WO2022258299A1 - Method for connecting two components, and battery module - Google Patents

Method for connecting two components, and battery module Download PDF

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Publication number
WO2022258299A1
WO2022258299A1 PCT/EP2022/062927 EP2022062927W WO2022258299A1 WO 2022258299 A1 WO2022258299 A1 WO 2022258299A1 EP 2022062927 W EP2022062927 W EP 2022062927W WO 2022258299 A1 WO2022258299 A1 WO 2022258299A1
Authority
WO
WIPO (PCT)
Prior art keywords
components
connection
cavity
connecting elements
freedom
Prior art date
Application number
PCT/EP2022/062927
Other languages
German (de)
French (fr)
Inventor
Markus Thurmeier
Florian Dirisamer
Original Assignee
Audi Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Audi Ag filed Critical Audi Ag
Priority to CN202280026277.4A priority Critical patent/CN117098642A/en
Publication of WO2022258299A1 publication Critical patent/WO2022258299A1/en

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/258Modular batteries; Casings provided with means for assembling
    • H01M50/26Assemblies sealed to each other in a non-detachable manner
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0053Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor combined with a final operation, e.g. shaping
    • B29C45/006Joining parts moulded in separate cavities
    • B29C45/0062Joined by injection moulding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467Joining articles or parts of a single article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40Applying molten plastics, e.g. hot melt
    • B29C65/42Applying molten plastics, e.g. hot melt between pre-assembled parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/40Applying molten plastics, e.g. hot melt
    • B29C65/42Applying molten plastics, e.g. hot melt between pre-assembled parts
    • B29C65/425Applying molten plastics, e.g. hot melt between pre-assembled parts characterised by the composition of the molten plastics applied between pre-assembled parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815Hot melt adhesives, e.g. thermoplastic adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4865Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives
    • B29C65/487Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives characterised by their shape, e.g. being fibres or being spherical
    • B29C65/488Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding containing additives characterised by their shape, e.g. being fibres or being spherical being longitudinal, e.g. fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/54Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts
    • B29C65/542Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts by injection
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/72Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/10Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/12Joint cross-sections combining only two joint-segments; Tongue and groove joints; Tenon and mortise joints; Stepped joint cross-sections
    • B29C66/124Tongue and groove joints
    • B29C66/1242Tongue and groove joints comprising interlocking undercuts
    • B29C66/12423Dovetailed interlocking undercuts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/01General aspects dealing with the joint area or with the area to be joined
    • B29C66/05Particular design of joint configurations
    • B29C66/303Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325Particular design of joint configurations the joint involving an anchoring effect making use of protusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00General aspects of processes or apparatus for joining preformed parts
    • B29C66/70General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/712Containers; Packaging elements or accessories, Packages
    • B29L2031/7146Battery-cases
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/218Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
    • H01M50/22Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
    • H01M50/227Organic material
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/249Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains

Definitions

  • the invention relates to a method for connecting two components and a battery module produced using the method.
  • connections especially in motor vehicles, are usually made by welding or bolts. However, these manufacturing processes can often only be used with metallic materials. The problem arises, in particular in the production of battery modules, that many connections are provided, which are also intended to have an insulating effect with respect to temperature and electrical conductivity.
  • DE 10 2015 014 360 A1 discloses a node structure for a vehicle body, with at least two profile components and a connection node made of fiber-reinforced plastic, which connects the profile components at the node-side profile ends, the connection node being made of a plastic reinforced with reoriented synthetic fibers and in at least one area is additionally reinforced with an insert.
  • the motor vehicle structural component consists of at least two semi-finished components made from a fiber-plastic composite pultrudate, which are connected by means of a cast node element.
  • the semi-finished component has at least one internal hollow volume, and the node element is on at least one wall of a connection end of each of the semi-finished components to be connected form-fitting.
  • the semi-finished components are free of cast material outside of the node element.
  • DE 10 2015 014 357 A1 discloses a node structure for a vehicle body, with at least two profile components and a connection node made of fiber-reinforced plastic, which connects the profile components at the node-side profile ends, with the connection node having at least one molded functional element on the outside, which forms part of the forms the outer contour.
  • the object of the present invention is to provide a method for connecting two components, in particular two motor vehicle components.
  • the invention provides a method for connecting two components, with the components having respective connecting elements which correspond to one another and which engage in one another to provide a pre-connection, with a cavity being formed between the connecting elements in the pre-connection which has at least one degree of freedom of movement and thus a tolerance range of the two Components relative to each other in the direction of at least one degree of freedom of movement.
  • the method comprises the steps of arranging the components relative to each other so that the pre-connection is provided, aligning the components using the tolerance range in an assembly position and filling the cavity with a hardening potting compound, with the at least one degree of freedom of movement being achieved after the potting compound has hardened Potting compound is blocked.
  • connecting elements When arranged to form a preliminary connection, connecting elements can intermesh, so that a form-fitting connection is produced at least in one, preferably two, spatial directions. Furthermore, in a further spatial direction, a hollow space or intermediate space can be provided between the connecting elements, which enable the components to move relative to one another in the direction of this at least one degree of freedom of movement. This means that in the pre-connection, the two components still have at least one degree of freedom of movement by means of the cavity and can therefore be displaced relative to one another. This cavity can therefore represent a tolerance range in which the components can still be aligned with one another.
  • the cavity can be filled with a hardening casting compound, the cavity being blocked after the casting compound has hardened and the connecting elements thus being connected to one another in a form-fitting and/or material-to-material and/or non-positive manner are.
  • An adhesive and/or plastic, for example, which can be injected into the cavity, can be used as the casting compound.
  • connection method can also be provided in this way that can be used for non-metallic components.
  • the connecting elements can be fixed to one another much more rigidly, since a unit can be formed by spraying with the casting compound.
  • the invention also includes embodiments that result in additional advantages.
  • One embodiment provides that the corresponding connecting elements are designed to
  • Dovetail connection an undercut connection or a spigot connection.
  • these connections can be provided as a pre-connection.
  • a dovetail connection means a connection similar to a bung, in which a bung or tenon with a substantially triangular or pyramidal shape is introduced into a corresponding counterpart.
  • the connection is only partially positive and a cavity may be provided within the connection at least on one side to allow movement of the dovetail within the mating connection structure for alignment in the final assembly position.
  • An undercut connection means a protruding, for example hook-shaped area of one of the connection elements, which can engage in a corresponding hook structure in order to produce the preliminary connection.
  • a tenon connection means a tenon that can be introduced into a tenon hole or a slot, the slot preferably having a larger volume than the tenon so that the cavity is formed for subsequent filling with the casting compound.
  • a further embodiment provides that a flow channel for the casting compound is provided in at least one of the connecting elements.
  • the flow channel can, for example, run on a surface of the respective connecting element or be formed through the connecting element.
  • the casting compound can thus be injected into the flow channel and passed through the flow channel into the cavity.
  • a further embodiment provides that the components and the respective connecting elements are made of a plastic. That's how they can Components and the connecting elements can be made of polyethylene or polypropylene, for example.
  • the casting compound that is injected into the cavity can be liquefied at a high temperature and connect to the plastic (hotmelt), so that the casting compound forms a unit with the plastic of the respective connecting elements.
  • a material-locking and/or form-locking connection can be produced by the sealing compound by means of the connecting elements designed as plastic.
  • the components and/or the connecting elements can be made of wood, for example, or of a metal, and a positive and/or non-positive connection can be produced as the connection.
  • the casting compound has a plastic, in particular a fiber-reinforced plastic.
  • a thermoplastic material in particular with fiber reinforcement, such as polyethylene or polypropylene, can be used as the casting compound.
  • the connecting elements are made of plastic, the liquefied plastic of the potting compound can melt them, which creates an integral connection and thus a particularly strong connection.
  • the connecting elements and the casting compound are preferably made of the same plastic.
  • a further embodiment provides that at least one connecting element has indentations into which the casting compound enters when the cavity is filled. In other words, one can
  • Connecting element preferably both connecting elements, have depressions, in particular knobs or concave depressions, which extend into the respective connecting element. These can be filled by the casting compound during the filling process, as a result of which the hardened casting compound can be wedged or hooked in these depressions. That is, the potting compound can enter into a mechanical undercut with the depressions. Due to the additional wedging, the hardened casting compound can hold the connecting elements firmly in position, in particular in the direction of the previously open degree of freedom of movement.
  • duromers can be injected into the cavity using an injection molding technique in order to block at least one degree of freedom of movement.
  • the casting compound can harden as it cools down and thus fix the connecting elements firmly to one another.
  • the respective connecting element is provided with the associated component as a coherent component. In other words, the connecting element and the component can be provided as a coherent component.
  • this can be achieved by means of a forming process, for example extrusion, or the connected parts can be produced by means of an injection molding process.
  • a further embodiment provides that the components for producing a battery module are provided, in particular as a base plate and a lateral pressure plate of the battery module.
  • the method for connecting the components can be used to produce a battery module, a lateral pressure plate or side wall being intended to be connected to a base plate to provide a housing for the battery module.
  • the method is particularly suitable here because a cell stack can be pushed through the lateral pressure plate must be clamped and the clamping requires a tolerance range that can be provided by the cavity.
  • the respective components of the battery module can then be connected to one another by injecting the casting compound.
  • a further aspect of the invention relates to a battery module with a cell stack and a housing, the housing being produced by a method according to one of the preceding embodiments.
  • the aforementioned base plate is connected to a lateral pressure plate, with the cell stack being braced by the lateral pressure plate and an opposite pressure plate before the cell stack is firmly fixed inside the housing by filling in the casting compound.
  • the battery module according to the invention can preferably be arranged in a motor vehicle, the motor vehicle preferably being designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle.
  • the invention also includes developments of the battery module according to the invention, which have features as have already been described in connection with the developments of the method according to the invention. For this reason, the corresponding developments of the battery module according to the invention are not described again here.
  • the invention also includes the combinations of features of the described embodiments.
  • the invention also includes implementations that each have a combination of the features of several of the described embodiments, provided that the embodiments were not described as mutually exclusive.
  • FIG. 1 shows a schematic representation of a battery module according to an exemplary embodiment
  • 2 shows a schematic representation of a connection of two components according to an exemplary embodiment.
  • the battery module 10 can have a base plate 12 and a cell stack 14, with the cell stack 14 being braced between two pressure plates 16, 18.
  • a first pressure plate 16 can already be connected to the base plate 12
  • the second pressure plate 18 being intended to close off the battery module 10 by being pressed against the side of the cell stack 14 .
  • the base plate 12 and the second pressure plate 18 can represent the two components to be connected.
  • the second pressure plate 18 After the second pressure plate 18 has been pressed against the cell stack 14 , it should be firmly connected to the base plate 12 in the connection area 20 . Since a tolerance range should be provided for the pressing of the second pressure plate 18 on the cell stack 14, the bottom plate 12 and the second pressure plate 18 have a respective connecting element 22, 24, which is explained in more detail in FIG.
  • the side pressure plate 18 and the bottom plate 12 are shown, each having a corresponding connecting element 22, 24 which interlock to provide a pre-connection.
  • the connecting elements can enter into a dovetail connection as a preliminary connection.
  • the connecting elements 22, 24 are preferably connected to the respective component, in particular the lateral pressure plate 18 and the base plate 12, in a materially bonded manner and are each provided as a single component.
  • the preliminary connection in which the respective connecting elements 22, 24 engage in one another, can be designed in such a way that a flea space 26 is formed between the connecting elements 22, 24, the at least one
  • a tolerance range can thus be created which enables the lateral pressure plate 18 to be pressed against the cell stack 14 . If the lateral pressure plate 18 is aligned in an assembly position using the tolerance range formed by the cavity 26, the cavity 26 can be filled with a casting compound by means of a casting process, in particular an injection molding process.
  • the casting compound is preferably a fiber-reinforced plastic, which can be made of the same material as the connecting elements 22, 24.
  • the casting compound can be a thermoplastic material, which connects to the structures of the respective connecting elements 22, 24 and thus forms a unit. This means that the thermoplastic can melt the connecting elements 22, 24 and connects to them.
  • the degree of freedom of movement previously provided by the Flea space 26 can be blocked, whereby the Connecting elements are positively and/or cohesively connected in all six degrees of freedom of movement.
  • a flow channel 28 can be provided for introducing the casting compound into the cavity 26, which is provided on or in a connecting element or component and through which the casting compound can be injected, in particular by means of an injection molding process.
  • one or more recesses 30 can be provided on one or both connecting elements 22, 24.
  • the indentations 30 can be inwardly directed nubs, ie concave nubs, which are filled by the injection molding compound when the cavity 26 is filled. After the injection molding compound has hardened, these indentations 30 provide barbs or wedges in the direction of the previously free degree of freedom of movement between the hardened casting compound and the connecting elements 22, 24.
  • the connection shown here was shown at a corner between two components 12, 18, but this connection can also be centered can be used anywhere and is not limited to components that are perpendicular to one another.
  • a schematic process diagram for connecting two components 12, 18 is shown in FIG. In a step S10, two components are provided, the respective connecting elements 22, 24 corresponding to one another, for example hook-shaped
  • Connecting elements which engage in one another to provide a preliminary connection, a cavity 26 being formed between the connecting elements 22, 24 in the preliminary connection, which cavity 26 provides at least one degree of freedom of movement and thus a tolerance range of the two components 12, 18 relative to one another in the direction of the at least one degree of freedom of movement .
  • the components 12, 18 can be provided for entering into the pre-connection, in which the components 12, 18 engage in one another with their connecting elements 22, 24.
  • the preliminary connection preferably at least four degrees of freedom of movement can be restricted for a form fit.
  • a step S14 the components 12, 18 can be aligned in an assembly position using the tolerance range provided by the cavity 26.
  • the cavity 26 can be filled with a hardening potting compound, with the at least one degree of freedom being blocked after the potting compound has hardened.

Abstract

The invention relates to a method for connecting two components (12, 18) and to a battery module (10) produced thereby, wherein the components (12, 18) comprise respective mutually corresponding connection elements (22, 24), which engage to provide a pre-connection, wherein a cavity (26) between the connection elements (22, 24) is formed in the pre-connection action, which cavity provides at least one degree of freedom of movement and thus a tolerance range of the two components (12, 18) relative to one another in the direction of the at least one degree of freedom of movement (S10). The method comprises the following steps: arranging (S12) the components (12, 18) relative to one another such that the pre-connection is provided; orienting (S14) the components (12, 18) utilising the tolerance range into an assembly position; and filling (S16) the cavity (26) with a casting compound for curing, wherein, after curing of the casting compound, the at least one degree of freedom of movement is blocked by the casting compound.

Description

Verfahren zum Verbinden zweier Bauteile und Batteriemodul Method of connecting two components and battery module
BESCHREIBUNG: Die Erfindung betrifft ein Verfahren zum Verbinden zweier Bauteile sowie ein mittels des Verfahrens hergestelltes Batteriemodul. DESCRIPTION: The invention relates to a method for connecting two components and a battery module produced using the method.
Verbindungen, insbesondere bei Kraftfahrzeugen, werden üblicherweise über Schweißen oder Schrauben hergestellt. Diese Herstellungsprozesse können jedoch oft nur bei metallischen Materialien verwendet werden. Insbesondere bei der Herstellung von Batteriemodulen ergibt sich das Problem, dass viele Verbindungen vorgesehen sind, die außerdem eine Isolationswirkung gegenüber einer Temperatur und einer elektrischen Leitfähigkeit aufweisen sollen. Connections, especially in motor vehicles, are usually made by welding or bolts. However, these manufacturing processes can often only be used with metallic materials. The problem arises, in particular in the production of battery modules, that many connections are provided, which are also intended to have an insulating effect with respect to temperature and electrical conductivity.
Aus der DE 10 2015 014 360 A1 ist eine Knotenstruktur für eine Fahrzeugkarosserie bekannt, mit wenigstens zwei Profilbauteilen und einem aus faserverstärkten Kunststoff gebildeten Verbindungsknoten, der die Profilbauteile an knotenseitigen Profilenden verbindet, wobei der Verbindungsknoten aus einem mit umorientierten Kunstfasern verstärkten Kunststoff gebildet ist und in wenigstens einem Bereich zusätzlich mit einem Einleger verstärkt ist. DE 10 2015 014 360 A1 discloses a node structure for a vehicle body, with at least two profile components and a connection node made of fiber-reinforced plastic, which connects the profile components at the node-side profile ends, the connection node being made of a plastic reinforced with reoriented synthetic fibers and in at least one area is additionally reinforced with an insert.
Aus der DE 102010050874 A1 sind ein Kraftfahrzeugstrukturbauteil und ein Verfahren zu dessen Herstellung bekannt. Das Kraftfahrzeugstrukturbauteil besteht aus zumindest zwei Halbzeug-Bauteilen aus einem Faser- Kunststoffverbund-Pultrudat, die mittels eines gegossenen Knotenelements verbunden sind. Das Halbzeug-Bauteil weist zumindest ein innen liegendes Hohlvolumen auf, und das Knotenelement ist an zumindest einer Wandung eines Verbindungsendes jedes der zu verbindenden Halbzeug-Bauteile formschlüssig angegossen. Die Halbzeug-Bauteile sind außerhalb des Knotenelements frei von Gussmaterial. DE 102010050874 A1 discloses a motor vehicle structural component and a method for its manufacture. The motor vehicle structural component consists of at least two semi-finished components made from a fiber-plastic composite pultrudate, which are connected by means of a cast node element. The semi-finished component has at least one internal hollow volume, and the node element is on at least one wall of a connection end of each of the semi-finished components to be connected form-fitting. The semi-finished components are free of cast material outside of the node element.
Aus der DE 10 2015 014 357 A1 ist eine Knotenstruktur für eine Fahrzeugkarosserie bekannt, mit wenigstens zwei Profilbauteilen und einem aus faserverstärktem Kunststoff gebildeten Verbindungsknoten, der die Profilbauteile an knotenseitigen Profilenden verbindet, wobei der Verbindungsknoten außenseitig wenigstens ein angeformtes Funktionselement aufweist, das einen Teil der Außenkontur bildet. DE 10 2015 014 357 A1 discloses a node structure for a vehicle body, with at least two profile components and a connection node made of fiber-reinforced plastic, which connects the profile components at the node-side profile ends, with the connection node having at least one molded functional element on the outside, which forms part of the forms the outer contour.
Die Aufgabe der vorliegenden Erfindung ist es, ein Verfahren zum Verbinden zweier Bauteile, insbesondere zweier Kraftfahrzeugbauteile, bereitzustellen. The object of the present invention is to provide a method for connecting two components, in particular two motor vehicle components.
Diese Aufgabe wird durch die Gegenstände der unabhängigen Patentansprüche gelöst. Vorteilhafte Weiterbildungen der Erfindung sind in den abhängigen Patentansprüchen, der folgenden Beschreibung sowie den Figuren offenbart. This object is solved by the subject matter of the independent patent claims. Advantageous developments of the invention are disclosed in the dependent patent claims, the following description and the figures.
Durch die Erfindung ist ein Verfahren zum Verbinden zweier Bauteile bereitgestellt, wobei die Bauteile jeweilige zueinander korrespondierende Verbindungselemente aufweisen, welche zur Bereitstellung einer Vorverbindung ineinandergreifen, wobei in der Vorverbindung ein Hohlraum zwischen den Verbindungselementen gebildet wird, der zumindest einen Bewegungsfreiheitsgrad und damit einen Toleranzbereich der beiden Bauteile relativ zueinander in Richtung des zum indest einen Bewegungsfreiheitsgrades bereitstellt. Das Verfahren umfasst als Schritte ein Anordnen der Bauteile zueinander, so dass die Vorverbindung bereitgestellt wird, ein Ausrichten der Bauteile unter Ausnutzung des Toleranzbereichs in eine Montageposition und ein Füllen des Hohlraums mit einer aushärtenden Vergussmasse, wobei nach Aushärten der Vergussmasse der zumindest eine Bewegungsfreiheitsgrad durch die Vergussmasse versperrt wird. The invention provides a method for connecting two components, with the components having respective connecting elements which correspond to one another and which engage in one another to provide a pre-connection, with a cavity being formed between the connecting elements in the pre-connection which has at least one degree of freedom of movement and thus a tolerance range of the two Components relative to each other in the direction of at least one degree of freedom of movement. The method comprises the steps of arranging the components relative to each other so that the pre-connection is provided, aligning the components using the tolerance range in an assembly position and filling the cavity with a hardening potting compound, with the at least one degree of freedom of movement being achieved after the potting compound has hardened Potting compound is blocked.
Mit anderen Worten werden zwei Bauteile, insbesondere Kraftfahrzeugbauteile, bereitgestellt, die jeweilige zueinander korrespondierende Verbindungselemente aufweisen. DieIn other words, two components, in particular motor vehicle components, are provided, each facing one another have corresponding connecting elements. the
Verbindungselemente können bei der Anordnung zu einer Vorverbindung ineinandergreifen, so dass zumindest in eine, vorzugsweise zwei Raumrichtungen, eine formschlüssige Verbindung hergestellt wird. Des Weiteren kann in eine weitere Raumrichtung ein Hohlraum beziehungsweise Zwischenraum zwischen den Verbindungselementen bereitgestellt sein, die eine Bewegung der Bauteile relativ zueinander in Richtung dieses zumindest einen Bewegungsfreiheitsgrades ermöglichen. Das heißt, dass in der Vorverbindung die beiden Bauteile mittels des Hohlraums noch zumindest einen Bewegungsfreiheitsgrad aufweisen und somit gegeneinander verschoben werden können. Dieser Hohlraum kann also einen Toleranzbereich darstellen, in dem die Bauteile noch zueinander ausgerichtet werden können. Nach der Ausrichtung in die Montageposition, die die jeweiligen Bauteile zueinander aufweisen sollen, kann der Hohlraum mit einer aushärtenden Vergussmasse ausgefüllt werden, wobei nach Aushärten der Vergussmasse der Hohlraum versperrt ist und somit die Verbindungselemente formschlüssig und/oder stoffschlüssig und/oder kraftschlüssig miteinander in Verbindung sind. Als Vergussmasse kann beispielsweise ein Klebstoff und/oder Kunststoff verwendet werden, der in den Hohlraum eingespritzt werden kann. When arranged to form a preliminary connection, connecting elements can intermesh, so that a form-fitting connection is produced at least in one, preferably two, spatial directions. Furthermore, in a further spatial direction, a hollow space or intermediate space can be provided between the connecting elements, which enable the components to move relative to one another in the direction of this at least one degree of freedom of movement. This means that in the pre-connection, the two components still have at least one degree of freedom of movement by means of the cavity and can therefore be displaced relative to one another. This cavity can therefore represent a tolerance range in which the components can still be aligned with one another. After alignment in the assembly position that the respective components should have in relation to one another, the cavity can be filled with a hardening casting compound, the cavity being blocked after the casting compound has hardened and the connecting elements thus being connected to one another in a form-fitting and/or material-to-material and/or non-positive manner are. An adhesive and/or plastic, for example, which can be injected into the cavity, can be used as the casting compound.
Durch die Erfindung ergibt sich der Vorteil, dass ein Kostenvorteil geschaffen werden kann, da keine zusätzlichen Bauteile, wie beispielsweise Schrauben, verwendet werden müssen und daher weniger Teile gefertigt und zusammengebaut werden müssen. Auch kann so ein Verbindungsverfahren bereitgestellt werden, dass für nicht metallische Bauteile verwendet werden kann. Die Verbindungselemente können deutlich steifer aneinander fixiert werden, da durch das Ausspritzen mit der Vergussmasse eine Einheit gebildet werden kann. The advantage resulting from the invention is that a cost advantage can be created, since no additional components, such as screws, have to be used and therefore fewer parts have to be manufactured and assembled. A connection method can also be provided in this way that can be used for non-metallic components. The connecting elements can be fixed to one another much more rigidly, since a unit can be formed by spraying with the casting compound.
Die Erfindung umfasst auch Ausführungsformen, durch die sich zusätzliche Vorteile ergeben. Eine Ausführungsform sieht vor, dass die korrespondierenden Verbindungselemente dazu ausgebildet sind, eineThe invention also includes embodiments that result in additional advantages. One embodiment provides that the corresponding connecting elements are designed to
Schwalbenschwanzverbindung, eine Hinterschnittverbindung oder eine Zapfenverbindung miteinander einzugehen. Insbesondere können diese Verbindungen als Vorverbindung bereitgestellt werden. Mit einer Schwalbenschwanzverbindung ist eine Verbindung ähnlich einer Spundung gemeint, bei der ein Spund beziehungsweise Zapfen mit einer im Wesentlichen dreieckigen beziehungsweise pyramidenförmigen Form in ein entsprechenden Gegenstück eingebracht wird. In der Vorverbindung ist die Verbindung jedoch nur teilweise formschlüssig, und es kann zumindest an einer Seite ein Hohlraum innerhalb der Verbindung bereitgestellt sein, die eine Bewegung des Schwalbenschwanzes innerhalb der korrespondierenden Verbindungsstruktur zur Ausrichtung in die endgültige Montageposition ermöglicht. Mit einer Hinterschnittverbindung ist ein hervorstehender, zum Beispiel hakenförmiger Bereich, eines der Verbindungselemente gemeint, der in eine korrespondierende Hakenstruktur eingreifen kann, um die Vorverbindung herzustellen. Mit einer Zapfenverbindung ist ein Zapfen gemeint, der in ein Zapfenloch beziehungsweise einen Schlitz eingebracht werden kann, wobei der Schlitz vorzugsweise ein größeres Volumen als der Zapfen aufweist, so dass der Hohlraum zum nachträglichen Ausfüllen mit der Vergussmasse gebildet ist. Durch diese Verbindungen können bevorzugte Verbindungselemente bereitgestellt werden. Dovetail connection, an undercut connection or a spigot connection. In particular, these connections can be provided as a pre-connection. A dovetail connection means a connection similar to a bung, in which a bung or tenon with a substantially triangular or pyramidal shape is introduced into a corresponding counterpart. However, in the pre-connection the connection is only partially positive and a cavity may be provided within the connection at least on one side to allow movement of the dovetail within the mating connection structure for alignment in the final assembly position. An undercut connection means a protruding, for example hook-shaped area of one of the connection elements, which can engage in a corresponding hook structure in order to produce the preliminary connection. A tenon connection means a tenon that can be introduced into a tenon hole or a slot, the slot preferably having a larger volume than the tenon so that the cavity is formed for subsequent filling with the casting compound. These connections can provide preferred connection elements.
Eine weitere Ausführungsform sieht vor, dass in zumindest einem der Verbindungselemente ein Fließkanal für die Vergussmasse bereitgestellt wird. Der Fließkanal kann beispielsweise an einer Oberfläche des jeweiligen Verbindungselements verlaufen oder durch das Verbindungselement hindurch gebildet sein. So kann in den Fließkanal die Vergussmasse eingespritzt werden und durch den Fließkanal in den Hohlraum geleitet werden. Durch diese Ausführungsform ergibt sich eine bessere Erreichbarkeit des Hohlraums, wodurch das Verfahren verbessert durchgeführt werden kann. A further embodiment provides that a flow channel for the casting compound is provided in at least one of the connecting elements. The flow channel can, for example, run on a surface of the respective connecting element or be formed through the connecting element. The casting compound can thus be injected into the flow channel and passed through the flow channel into the cavity. This embodiment results in better accessibility of the cavity, as a result of which the method can be carried out in an improved manner.
Eine weitere Ausführungsform sieht vor, dass die Bauteile und die jeweiligen Verbindungselemente aus einem Kunststoff gefertigt sind. So können die Bauteile und die Verbindungselemente beispielsweise aus Polyethylen oder Polypropylen gefertigt sein. Insbesondere kann die Vergussmasse, die in den Hohlraum eingespritzt wird, mit einer hohen Temperatur verflüssigt sein und sich mit dem Kunststoff verbinden (Hotmelt), so dass die Vergussmasse mit dem Kunststoff der jeweiligen Verbindungselemente eine Einheit bildet. Das heißt, durch die Vergussmasse kann mittels der als Kunststoff ausgebildeten Verbindungselemente eine stoffschlüssige und/oder formschlüssige Verbindung hergestellt werden. Alternativ können die Bauteile und/oder die Verbindungselemente beispielsweise aus Holz gefertigt sein oder aus einem Metall und als Verbindung kann eine formschlüssige und/oder kraftschlüssige Verbindung hergestellt werden. A further embodiment provides that the components and the respective connecting elements are made of a plastic. That's how they can Components and the connecting elements can be made of polyethylene or polypropylene, for example. In particular, the casting compound that is injected into the cavity can be liquefied at a high temperature and connect to the plastic (hotmelt), so that the casting compound forms a unit with the plastic of the respective connecting elements. This means that a material-locking and/or form-locking connection can be produced by the sealing compound by means of the connecting elements designed as plastic. Alternatively, the components and/or the connecting elements can be made of wood, for example, or of a metal, and a positive and/or non-positive connection can be produced as the connection.
Eine weitere Ausführungsform sieht vor, dass die Vergussmasse einen Kunststoff, insbesondere einen faserverstärkten Kunststoff, aufweist. Mit anderen Worten kann als Vergussmasse ein thermoplastischer Kunststoff, insbesondere mit Faserverstärkung, verwendet werden, wie beispielsweise Polyethylen oder Polypropylen. Das hat den Vorteil, dass nach Aushärten der Vergussmasse eine besonders feste Struktur geschaffen werden kann. Des Weiteren kann, falls die Verbindungselemente aus Kunststoff ausgebildet sein, ein Anschmelzen durch den verflüssigten Kunststoff der Vergussmasse erreicht werden, was eine stoffschlüssige Verbindung und damit eine besonders feste Verbindung erzeugt. Vorzugsweise sind die Verbindungselemente und die Vergussmasse aus dem gleichen Kunststoff ausgebildet. A further embodiment provides that the casting compound has a plastic, in particular a fiber-reinforced plastic. In other words, a thermoplastic material, in particular with fiber reinforcement, such as polyethylene or polypropylene, can be used as the casting compound. This has the advantage that a particularly solid structure can be created after the casting compound has hardened. Furthermore, if the connecting elements are made of plastic, the liquefied plastic of the potting compound can melt them, which creates an integral connection and thus a particularly strong connection. The connecting elements and the casting compound are preferably made of the same plastic.
Eine weitere Ausführungsform sieht vor, dass zumindest ein Verbindungselement Vertiefungen aufweist, in die die Vergussmasse beim Füllen des Hohlraums eintritt. Mit anderen Worten kann einA further embodiment provides that at least one connecting element has indentations into which the casting compound enters when the cavity is filled. In other words, one can
Verbindungselement, vorzugsweise beide Verbindungselemente, Vertiefungen aufweisen, insbesondere Noppen beziehungsweise konkave Vertiefungen, die in das jeweilige Verbindungselement hereinreichen. Diese können beim Füllvorgang durch die Vergussmasse ausgefüllt werden, wodurch die ausgehärtete Vergussmasse in diesen Vertiefungen verkeilt beziehungsweise verhakt werden kann. Das heißt, dass die Vergussmasse mit den Vertiefungen einen mechanischen Hinterschnitt eingehen kann. Durch die zusätzliche Verkeilung kann die ausgehärtete Vergussmasse die Verbindungselemente fest in Position halten, insbesondere in Richtung des zuvor offenen Bewegungsfreiheitsgrades. Connecting element, preferably both connecting elements, have depressions, in particular knobs or concave depressions, which extend into the respective connecting element. These can be filled by the casting compound during the filling process, as a result of which the hardened casting compound can be wedged or hooked in these depressions. That is, the potting compound can enter into a mechanical undercut with the depressions. Due to the additional wedging, the hardened casting compound can hold the connecting elements firmly in position, in particular in the direction of the previously open degree of freedom of movement.
Vorzugsweise ist vorgesehen, dass der Hohlraum durch ein Gussverfahren, insbesondere ein Spritzgussverfahren, gefüllt wird. So können über eine Spritzgusstechnik Duromere in den Hohlraum gespritzt werden, um den zumindest einen Bewegungsfreiheitsgrad zu versperren. Vorzugsweise ist vorgesehen, dass bei dem Gussverfahren die Vergussmasse vorher verflüssigt, insbesondere thermisch verflüssigt, und anschließend in den Hohlraum eingefüllt wird. Durch Abkühlen kann sich die Vergussmasse verhärten und somit die Verbindungselemente fest aneinander fixieren. Des Weiteren ist vorzugsweise vorgesehen, dass das jeweilige Verbindungselement mit dem dazugehörigen Bauteil als ein zusammenhängendes Bauteil bereitgestellt wird. Mit anderen Worten können das Verbindungselement und das Bauteil als ein zusammenhängendes Bauteil bereitgestellt werden. Beispielsweise kann dies mittels eines Umformverfahrens, beispielsweise Fließpressens, erreicht werden, oder die zusammenhängenden Teile können mittels eines Spritzgussverfahrens erzeugt werden. Hierdurch ergibt sich der Vorteil, dass ein zusätzlicher Verfahrensschritt zur Anbringung des Verbindungselements an dem jeweiligen Bauteil weggelassen werden kann und dass keine zusätzliche Verbindung vorgesehen sein muss. Provision is preferably made for the cavity to be filled by a casting process, in particular an injection molding process. For example, duromers can be injected into the cavity using an injection molding technique in order to block at least one degree of freedom of movement. Provision is preferably made for the casting compound to be liquefied beforehand, in particular thermally liquefied, during the casting process, and then to be filled into the cavity. The casting compound can harden as it cools down and thus fix the connecting elements firmly to one another. Furthermore, it is preferably provided that the respective connecting element is provided with the associated component as a coherent component. In other words, the connecting element and the component can be provided as a coherent component. For example, this can be achieved by means of a forming process, for example extrusion, or the connected parts can be produced by means of an injection molding process. This results in the advantage that an additional method step for attaching the connecting element to the respective component can be omitted and that no additional connection has to be provided.
Eine weitere Ausführungsform sieht vor, dass die Bauteile zur Herstellung eines Batteriemoduls bereitgestellt werden, insbesondere als eine Bodenplatte und eine seitliche Druckplatte des Batteriemoduls. Mit anderen Worten kann das Verfahren zur Verbindung der Bauteile dazu verwendet werden, ein Batteriemodul herzustellen, wobei für die Bereitstellung eines Gehäuses des Batteriemoduls eine seitliche Druckplatte beziehungsweise Seitenwand mit einer Bodenplatte verbunden werden soll. Das Verfahren eignet sich hierbei besonders, da ein Zellstapel durch die seitliche Druckplatte verspannt werden muss und das Verspannen einen Toleranzbereich erfordert, der durch den Hohlraum bereitgestellt werden kann. Anschließend können durch Einspritzen der Vergussmasse die jeweiligen Bauteile des Batteriemoduls miteinander verbunden werden. A further embodiment provides that the components for producing a battery module are provided, in particular as a base plate and a lateral pressure plate of the battery module. In other words, the method for connecting the components can be used to produce a battery module, a lateral pressure plate or side wall being intended to be connected to a base plate to provide a housing for the battery module. The method is particularly suitable here because a cell stack can be pushed through the lateral pressure plate must be clamped and the clamping requires a tolerance range that can be provided by the cavity. The respective components of the battery module can then be connected to one another by injecting the casting compound.
Ein weiterer Aspekt der Erfindung betrifft ein Batteriemodul mit einem Zellstapel und einem Gehäuse, wobei das Gehäuse durch ein Verfahren nach einer der vorhergehenden Ausführungsformen hergestellt ist. Insbesondere wird beim Gehäuse die zuvor genannte Bodenplatte mit einer seitlichen Druckplatte verbunden, wobei der Zellstapel durch die seitliche Druckplatte und eine gegenüberliegende Druckplatte verspannt wird, bevor durch Einfüllen der Vergussmasse der Zellstapel innerhalb des Gehäuses fest fixiert wird. Hierbei ergeben sich gleiche Vorteile und Variationsmöglichkeiten wie bei dem Verfahren. A further aspect of the invention relates to a battery module with a cell stack and a housing, the housing being produced by a method according to one of the preceding embodiments. In particular, in the case of the housing, the aforementioned base plate is connected to a lateral pressure plate, with the cell stack being braced by the lateral pressure plate and an opposite pressure plate before the cell stack is firmly fixed inside the housing by filling in the casting compound. This results in the same advantages and possible variations as in the method.
Das erfindungsgemäße Batteriemodul kann vorzugsweise in einem Kraftfahrzeug angeordnet werden, wobei das Kraftfahrzeug bevorzugt als Kraftwagen, insbesondere als Personenkraftwagen oder Lastkraftwagen, oder als Personenbus oder Motorrad ausgestaltet ist. The battery module according to the invention can preferably be arranged in a motor vehicle, the motor vehicle preferably being designed as a motor vehicle, in particular as a passenger car or truck, or as a passenger bus or motorcycle.
Zu der Erfindung gehören auch Weiterbildungen des erfindungsgemäßen Batteriemoduls, die Merkmale aufweisen, wie sie bereits im Zusammenhang mit den Weiterbildungen des erfindungsgemäßen Verfahrens beschrieben worden sind. Aus diesem Grund sind die entsprechenden Weiterbildungen des erfindungsgemäßen Batteriemoduls hier nicht noch einmal beschrieben. The invention also includes developments of the battery module according to the invention, which have features as have already been described in connection with the developments of the method according to the invention. For this reason, the corresponding developments of the battery module according to the invention are not described again here.
Die Erfindung umfasst auch die Kombinationen der Merkmale der beschriebenen Ausführungsformen. Die Erfindung umfasst also auch Realisierungen, die jeweils eine Kombination der Merkmale mehrerer der beschriebenen Ausführungsformen aufweisen, sofern die Ausführungsformen nicht als sich gegenseitig ausschließend beschrieben wurden. The invention also includes the combinations of features of the described embodiments. The invention also includes implementations that each have a combination of the features of several of the described embodiments, provided that the embodiments were not described as mutually exclusive.
Im Folgenden sind Ausführungsbeispiele der Erfindung beschrieben. Hierzu zeigt: Fig. 1 eine schematische Darstellung eines Batteriemoduls gemäß einer beispielhaften Ausführungsform; Fig. 2 eine schematische Darstellung einer Verbindung zweier Bauteile gemäß einer beispielhaften Ausführungsform. Exemplary embodiments of the invention are described below. For this shows: 1 shows a schematic representation of a battery module according to an exemplary embodiment; 2 shows a schematic representation of a connection of two components according to an exemplary embodiment.
Bei den im Folgenden erläuterten Ausführungsbeispielen handelt es sich um bevorzugte Ausführungsformen der Erfindung. Bei den Ausführungsbeispielen stellen die beschriebenen Komponenten der Ausführungsformen jeweils einzelne, unabhängig voneinander zu betrachtende Merkmale der Erfindung dar, welche die Erfindung jeweils auch unabhängig voneinander weiterbilden. Daher soll die Offenbarung auch andere als die dargestellten Kombinationen der Merkmale der Ausführungsformen umfassen. Des Weiteren sind die beschriebenen Ausführungsformen auch durch weitere der bereits beschriebenen Merkmale der Erfindung ergänzbar. The exemplary embodiments explained below are preferred embodiments of the invention. In the exemplary embodiments, the described components of the embodiments each represent individual features of the invention that are to be considered independently of one another and that each also develop the invention independently of one another. Therefore, the disclosure is also intended to encompass combinations of the features of the embodiments other than those illustrated. Furthermore, the described embodiments can also be supplemented by further features of the invention that have already been described.
In den Figuren bezeichnen gleiche Bezugszeichen jeweils funktionsgleiche Elemente. In the figures, the same reference symbols designate elements with the same function.
In Fig. 1 ist ein Batteriemodul 10 dargestellt, an dem das Verfahren zum Verbinden der Bauteile im Nachfolgenden erklärt wird. Das Batteriemodul 10 kann eine Bodenplatte 12 und einen Zellstapel 14 aufweisen, wobei der Zellstapel 14 zwischen zwei Druckplatten 16, 18 verspannt werden soll. Hierfür kann eine erste Druckplatte 16 bereits mit der Bodenplatte 12 verbunden sein, wobei die zweite Druckplatte 18 durch Anpressen an die Seite des Zellstapels 14 das Batteriemodul 10 abschließen soll. In diesem Beispiel können also die Bodenplatte 12 und die zweite Druckplatte 18 die beiden zu verbindenden Bauteile darstellen. 1 shows a battery module 10 on which the method for connecting the components is explained below. The battery module 10 can have a base plate 12 and a cell stack 14, with the cell stack 14 being braced between two pressure plates 16, 18. For this purpose, a first pressure plate 16 can already be connected to the base plate 12 , the second pressure plate 18 being intended to close off the battery module 10 by being pressed against the side of the cell stack 14 . In this example, the base plate 12 and the second pressure plate 18 can represent the two components to be connected.
Nach Anpressen der zweiten Druckplatte 18 an den Zellstapel 14 soll diese mit der Bodenplatte 12 im Verbindungsbereich 20 fest verbunden werden. Da für das Anpressen der zweiten Druckplatte 18 an den Zellstapel 14 ein Toleranzbereich vorgesehen sein soll, können die Bodenplatte 12 und die zweite Druckplatte 18 ein jeweiliges Verbindungselement 22, 24 aufweisen, was in Fig. 2 näher erläutert wird. After the second pressure plate 18 has been pressed against the cell stack 14 , it should be firmly connected to the base plate 12 in the connection area 20 . Since a tolerance range should be provided for the pressing of the second pressure plate 18 on the cell stack 14, the bottom plate 12 and the second pressure plate 18 have a respective connecting element 22, 24, which is explained in more detail in FIG.
In Fig. 2 sind die seitliche Druckplatte 18 und die Bodenplatte 12 dargestellt, wobei diese jeweils ein korrespondierendes Verbindungselement 22, 24 aufweisen, welche zur Bereitstellung einer Vorverbindung ineinandergreifen. Beispielsweise können die Verbindungselemente, wie hier dargestellt, eine Schwalbenschwanzverbindung als Vorverbindung eingehen. Dabei sind die Verbindungselemente 22, 24 vorzugsweise stoffschlüssig mit dem jeweiligen Bauteil, insbesondere der seitlichen Druckplatte 18 und der Bodenplatte 12, verbunden und jeweils als ein einziges Bauteil bereitgestellt. In Fig. 2, the side pressure plate 18 and the bottom plate 12 are shown, each having a corresponding connecting element 22, 24 which interlock to provide a pre-connection. For example, as shown here, the connecting elements can enter into a dovetail connection as a preliminary connection. The connecting elements 22, 24 are preferably connected to the respective component, in particular the lateral pressure plate 18 and the base plate 12, in a materially bonded manner and are each provided as a single component.
Die Vorverbindung, bei der die jeweiligen Verbindungselemente 22, 24 ineinandergreifen, kann so ausgebildet sein, dass ein Flohlraum 26 zwischen den Verbindungselementen 22, 24 gebildet ist, der zumindest einenThe preliminary connection, in which the respective connecting elements 22, 24 engage in one another, can be designed in such a way that a flea space 26 is formed between the connecting elements 22, 24, the at least one
Bewegungsfreiheitsgrad, in diesem Beispiel aus der Bildebene heraus oder herein, ermöglicht. Somit kann ein Toleranzbereich geschaffen werden, der ein Anpressen der seitlichen Druckplatte 18 an den Zellstapel 14 ermöglicht. Ist die seitliche Druckplatte 18 in einer Montageposition unter Ausnutzung des durch den Flohlraum 26 gebildeten Toleranzbereichs ausgerichtet, kann der Flohlraum 26 mittels eines Gussverfahrens, insbesondere eines Spritzgussverfahrens, mit einer Vergussmasse gefüllt werden. Die Vergussmasse ist vorzugsweise ein faserverstärkter Kunststoff, der aus dem gleichen Material sein kann, wie die Verbindungselemente 22, 24.Degree of freedom of movement, in this example out of or in from the image plane. A tolerance range can thus be created which enables the lateral pressure plate 18 to be pressed against the cell stack 14 . If the lateral pressure plate 18 is aligned in an assembly position using the tolerance range formed by the cavity 26, the cavity 26 can be filled with a casting compound by means of a casting process, in particular an injection molding process. The casting compound is preferably a fiber-reinforced plastic, which can be made of the same material as the connecting elements 22, 24.
Vorzugsweise kann die Vergussmasse ein thermoplastischer Kunststoff sein, der sich mit den Strukturen der jeweiligen Verbindungselemente 22, 24 verbindet und so eine Einheit bildet. Das heißt, dass der thermoplastische Kunststoff die Verbindungselemente 22, 24 anschmelzen kann und sich mit diesen verbindet. Preferably, the casting compound can be a thermoplastic material, which connects to the structures of the respective connecting elements 22, 24 and thus forms a unit. This means that the thermoplastic can melt the connecting elements 22, 24 and connects to them.
Nach Aushärten der Vergussmasse kann der zuvor durch den Flohlraum 26 bereitgestellte Bewegungsfreiheitsgrad versperrt werden, wodurch die Verbindungselemente in alle sechs Bewegungsfreiheitsgrade form- und/oder stoffschlüssig verbunden sind. After the sealing compound has hardened, the degree of freedom of movement previously provided by the Flea space 26 can be blocked, whereby the Connecting elements are positively and/or cohesively connected in all six degrees of freedom of movement.
Zum Einleiten der Vergussmasse in den Hohlraum 26 kann ein Fließkanal 28 bereitgestellt sein, der an oder in einem Verbindungselement beziehungsweise Bauteil vorgesehen ist und durch den die Vergussmasse, insbesondere mittels eines Spritzgussverfahrens, eingespritzt werden kann. A flow channel 28 can be provided for introducing the casting compound into the cavity 26, which is provided on or in a connecting element or component and through which the casting compound can be injected, in particular by means of an injection molding process.
Damit die ausgehärtete Verbindung zwischen den Verbindungselementen 22, 24 weiter verfestigt werden kann, insbesondere in Richtung des zuvor freienSo that the hardened connection between the connecting elements 22, 24 can be further strengthened, in particular in the direction of the previously free
Bewegungsfreiheitsgrades, kann an einem oder beiden Verbindungselementen 22, 24 eine oder mehrere Vertiefungen 30 bereitgestellt sein. Die Vertiefungen 30 können nach innen gerichtete Noppen, also konkave Noppen, sein, die beim Befüllen des Hohlraums 26 durch die Spritzgussmasse gefüllt werden. Nach Aushärten der Spritzgussmasse bieten diese Vertiefungen 30 in Richtung des zuvor freien Bewegungsfreiheitsgrades Widerhaken beziehungsweise Keile zwischen der ausgehärteten Vergussmasse und den Verbindungselementen 22, 24. Die hier gezeigte Verbindung wurde an einer Ecke zwischen zwei Bauteilen 12, 18 gezeigt, diese Verbindung kann jedoch auch mittig an jeder beliebigen Stelle verwendet werden und ist nicht auf senkrecht aufeinander stehende Bauteile limitiert. In Fig. 3 ist ein schematisches Verfahrensdiagramm zum Verbinden zweier Bauteile 12, 18 dargestellt. In einem Schritt S10 werden zwei Bauteile bereitgestellt, die jeweilig zueinander korrespondierende Verbindungselemente 22, 24, beispielsweise hakenförmigeDegree of freedom of movement, one or more recesses 30 can be provided on one or both connecting elements 22, 24. The indentations 30 can be inwardly directed nubs, ie concave nubs, which are filled by the injection molding compound when the cavity 26 is filled. After the injection molding compound has hardened, these indentations 30 provide barbs or wedges in the direction of the previously free degree of freedom of movement between the hardened casting compound and the connecting elements 22, 24. The connection shown here was shown at a corner between two components 12, 18, but this connection can also be centered can be used anywhere and is not limited to components that are perpendicular to one another. A schematic process diagram for connecting two components 12, 18 is shown in FIG. In a step S10, two components are provided, the respective connecting elements 22, 24 corresponding to one another, for example hook-shaped
Verbindungselemente, aufweisen, welche zur Bereitstellung einer Vorverbindung ineinandergreifen, wobei in der Vorverbindung ein Hohlraum 26 zwischen den Verbindungselementen 22, 24 gebildet wird, der zumindest einen Bewegungsfreiheitsgrad und damit einen Toleranzbereich der beiden Bauteile 12, 18 relativ zueinander in Richtung des zumindest einen Bewegungsfreiheitsgrades bereitstellt. In einem Schritt S12 können die Bauteile 12, 18 zum Eingehen der Vorverbindung, in der die Bauteile 12, 18 mit ihren Verbindungselementen 22, 24 ineinandergreifen, bereitgestellt werden. In der Vorverbindung können vorzugsweise zumindest vier Bewegungsfreiheitsgrade furch einen Formschluss eingeschränkt werden. Connecting elements, which engage in one another to provide a preliminary connection, a cavity 26 being formed between the connecting elements 22, 24 in the preliminary connection, which cavity 26 provides at least one degree of freedom of movement and thus a tolerance range of the two components 12, 18 relative to one another in the direction of the at least one degree of freedom of movement . In a step S12, the components 12, 18 can be provided for entering into the pre-connection, in which the components 12, 18 engage in one another with their connecting elements 22, 24. In the preliminary connection, preferably at least four degrees of freedom of movement can be restricted for a form fit.
In einem Schritt S14 können die Bauteile 12, 18 unter Ausnutzung des Toleranzbereichs, der durch den Hohlraum 26 bereitgestellt wird, in eine Montageposition ausgerichtet werden. In a step S14, the components 12, 18 can be aligned in an assembly position using the tolerance range provided by the cavity 26.
Schließlich kann in einem Schritt S16 der Hohlraum 26 mit einer aushärtenden Vergussmasse gefüllt werden, wobei nach Aushärten der Vergussmasse der zumindest eine Bewegungsfreiheitsgrad versperrt wird. Finally, in a step S16, the cavity 26 can be filled with a hardening potting compound, with the at least one degree of freedom being blocked after the potting compound has hardened.
Insgesamt zeigen die Beispiele, wie durch die Erfindung eine Verbindung mit Toleranzausgleich erzeugt werden kann. Overall, the examples show how a connection with tolerance compensation can be produced using the invention.

Claims

PATENTANSPRÜCHE: PATENT CLAIMS:
1. Verfahren zum Verbinden zweier Bauteile (12, 18), 1. Method for connecting two components (12, 18),
- wobei die Bauteile (12, 18) jeweilige zueinander korrespondierende Verbindungselemente (22, 24) aufweisen, welche zur Bereitstellung einer Vorverbindung ineinandergreifen, wobei in der Vorverbindung ein Hohlraum (26) zwischen den Verbindungselementen (22, 24) gebildet wird, der zumindest einen Bewegungsfreiheitsgrad und damit einen Toleranzbereich der beiden Bauteile (12, 18) relativ zueinander in Richtung des zumindest einen Bewegungsfreiheitsgrades bereitstellt (S10), umfassend die Schritte: - wherein the components (12, 18) have respective connecting elements (22, 24) which correspond to one another and which engage in one another to provide a pre-connection, with a cavity (26) being formed between the connecting elements (22, 24) in the pre-connection and having at least one degree of freedom of movement and thus a tolerance range of the two components (12, 18) relative to each other in the direction of the at least one degree of freedom of movement (S10), comprising the steps:
- Anordnen (S12) der Bauteile (12, 18) zueinander, so dass die Vorverbindung bereitgestellt wird; - arranging (S12) the components (12, 18) to each other, so that the pre-connection is provided;
- Ausrichten (S14) der Bauteile (12, 18) unter Ausnutzung des Toleranzbereichs in eine Montageposition; - Aligning (S14) the components (12, 18) using the tolerance range in an assembly position;
- Füllen (S16) des Hohlraums (26) mit einer aushärtenden Vergussmasse, wobei nach Aushärten der Vergussmasse der zumindest eine Bewegungsfreiheitsgrad durch die Vergussmasse versperrt wird. - Filling (S16) of the cavity (26) with a hardening potting compound, wherein after the potting compound has hardened, the at least one degree of freedom of movement is blocked by the potting compound.
2. Verfahren nach Anspruch 1, wobei die korrespondierenden Verbindungselemente (22, 24) dazu ausgebildet sind, eine2. The method of claim 1, wherein the corresponding connecting elements (22, 24) are adapted to a
Schwalbenschwanzverbindung, eine Hinterschnittverbindung oder eine Zapfenverbindung miteinander einzugehen. Dovetail connection, an undercut connection or a spigot connection.
3. Verfahren nach einem der vorhergehenden Ansprüche, wobei in zumindest einem der Verbindungselemente (22, 24) ein Fließkanal (28) für die Vergussmasse bereitgestellt wird. 3. The method according to any one of the preceding claims, wherein in at least one of the connecting elements (22, 24) a flow channel (28) is provided for the casting compound.
4. Verfahren nach einem der vorhergehenden Ansprüche, wobei die4. The method according to any one of the preceding claims, wherein the
Bauteile (12, 18) und die jeweiligen Verbindungselemente (22, 24) aus einem Kunststoff gefertigt sind. Components (12, 18) and the respective connecting elements (22, 24) are made of a plastic.
5. Verfahren nach einem der vorhergehenden Ansprüche, wobei die Vergussmasse einen Kunststoff, insbesondere einen faserverstärkten Kunststoff, aufweist. 5. The method according to any one of the preceding claims, wherein the potting compound comprises a plastic, in particular a fiber-reinforced plastic.
6. Verfahren nach einem der vorhergehenden Ansprüche, wobei zumindest ein Verbindungselement (22, 24) Vertiefungen (30) aufweist, in die die Vergussmasse beim Füllen des Hohlraums (26) eintritt. 6. The method according to any one of the preceding claims, wherein at least one connecting element (22, 24) has depressions (30) into which the casting compound when filling the cavity (26) occurs.
7. Verfahren nach einem der vorhergehenden Ansprüche, wobei der Hohlraum (26) durch ein Gussverfahren, insbesondere ein Spritzgussverfahren, gefüllt wird. 7. The method according to any one of the preceding claims, wherein the cavity (26) is filled by a casting process, in particular an injection molding process.
8. Verfahren nach einem der vorhergehenden Ansprüche, wobei das jeweilige Verbindungselement (22, 24) mit dem dazugehörigen Bauteil (12, 18) als ein zusammenhängendes Bauteil bereitgestellt wird. 8. The method according to any one of the preceding claims, wherein the respective connecting element (22, 24) with the associated component (12, 18) is provided as a coherent component.
9. Verfahren nach einem der vorhergehenden Ansprüche, wobei die Bauteile (12, 18) zur Herstellung eines Batteriemoduls (10) bereitgestellt werden, insbesondere als eine Bodenplatte (12) und eine seitliche Druckplatte (18) des Batteriemoduls (10). 9. The method according to any one of the preceding claims, wherein the components (12, 18) for producing a battery module (10) are provided, in particular as a base plate (12) and a lateral pressure plate (18) of the battery module (10).
10. Batteriemodul (10) mit einem Zellstapel (14) und einem Gehäuse (12, 16, 18), wobei das Gehäuse (12, 16, 18) durch ein Verfahren nach einem der vorhergehenden Ansprüche hergestellt ist. 10. Battery module (10) with a cell stack (14) and a housing (12, 16, 18), wherein the housing (12, 16, 18) is produced by a method according to any one of the preceding claims.
PCT/EP2022/062927 2021-06-07 2022-05-12 Method for connecting two components, and battery module WO2022258299A1 (en)

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DE102010050874A1 (en) 2010-11-09 2012-05-10 Daimler Ag Motor vehicle structural component made of semi-finished parts connected by means of a node element and manufacturing method
EP2860795A1 (en) * 2012-08-17 2015-04-15 LG Chem, Ltd. Battery module having assembly coupling structure
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