.

In one configuration of the device, it is provided that the holding device comprises a guiding and/or aligning device, by means of which a plurality of battery cells can be positioned relative to one another, in particular substantially parallel to one another, and/or relative to the holding device.

The guiding and/or aligning device is designed in particular in such a way that battery cells are guided in the area of their cell heads, for example in an upper quarter of a cell housing of the battery cells.

An upper quarter of a cell housing of a battery cell is in particular an upper quarter of the cell housing in relation to a length of the battery cell in the region of the cell head of the battery cell.

The guiding and/or aligning device preferably comprises a plurality of guiding and/or aligning elements.

It can be favorable if the battery cells are guided between a plurality of guiding and/or aligning elements or if the battery cells are guided within a guiding and/or aligning element.

For example, it is conceivable that the guide and/or alignment elements are designed as guide pins.

A guide and/or alignment element, in particular a guide pin, is preferably arranged between each three battery cells.

One battery cell is preferably arranged between each three guide and/or alignment elements, in particular between each three guide pins.

The guide pins are preferably arranged parallel to one another.

A length of the guide pins is preferably designed in such a way that the battery cells protrude beyond the guide pins when they are held or gripped by the holding device.

For example, it is conceivable that the length of the guide pins is smaller than the length of the battery cells.

As an alternative to this, it is conceivable that the guide and/or alignment elements are designed as a recess, for example as a circular-cylindrical recess, it being possible for one battery cell to be guided in each recess.

A depth of such a recess is preferably less than a length of the battery cells.

1. a) die Haltevorrichtung eine Anschlagvorrichtung umfasst, wobei die Haltevorrichtung mittels der Anschlagvorrichtung derart an einer Gießform mittelbar oder unmittelbar anschlagbar ist, dass die Haltevorrichtung in einer vorgegebenen Position relativ zu der Gießform positionierbar ist; und/oder
2. b) die Vorrichtung eine Positioniervorrichtung umfasst, wobei die Haltevorrichtung mittels der Positioniervorrichtung relativ zu einer Gießform positionierbar ist.

In one embodiment of the device it is provided that

1. a) the holding device comprises a stop device, wherein the holding device can be directly or indirectly attached to a mold by means of the stop device in such a way that the holding device can be positioned in a predetermined position relative to the mold; and or
2. b) the device comprises a positioning device, wherein the holding device can be positioned relative to a casting mold by means of the positioning device.

The stop device is preferably designed in such a way that the holding device can be positioned in a predetermined position relative to the mold by striking the stop device on a casting mold.

In order to position the holding device in a predetermined position relative to the casting mold, it can be provided that the stop device is placed against an edge of the casting mold.

It can be favorable if the casting mold includes a stop on which the stop device can be struck.

The positioning device preferably includes a positioning drive.

It can also be favorable if the positioning device includes a displacement measuring device.

The distance measuring device can preferably be used to determine whether the holding device has been brought into a predetermined position by means of the positioning drive of the positioning device.

In one configuration of the device, it is provided that the holding device comprises an electrical insulation device, by means of which battery cells can be electrically insulated from one another, while the battery cells are held and/or gripped by means of the holding device, and/or by means of which the holding device can be electrically insulated from the battery cells , while the battery cells are held and/or gripped by the holding device.

For example, the electrical insulation device includes an electrically insulating coating, which is applied, for example, to a respective holding element of the holding device.

In particular, it can be favorable if all surfaces of the holding device that are brought into direct contact with battery cells to hold them have an insulating coating.

For example, it can be provided that a surface of a holding element of the holding device, which is brought into contact with the cell head of the battery cell and/or with the cell head cover of the cell housing of the battery cell when holding and/or gripping a battery cell, has an electrically insulating coating.

For example, it can be favorable if the electrical insulation device comprises one or more electrical insulation films.

A surface of guiding and/or aligning elements of a guiding and/or aligning device of the holding device preferably has an electrically insulating coating.

The device according to the invention for producing a battery module preferably has one or more of the features and/or advantages described in connection with the method according to the invention for producing a battery module and the features and/or advantages described in connection with the battery module according to the invention.

Furthermore, the method according to the invention for producing a battery module and the battery module according to the invention preferably have one or more of the features and/or advantages described in connection with the device according to the invention for producing a battery module.

Further preferred features and/or advantages of the invention are the subject of the following description and the graphic representation of exemplary embodiments.

• 1 einen schematischen Schnitt durch eine Gießform zu Beginn eines Verfahrens zum Herstellen eines Batteriemoduls;
• 2 eine dem schematischen Schnitt aus 1 entsprechende Darstellung einer Gießform, wobei zum Herstellen eines Batteriemoduls ein Vergussmaterial in die Gießform eingebracht wird;
• 3 eine dem schematischen Schnitt aus 1 entsprechende Darstellung, wobei zum Herstellen eines Batteriemoduls mehrere Batteriezellen mit dem Vergussmaterial in Kontakt gebracht werden und dabei mittels einer Haltevorrichtung gehalten und/oder gegriffen werden;
• 4 eine schematische Schnittdarstellung einer Ausführungsform eines Batteriemoduls, welches durch das Verfahren gemäß den 1 bis 3 hergestellt worden ist;
• 5 eine schematische Schnittdarstellung einer weiteren Ausführungsform eines Batteriemoduls, welches durch das Verfahren gemäß den 1 bis 3 hergestellt worden ist;
• 6 eine schematische perspektivische Darstellung einer Haltevorrichtung einer Ausführungsform einer Vorrichtung zum Herstellen eines Batteriemoduls;
• 7 eine schematische Seitenansicht eines Halteelements der Haltevorrichtung der Ausführungsform der Vorrichtung zum Herstellen eines Batteriemoduls aus 6;
• 8 eine schematische perspektivische Darstellung der Haltevorrichtung der Ausführungsform der Vorrichtung zum Herstellen eines Batteriemoduls aus 6, wobei bei einem Verfahren zum Herstellen eines Batteriemoduls mehrere Batteriezellen mittels der Haltevorrichtung gehalten und/oder gegriffen werden;
• 9 eine dem Verfahrensschritt aus 3 entsprechende perspektivische Darstellung der Haltevorrichtung der Ausführungsform der Vorrichtung zum Herstellen eines Batteriemoduls aus 6;
• 10 eine schematische perspektivische Darstellung einer weiteren Ausführungsform eines Batteriemoduls;
• 11 eine schematische perspektivische Darstellung eines Verfahrensschritts eines Verfahrens zur Herstellung eines Batteriemoduls, wobei Batteriezellen mittels eines Vergussmaterials mit zwei Montageelementen vergossen werden; und
• 12 eine schematische perspektivische Darstellung einer weiteren Ausführungsform eines Montageelements.

In the drawings show:

• 1 a schematic section through a mold at the beginning of a method for manufacturing a battery module;
• 2 one from the schematic section 1 Corresponding representation of a casting mold, wherein a casting material is introduced into the casting mold to produce a battery module;
• 3 one from the schematic section 1 Corresponding representation, in which, in order to produce a battery module, a plurality of battery cells are brought into contact with the potting material and are held and/or gripped by means of a holding device;
• 4 a schematic sectional view of an embodiment of a battery module, which by the method according to 1 until 3 has been manufactured;
• 5 a schematic sectional view of a further embodiment of a battery module, which by the method according to 1 until 3 has been manufactured;
• 6 a schematic perspective view of a holding device of an embodiment of a device for producing a battery module;
• 7 shows a schematic side view of a holding element of the holding device of the embodiment of the device for producing a battery module 6 ;
• 8th a schematic perspective view of the holding device of the embodiment of the device for producing a battery module 6 , wherein in a method for producing a battery module, a plurality of battery cells are held and/or gripped by means of the holding device;
• 9 one of the process step 3 corresponding perspective view of the holding device of the embodiment of the device for producing a battery module 6 ;
• 10 a schematic perspective view of a further embodiment of a battery module;
• 11 a schematic perspective representation of a method step of a method for producing a battery module, wherein battery cells are encapsulated by means of an encapsulation material with two assembly elements; and
• 12 a schematic perspective view of a further embodiment of a mounting element.

Identical or functionally equivalent elements are provided with the same reference symbols in all figures.

1 shows a schematic section of a casting mold, designated as a whole by 100, at the beginning of a method for producing a battery module that is still to be described.

The casting mold 100 is preferably formed by a trough 102, for example a metallic trough.

The trough 102 comprises, for example, a base 104 and/or a side wall 106 closed in the form of a ring.

The bottom 104 of the trough 102 comprises or is formed from a metallic material, for example.

In a first step, a potting material 108 is preferably introduced into the casting mold 100, preferably in liquid form (cf. 2 ).

The potting material 108 comprises or is formed from a polyurethane material or an epoxy resin material, for example.

For example, it is conceivable that the potting material 108 is a one-component material, a two-component material or a multi-component material.

For example, it is conceivable that the potting material 108 is a two-component material a hardener, in particular a crosslinking agent.

In particular, it can be favorable if the potting material 108 is heat-curing and/or moisture-curing.

The potting material 108 preferably has a high thermal conductivity.

A thermal conductivity of the potting material 108 is preferably greater than approximately 0.5 W/m*K, for example greater than approximately 0.7 W/m*K.

In one to the procedural step 2 In the subsequent method step, a plurality of battery cells 110 are preferably secured by means of a holding device 112, which is 3 only shown schematically, held and/or grasped (cf. 3 ).

The holding device 112 is preferably part of a device 113 for producing a battery module, which in addition to the holding device 112 can also include other components or parts.

The battery cells 110 are preferably circular-cylindrical battery cells 110, in particular circular-cylindrical round cells 114, only individual battery cells 100 being provided with the reference symbols for circular-cylindrical round cells 114 in the figures for reasons of clarity.

The battery cells 110 are preferably formed at least approximately rotationally symmetrically to a longitudinal axis 116 thereof.

The battery cells 110 preferably each comprise a cell head 118 and a cell base 120.

The cell head 118 and the cell base 120 of a respective battery cell 110 are preferably arranged at opposite ends of the battery cells 110 .

It can be favorable if the battery cells 110 each include a cell housing 122 in which a cell coil (not shown in the drawing) is arranged.

The cell housing 122 of a battery cell 110 preferably comprises a cell head cover 124, a cell floor 126 and a cell jacket 128.

The cell housing 122 of a battery cell 110 is preferably formed from a metallic material, for example steel.

The cell housing 122 of a respective battery cell 110 preferably has corrosion protection.

For electrical contacting, each of the battery cells 110 preferably includes two cell poles 130, which are arranged, for example, in the region of the cell head 118 of the battery cells 110 and are indicated only schematically by means of an arrow.

The battery cells 110 are preferably held and/or gripped by their cell heads 118 by means of the holding device 112 .

For example, it is conceivable that the battery cells 110 are only held and/or gripped by the holding device 112 on the cell head cover 124 of a respective cell housing 122 .

As an alternative to this, it is conceivable for the battery cells 110 to be held and/or gripped by the holding device 112 at an upper end region 132 of their cell housing 122 .

The upper end area 132 of the cell housing 122 preferably comprises the cell head 118 of the battery cells 110 or borders on it.

The battery cells 110 are preferably held and/or gripped by the holding device 112 only on the cell head cover 124 and only on the upper end region 132 of the cell casing 128 of a respective cell housing 122, for example on at most approximately 25% of a surface of the cell casing 128 at the upper end region 132 of the cell housing 122.

The battery cells 110 are held and/or gripped by the holding device 112, for example magnetically, electromagnetically, pneumatically or mechanically.

The battery cells 110 are preferably positioned by means of the holding device 112 in such a way that the cell heads 118 of the battery cells 110, in particular the cell head covers 124 of the cell housing 122, are arranged essentially in a positioning plane 134.

In particular, the battery cells 110 can have length tolerances in a direction running parallel to their longitudinal axes 116 .

It is possible, for example, for the battery cells 110 to have length tolerances of approximately 0.5 mm in the direction running parallel to their longitudinal axes 116 .

By arranging the cell heads 118 of the battery cells 110 in a positioning plane 134, an electrical connection of the battery cells 110 by means of cell connectors, in particular a bonding of the battery cells 110, can preferably be facilitated and/or accelerated.

In addition, a compensation of length tolerances of the battery cells 110 in the area of the cell heads 118 of the battery cells 110 can be achieved, so that a length tolerance of the battery cells 110 preferably only has an effect in the area of the cell bases 120 of the battery cells 110 .

A deviation of the cell heads 118 of the battery cells 110 and/or the cell head covers 124 of the cell housing 122 of the battery cells 110 from the positioning plane 134 is preferably at most approximately 0.2 mm, in particular at most approximately 0.1 mm.

2 shows that, for example, first the potting material 108 is introduced into the casting mold 100, the battery cells 110 preferably then being pressed into the potting material 108 and thereby being potted with the potting material 108.

The battery cells 110 are preferably pressed into the potting material 108 which is still liquid.

Alternatively, it is conceivable that first the battery cells 110 are at least partially arranged in the casting mold 100 and then the casting material 108 is introduced into the casting mold 100, the battery cells 110 being cast with the casting material 108 in the process.

The casting material 108 is preferably poured into the casting mold 100 in liquid form, so that it flows around the battery cells 110 .

The battery cells 110 are preferably pressed into the potting material 108 or arranged in the casting mold 100 by means of the holding device 112 in a direction running parallel to the longitudinal axes 116 of the battery cells 110 .

The battery cells 110 are preferably positioned relative to the mold 100 by means of the holding device 112 in such a way that the battery cells 110 are spaced apart from the bottom 104 of the mold 100 .

The battery cells 110 are positioned by means of the holding device 112 in particular relative to the mold 100 in such a way that the cell base 120 of the battery cells 110 and/or the cell base 126 of the cell housing 122 of the battery cells 110 have a spacing 135 from the base 104 of the mold 100.

It can be favorable if the battery cells 110 are positioned using the holding device 112 in such a way that a minimum cell spacing 137 between adjacent battery cells 110, in particular a minimum spacing 137 between the cell casings 128 of the cell housing 122 of adjacent battery cells 110, is at least approximately 0.3 mm, preferably at least about 0.7 mm, and/or at most about 2.0 mm, preferably at most about 1.3 mm.

A particularly high energy density of the battery module 140 can preferably be achieved by such a minimum cell spacing 137 .

The minimum cell spacing 137 between adjacent battery cells 110 is preferably adapted to a capillary behavior of the potting material 108 . For example, it can be provided that a minimum cell spacing 137 between adjacent battery cells 110 and/or a viscosity of the potting material 108 are matched to one another in such a way that the potting material 108 between the battery cells 110 rises to the desired height before it hardens.

It can be favorable, for example, if the potting material 108 has a viscosity, in particular a mixture viscosity, of at most approximately 5000 mPas, preferably at most approximately 2000 mPas.

It can be favorable if the battery cells 110, when they are cast, are at least approximately 10%, preferably at least approximately 25%, and/or at most approximately 90%, preferably at most approximately 75%, based on their length 136 in the casting material 108 be introduced.

The length 136 of a respective battery cell 110 is preferably a length taken parallel to the longitudinal axis 116 of the respective battery cell 110 .

It can be favorable if the encapsulation material 108 preferably hardens and/or crosslinks after the encapsulation and a encapsulation body 138 is formed by curing and/or crosslinking of the encapsulation material 108 .

An alignment of the battery cells 110 relative to one another and/or relative to the casting mold 100 is preferably fixed by the curing and/or crosslinking of the casting material 108 .

The battery cells 110 are preferably held by the holding device 112 until the potting material 108 is crosslinked in such a way that a position of the battery cells 110 relative to one another and/or relative to the casting mold 100 is fixed.

For example, it can be provided that the battery cells 110 are held by the holding device 112 for at least approximately 5 minutes, for example at least approximately 10 minutes, while the potting material 108 hardens and/or crosslinks.

Battery cells 110 are held by holding device 112, for example, until at least approximately 60%, for example at least approximately 70%, preferably at least approximately 80%, of potting material 108 is crosslinked and/or cured.

For example, it is conceivable that the battery cells 110 and the encapsulation body 138 are removed from the casting mold 100 after the encapsulation material 108 has hardened and/or crosslinked.

The battery cells 110 and the potting body 138 are part of a battery module 140, which in 4 is shown.

If the battery cells 110 and the potting body 138 are removed from the casting mold 100 after the potting material 108 has crosslinked and/or cured, it can be provided that the casting mold 100 is lined with a separating material 142, for example with a film material, before the potting material 108 is introduced 144

The release material 142 and the foil material 144 are in FIGS 1 until 4 only indicated schematically by an arrow.

For example, it can be provided that the casting mold 100 is lined with a deep-drawing film before the casting material 108 is introduced, which remains on the battery module 140 after the casting mold 100 has been removed.

The separating material 142, in particular the foil material 144, for example the thermoforming foil, preferably forms part of the battery module 140.

The potting body 138 is covered by the film material 144, for example by a thermoforming film, in particular on several sides, preferably on five sides.

However, it is also conceivable that the battery cells 110 and the encapsulation body 138 are not removed from the casting mold 100 and remain in the casting mold 100 after the encapsulation material 108 has hardened and/or crosslinked and form a composite component 145 with it (cf. 5 ).

The casting mold 100 preferably forms part of the battery module 140.

The potting material 108 and/or the potting body 138 are used in a battery module 140, preferably for the mechanical fixation of the battery cells 110 and/or for the electrical insulation of the battery cells 110.

The potting material 108 is preferably also designed to dissipate heat from the battery cells 110 .

The battery cells 110 of the battery module 140 are preferably electrically connected to one another by means of cell connectors that are not shown in the drawing, for example by means of a plurality of bonded connections and/or welded connections.

In this case, the battery module 140 is preferably configured to be rigid, with increased reliability of the bonded connections and/or welded connections preferably being able to be achieved as a result of a high rigidity of the battery module 140 .

• - Gesamtmasse des Batteriemoduls 140; und/oder
• - thermische Kopplung der Zellköpfe 118 der Batteriezellen 110 mit dem Vergussmaterial 108; und/oder
• - zu erzielende mechanische Steifigkeit des Batteriemoduls 140.

The encapsulation height of the encapsulation material 108 is therefore preferably selected taking into account the following optimization parameters:

• - total mass of the battery module 140; and or
• - Thermal coupling of the cell heads 118 of the battery cells 110 with the potting material 108; and or
• - Mechanical rigidity to be achieved for the battery module 140.

A mechanical rigidity of the battery module 140 can preferably be increased by increasing the encapsulation height.

An improved thermal coupling of the cell heads 118 of the battery cells 110 to the potting material 108 can preferably dissipate heat more effectively from the cell heads 118 .

Due to the small distances between adjacent battery cells 110, in particular the cell casings 128 of the cell housing 122 of adjacent battery cells 110, forces acting on the battery module 140, for example bending forces acting on the battery module 140, preferably from a cell structure housing 122 of a battery cell 110 are transferred to the cell housing 122 of an adjacent battery cell 110 .

In this case, a bending stiffness of the battery module 140 can preferably be increased by a factor of approximately 2 to approximately 10 compared to the prior art.

In this case, natural resonance frequencies of the battery module 140 are preferably increased by a factor of approximately 2 to approximately 10 compared to the prior art.

In particular, the reliability and/or service life of bonded connections and/or welded connections, by means of which the battery cells 110 of the battery module 140 are electrically connected to one another, can be increased.

the 6 until 10 show an embodiment of a holding device 112, which can be used to produce an embodiment of a battery module 140, the method being analogous to that of FIGS 1 until 5 can be carried out.

The holding device 112 preferably comprises a plurality of holding elements 146, only individual holding elements 146 being identified by a reference number in the figures for reasons of clarity.

A respective holding element 146 is preferably designed in such a way that a battery cell 110 can be held and/or gripped on the cell head cover 124 of the cell housing 122 of the battery cell 110 .

Such a holding element 146 is, for example, in 7 shown.

A respective holding element 146 comprises, for example, a holding and/or gripping section 148, which is designed in such a way that a battery cell 110 can be held and/or gripped with it.

a in 7 The holding element 146 shown preferably also comprises a fastening section 150, by means of which the holding element 146 is fixed to a base body 152 of the holding device 112.

Each gripping section 148 preferably includes a surface 154 which, when a battery cell 110 is held and/or gripped, is brought into contact with the battery cell 110, in particular with the cell head 118 of the battery cell 110 and/or with the cell head cover 124 of the cell housing 11 of the battery cell 110 .

The surface 154, which is brought into contact with the cell head 118 of the battery cell 110 and/or with the cell head cover 124 of the cell housing 122 of the battery cell 110 when holding and/or gripping a battery cell 110, is preferably essentially complementary to a surface 156 of the battery cell 110 on the cell head 118 of the cell head cover 124 of the cell housing 122 of the battery cell 110 is formed.

The holding elements 146 are preferably magnetic holding elements 158 or electromagnetic holding elements 160.

If the holding elements 146 are magnetic holding elements or electromagnetic holding elements, the potting material 108 can preferably be subjected to a negative pressure, in particular without the battery cells 110 falling off the holding elements 146 of the holding device 112 .

Gas bubbles can preferably be removed from the potting material 108 by subjecting it to negative pressure.

It may be favorable if holding device 112 is configured in such a way that holding device 112 can switch between a switching state, in which battery cells 110 are held and/or gripped by means of a respective holding element 146, and a release state, in which battery cells 110 are not held and/or be taken, is switchable.

For example, it is conceivable that the holding device 112 comprises electromagnetic holding elements 160, with a holding force of the electromagnetic holding elements 160 being switchable.

Alternatively or additionally, it is conceivable that the holding device 112 comprises magnetic holding elements 158 which comprise a switchable permanent magnet, for example a mechanically switchable permanent magnet or an electrically switchable permanent magnet.

The device 113 for producing a battery module 140 preferably includes a testing device 162, by means of which a holding state of the holding elements 146 can be checked.

The test device 162 is in the 6 , 8th and 9 shown only schematically.

If the holding device 112 comprises electromagnetic holding elements 160, it can be provided, for example, that a change in a holding state of the holding elements 146 can be detected by measuring a change in inductance using the testing device 162.

A change in a gap between a battery cell 110, in particular between a cell head cover 124 of the battery cell 110, and a respective holding element 146 can be detected by measuring a change in inductance.

An alternating current component is preferably applied to the holding current of a respective electromagnetic holding element 160 in order to detect a change in inductance.

The holding current is formed, for example, by a first holding current component and by a superimposed second holding current component, with the second holding current component preferably being in the form of a periodic alternating current component.

The first holding current component is preferably used essentially to apply the holding force of a respective electromagnetic holding element 160.

In contrast, the second holding current component preferably serves as a measurement or signal variable, with an inductance of a coil of electromagnetic holding element 160 changing as a result of a change in the air gap between a respective electromagnetic holding element 160 and a battery cell 110 .

The change in inductance changes, in particular, a phase shift between the alternating current component and the alternating voltage component of the second holding current component.

This phase shift can preferably be detected and used to check a holding state of a respective holding element 146 .

It may be favorable if holding device 112 includes a guiding and/or aligning device 164, by means of which a plurality of battery cells 110 can be positioned relative to one another, in particular substantially parallel to one another, and/or relative to holding device 112.

The battery cells 112 are preferably positioned relative to one another, in particular essentially parallel to one another, and/or relative to the holding device 112 by means of the holding device 112 .

The battery cells 110 are preferably positioned relative to one another by means of the holding device 112 in such a way that the longitudinal axes 116 of the battery cells 110 are arranged essentially parallel to one another.

In order to position the battery cells 110 , they are preferably guided in the holding device 112 in a direction running parallel to the longitudinal axes 116 of the battery cells 100 .

The battery cells 110 are arranged parallel to one another, for example, in such a way that the battery cells 110 are arranged as closely packed as possible.

It can be favorable, for example, if the battery cells 110 are arranged with a packing density in the range from approximately 60% to approximately 90%, for example with a packing density in the range from approximately 70% to approximately 80%.

The guiding and/or aligning device 164 is designed in particular in such a way that the battery cells 110 are guided in the region of their cell heads 124, for example in an upper quarter of the cell housing 122 of the battery cells.

An upper quarter of the cell housing 122 of a battery cell 110 is in particular an upper quarter of the cell housing 122 in relation to the length 136 of the battery cell 110 in the region of the cell head 118 of the battery cell 110.

It can be favorable if the guiding and/or aligning device 164 comprises a plurality of guiding and/or aligning elements 166.

For reasons of clarity, only individual guide and/or alignment elements 166 are identified in the figures with a reference number.

The guiding and/or alignment elements 166 are preferably arranged in a regular pattern on the holding device 112 .

For example, it is conceivable that the guiding and/or aligning elements 166 are in the form of guiding pins 168 which are preferably arranged parallel to one another.

The battery cells 110 are preferably guided between a plurality of guide and/or alignment elements 166, in particular between a plurality of guide pins 168.

Provision can preferably be made for a guide and/or alignment element 166, in particular a guide pin 168, to be arranged between each three battery cells 110.

One battery cell 110 is preferably arranged between each three guide and/or alignment elements 166, in particular between each three guide pins 168.

A length 170 of the guide pins 168 is preferably formed in such a way that the battery cells 110 protrude beyond the guide pins 168 when they are held or gripped by the holding device 112 .

For example, it is conceivable that the guide pins 168 have a length 170 which is less than the length 136 of the battery cells 110.

In an embodiment of the holding device 112 that is not shown in the drawing, it can be provided that the battery cells 110 are guided within a guiding and/or aligning element 166 .

The guiding and/or aligning elements 166 are designed, for example, as a recess, preferably as a circular-cylindrical recess, it being possible for one battery cell 110 to be guided in each recess.

A depth of such a recess is preferably less than the length 136 of the battery cells 110.

Holding device 112 preferably also includes an electrical insulation device 172 for electrically insulating holding device 112 from battery cells 110.

The electrical insulation device 172 is preferably also designed in such a way that the battery cells 110 are electrically insulated from one another while the battery cells 110 are held and/or gripped by the holding device 112 .

The electrical isolation device 172 is shown in FIGS 6 , 8th and 9 only indicated schematically by an arrow.

In particular, it can be favorable if all surfaces of the holding device 112 which are brought into direct contact with battery cells 110 in order to hold them have an insulating coating 174 .

For example, it can be provided that the surface 154 of a holding element 146 of the holding device 112, which when holding and/or gripping a battery cell 110, is brought into contact with the cell head 118 of the battery cell 110 and/or with the cell head cover 124 of the cell housing 122 of the battery cell 110 , an electrically insulating coating 174 has.

A surface of guiding and/or aligning elements 166 of guiding and/or aligning device 164 of holding device 122 preferably has an electrically insulating coating 174.

For example, it can be provided that the electrical insulation device 172 comprises one or more electrical insulation films 176 .

It can be favorable if the holding device 112 comprises a stop device 178, wherein the holding device 112 can be directly or indirectly attached to the casting mold 100 by means of the stop device 178 in such a way that the holding device 112 can be positioned in a predetermined position relative to the casting mold 100.

The stop device 178 is preferably designed in such a way that the holding device 112 can be positioned in a predetermined position relative to the mold 100 by striking the stop device 178 on the mold 100 .

In order to position the holding device 112 in a predetermined position relative to the casting mold 100, it can be provided that the stop device 178 is placed against an edge of the casting mold 100.

It can also be favorable if the casting mold 100 includes a stop, not shown in the drawing, against which the stop device 178 can be attached.

The device 113 for producing a battery module 140 further includes, for example, a positioning device 180, which in the 6 , 8th and 9 is shown only schematically.

The holding device 112 can preferably be positioned relative to the casting mold 100 by means of the positioning device 180 .

Positioning device 180 preferably includes a positioning drive 182.

It can also be favorable if the positioning device 180 includes a path measuring device 184 .

The position measuring device 184 can preferably be used to determine whether the holding device 112 has been brought into a predetermined position by means of the positioning drive 182 of the positioning device 180 .

The stop device 178 is preferably adjusted in such a way that at a maximum length 136 of the battery cells 110, in particular at an upper length tolerance range, a minimum distance 135a of the battery cells 110 from the bottom 104 of the mold 100 is maintained, in particular a minimum distance 135a of the cell base 120 of the battery cells 110 and/or the cell floor 126 of the cell housing 122 of the battery cells 110 from the floor 104 of the casting mold 100.

To set a predetermined spacing 135 between battery cells 110 and base 104 of casting mold 100, holding device 112 is placed against an edge of casting mold 100, for example, in particular by means of stop device 178.

The minimum distance 135a of the battery cells 110 from the bottom 104 of the mold 100, in particular the minimum distance 135a of a cell base 120 of the battery cells 110 and/or a cell bottom 126 of the cell housing 122 of the battery cells 110 from the bottom 104 of the mold 100, preferably corresponds to a minimum thickness 186 of the potting material 108, which is arranged between the bottom 104 of the mold 100 and the battery cells 110 (cf. 3 until 5 ).

The minimum distance 135a of the battery cells 110 from the base 104 of the mold 100, in particular the minimum distance 135a of a cell base 120 of the battery cells 110 and/or a cell base 126 of the cell housing 122 of the battery cells 110 from the base 104 of the mold 100, is preferably at least approximately 0, 3 mm, for example at least about 0.4 mm.

A maximum distance 135b of the battery cells 110 from the base 104 of the mold 100, in particular a maximum distance 135b of a cell base 120 of the battery cells 110 and/or a cell base 126 of the cell housing 122 of the battery cells 110 from the base 104 of the mold 100, is preferably at most approximately 1, 5 mm, for example at most about 1.0 mm.

The maximum distance 135b of the battery cells 110 from the base 104 of the mold 100, in particular the maximum distance 135b of a cell base 120 of the battery cells 110 and/or a cell base 126 of the cell housing 122 of the battery cells 110 from the base 104 of the mold 100, preferably corresponds to a maximum thickness 188 of the potting material 108, which is arranged between the bottom 104 of the mold 100 and the battery cells 100.

A thickness of the potting material 108, which is arranged between the bottom 104 of the mold 100 and the battery cells 110, is therefore preferably in a range from approximately 0.3 mm to approximately 1.5 mm, preferably in a range of approximately 0.4 mm to about 1.0 mm.

If the holding elements 146 are magnetic holding elements 158 or electromagnetic holding elements 160, it can be provided that the casting material 108 is subjected to a negative pressure after it has been introduced into the casting mold 100, in particular after the battery cells 110 have been brought into contact with the casting material 108.

The device 113 for producing a battery module 140 preferably also includes a vacuum device 190, which is designed in particular in such a way that the potting material 108 can be subjected to a vacuum.

The vacuum device 190 is in the 6 , 8th and 9 marked only schematically.

A vacuum is preferably applied to the potting material 108 by means of the vacuum device 190 while the potting material 108 is still liquid and/or flowable.

Gas bubbles are preferably removed from the casting material 108 by subjecting the casting material 108 to a negative pressure.

10 shows a method step of a method for producing a battery module 140, wherein battery cells 110 are encapsulated by means of the encapsulation material 108 with two assembly elements 192.

For example, it is conceivable that the assembly elements 192 are arranged parallel to a long secondary side of the battery module 140 .

The mounting elements 192 are preferably designed to fix the battery module 140 to a housing of a battery device, not shown in the drawing.

The battery cells 110 are encapsulated with the assembly elements 192 in particular in one embodiment of a battery module 140 in which the battery cells 110 and the encapsulation body 138 can be removed from the casting mold 100 after the crosslinking and/or curing of the casting material 108 .

For example, it is conceivable that the battery module 140 can be fixed to a housing of a battery device only by means of the mounting elements 192 .

It can be favorable if the casting body 138 is connected to the mounting elements 192 in a form-fitting manner.

The mounting elements 192 preferably include a casting section 194, by means of which the mounting elements 192 are cast with the casting material 108.

The mounting elements 192 preferably also include a mounting section 196, by means of which the mounting elements 192 can be fixed to a housing of a battery device, for example to a fastening rail of the housing.

The encapsulation section 194 of the mounting elements 192 is in particular embedded in the encapsulation material 108 of the encapsulation body 138 .

The cast portion 194 of the assembly elements 192 preferably includes a plurality of undercut elements 198 which are formed in such a way that the cast portion 194 of the respective assembly element 192 and the cast body 138 undercut one another after the battery cells 110 have been cast.

In 11 only individual ones of the undercut elements 198 are marked with a reference number for reasons of clarity.

The cast section 194 of one of the assembly elements 192 and the cast body 138 are preferably connected to one another in a form-fitting manner by means of the undercut elements 198 .

A secure hold of the encapsulation section 194 in the encapsulation body 138 can preferably be made possible in this case.

For example, it can be favorable if the undercut elements 198 are passage openings in the cast section 194 of the assembly elements 192 .

The assembly section 196 of the assembly elements 192 preferably comprises a plurality of positive-locking elements 200 which can be positively connected, for example in the manner of a jigsaw puzzle, to a fastening rail of a housing of a battery device.

As an alternative or in addition to this, it can be provided that the mounting section 196 of the mounting elements 192 each includes a plurality of fastening elements, not shown in the drawing, which are designed, for example, as through-openings in the mounting section 196 .

For example, the mounting section 196 of a mounting element 192 can be screwed to a fastening rail of a housing of a battery device by means of the fastening elements designed as passage openings.

The mounting elements 192 are, for example, profile elements 202, for example sheet metal angles 204.

For reasons of space, it can be provided that a material thickness 206 of the profile elements 202, in particular the sheet metal angle 204, is at most approximately 2 mm.

During the encapsulation of the battery cells 110, the assembly elements 192 are preferably fixed to the casting mold 100, for example by means of one or more hold-down devices (not shown in the drawing).

Alternatively or additionally, it is possible for the assembly elements 192 to be screwed to the casting mold 100 in order to fix them to the casting mold 100 .

By fixing the mounting elements 192 to the casting mold 100, a spacing of the mounting elements 192 relative to the casting mold 100, for example relative to the side wall 106 of the casting mold 100 and/or relative to the bottom 104 of the casting mold, can preferably be fixed.

Precisely fitting installation of the battery module 140 can preferably be made possible in this way.

It can also be favorable if the mounting elements 192 include or form a temperature control device, not shown in the drawing, for temperature control of the battery cells 110 .

In particular, it can be provided that the assembly elements 192 include a temperature control channel structure through which a temperature control medium can be conducted.

Claims (26)

A method of manufacturing a battery module (140), the method comprising: - Providing a plurality of battery cells (110), which are preferably designed as round cells (114); - Potting the battery cells (110) with a potting material (108), the potting material (108) preferably curing and/or crosslinking after the potting and a potting body (138) being formed by curing and/or crosslinking the potting material (108). procedure after claim 1 , characterized in that the battery cells (110) are positioned relative to one another, in particular essentially parallel to one another, and/or relative to the holding device (112) before the casting by means of a holding device (112). procedure after claim 2 , characterized in that the battery cells (110) for positioning them in the holding device (112) are guided in a direction parallel to the longitudinal axes (116) of the battery cells (110). procedure after claim 2 or 3 , characterized in that the battery cells (110) are positioned by means of the holding device (112) such that cell heads (118) of the battery cells (110) are arranged substantially in a positioning plane (134). Procedure according to one of claims 2 until 4 , characterized in that the battery cells (110) are held and/or gripped by the holding device (112) at their cell heads (118). procedure after claim 5 , characterized in that the battery cells (110) are held and/or gripped magnetically, electromagnetically, pneumatically or mechanically by means of the holding device (112). Procedure according to one of claims 2 until 6 , characterized in that the battery cells (110) are held by means of the holding device (112) until the potting material (108) is crosslinked in such a way that a position of the battery cells (110) relative to one another and/or relative to a casting mold (100 ) is fixed. procedure after claim 7 , characterized in that a) the battery cells (110) and the potting body (138) are removed from the casting mold (100) after the curing and/or crosslinking of the potting material (108); or b) the battery cells (110) and the cast body (138) remain in the casting mold (100) after the casting material (108) has hardened and/or crosslinked and form a composite component (145) therewith. Procedure according to one of claims 2 until 8th , characterized in that the battery cells (110) are positioned relative to a mold (100) prior to casting by means of the holding device (110) in such a way that the battery cells (110) are spaced apart from a bottom (104) of the mold (100). procedure after claim 9 , characterized in that the holding device (112) is directly or indirectly attached to a casting mold (100) by means of a stop device (178) in such a way that the holding device (112) can be positioned in a predetermined position relative to the casting mold (100). Procedure according to one of claims 2 until 10 , characterized in that the battery cells (110) are positioned before casting by means of the holding device (112) such that a minimum cell spacing (137) of adjacent battery cells (110), in particular a minimum spacing of the cell casings (128) of the cell housing (122) of adjacent battery cells (110), at least about 0.3 mm, preferably at least about 0.7 mm, and/or at most about 2.0 mm, preferably at most about 1.3 mm. Procedure according to one of claims 2 until 11 , characterized in that a) the battery cells (110) are electrically insulated from one another by means of the holding device (112), while the battery cells (110) are held and/or gripped by means of the holding device (112); and/or b) the holding device (112) is electrically insulated from the battery cells (110), while the battery cells (110) are held and/or gripped by the holding device (112). Procedure according to one of Claims 1 until 12 , characterized in that the battery cells (110) are encapsulated by means of the encapsulation material (108) with one, preferably with several, for example two, mounting elements (192), which are preferably designed to fix a battery module (140) on a housing of a battery device. Procedure according to one of Claims 1 until 13 , characterized in that the casting material (108) for casting the battery cells (110) is introduced into a casting mold (100), wherein preferably a) first the casting material (108) is introduced into the casting mold (100) and then the battery cells (110 ) into the potting material (108) to be pushed in; or b) first the battery cells (110) are at least partially arranged in the casting mold (100) and then the casting material (108) is introduced into the casting mold (100). procedure after Claim 14 , characterized in that the potting material (108) is subjected to a negative pressure after it has been introduced into the mold (100), in particular after the battery cells (110) are brought into contact with the potting material (108). Procedure according to one of Claims 1 until 15 , characterized in that the battery cells (110) when they are cast at least approximately 10%, preferably at least approximately 25%, and / or at most approximately 90%, preferably at most approximately 75%, based on their length (136) in the potting material (108) are introduced. Battery module (140), in particular produced by the method according to one of Claims 1 until 16 , wherein the battery module (140) comprises the following: - a plurality of battery cells (110), which are preferably designed as round cells (114); - A casting body (138) made of a casting material (108), by means of which the battery cells (110) are cast, wherein cell heads (118) of the battery cells (110) are arranged essentially in one plane (134). Battery module (140) after Claim 17 , characterized in that the casting body (138) of the battery module (140) is arranged in a mold (100) and forms a composite component (145) with the mold (100). Battery module (140) after Claim 17 or 18 , characterized in that the casting body (138) is positively connected to one or more, for example two, assembly elements (192). Device (113) for producing a battery module (140), in particular by carrying out the method according to one of Claims 1 until 16 , wherein the device (113) comprises the following: - a holding device (112) which comprises one or more holding elements (146) for holding and/or gripping one battery cell (110) in each case, with a respective holding element (146) being designed in such a way that that in each case one battery cell (110) can be held and/or gripped on a cell head (118) of the same, for example magnetically, electromagnetically, pneumatically or mechanically. Device (113) after claim 20 , characterized in that a surface (154) of a holding element (146) of the holding device (112), which when holding and / or gripping a battery cell (110) with the cell head (118) of the battery cell (110) and / or with a cell head cover (124) of a cell housing (122) of the battery cell (110) is brought into contact, essentially complementary to a surface (156) of the battery cell (110) on the cell head (118) and/or a surface (156) of the cell head cover (124) of the cell housing (122) of the battery cell (110) is formed. Device (113) after claim 20 or 21 , characterized in that the holding device (112) is designed in such a way that the holding device (112) moves between a switching state in which battery cells (110) are held and/or gripped by means of a respective holding element (146) and a release state in which Battery cells (110) are not held and / or gripped, is switchable. Device (113) according to one of claims 20 until 22 , characterized in that the device (113) comprises a testing device (162) by means of which a holding state of the one or more holding elements (146) can be checked. Device (113) according to one of claims 20 until 23 , characterized in that the holding device (112) comprises a guiding and/or aligning device (164), by means of which a plurality of battery cells (110) can be positioned relative to one another, in particular essentially parallel to one another, and/or relative to the holding device (112). . Device (113) according to one of claims 20 until 24 , characterized in that a) the holding device (112) comprises a stop device (178), wherein the holding device (112) can be directly or indirectly attached to a casting mold (100) by means of the stop device (178) in such a way that the holding device (112) positionable in a predetermined position relative to the mold (100); and/or b) the device (113) comprises a positioning device (180), wherein the holding device (112) can be positioned relative to a casting mold (100) by means of the positioning device (180). Device (113) according to one of claims 20 until 25 , characterized in that the holding device (112) comprises an electrical insulation device (172), by means of which battery cells (110) can be electrically insulated from one another, while the battery cells (110) are held and/or gripped by the holding device (112). and/or by means of which the holding device (112) can be electrically isolated from the battery cells (110), while the battery cells (110) are held and/or gripped by means of the holding device (112).

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