Method for producing a battery assembly for a battery module, and a battery assembly

Patent metadata

Field	Value
Publication number	US-2025343338-A1
Application number	US-202519198366-A
Country	US
Kind code	A1
Filing date	May 5, 2025
Priority date	May 6, 2024
Publication date	Nov 6, 2025
Grant date	—

Abstract

A method for producing a battery assembly for a battery module, comprising the following steps: providing a battery cell block comprising a plurality of battery cells, where a battery cell block top side has one or more electrical contacts (of the plurality of battery cells; applying a foaming adhesive onto or into a mold; positioning the battery cell block on or in the mold and inserting the battery cell block top side into the foaming adhesive so that the battery cell block top side is at least partially wetted by the foaming adhesive in order to form contact protection for the battery cell block top side by means of the foaming adhesive; waiting until the foaming adhesive adheres to the battery cell block top side; and removing the battery cell block from or out of the mold.

First claim

1 . A method for producing a battery assembly for a battery module, comprising the following steps:
providing a battery cell block comprising a plurality of battery cells, wherein a battery cell block top side has one or more electrical contacts of the plurality of battery cells; applying a foaming adhesive at least one of: onto a mold and into the mold; positioning the battery cell block at least one of: on the mold and in the mold and inserting the battery cell block top side into the foaming adhesive so that the battery cell block top side is at least partially wetted by the foaming adhesive in order to form a contact protection for the battery cell block top side by means of the foaming adhesive; waiting until the foaming adhesive adheres to the battery cell block top side; and removing the battery cell block from or out of the mold.

2 . The method as claimed in claim 1 , wherein prior to applying the foaming adhesive at least one of: onto the mold and into the mold, the following step is carried out:
providing an anti-adhesive agent at least one of: on the mold and in the mold to prevent the foaming adhesive from adhering to the mold.

3 . The method as claimed in claim 2 , wherein the provision of the anti-adhesive agent is carried out at least one of: on the mold and in the mold by at least one of: using an anti-adhesive coating with which the mold is coated; and by applying a release agent to the mold.

4 . The method as claimed in claim 2 , wherein the provision of the anti-adhesive agent is further carried out at least one of: on the mold and in the mold by means of providing a release layer on the mold, wherein the release layer is attached to the battery cell block by means of the foaming adhesive, so that the release layer is provided in the form of an outer layer for the battery cell block top side.

5 . The method as claimed in claim 1 , wherein after removing the battery cell block fromout of the mold, the following step takes place:
providing the foaming adhesive with an outer layer.

6 . The method as claimed in claim 4 , wherein the outer layer is at least one of: a lid, a film, and a lacquer, wherein the outer layer is electrically insulating.

7 . The method as claimed in claim 4 , wherein the outer layer and the foaming adhesive together form a composite material, which is formed by means of layers bonded together over their entire surface.

8 . The method as claimed in claim 1 , further comprising at least one of the following steps:
heating the foaming adhesive prior to application to an application temperature such that the application temperature does not exceed a first threshold value; and controlling a mold surface temperature of the mold so that the mold surface temperature does not exceed a second threshold value.

9 . The method as claimed in claim 1 , wherein providing the battery cell block comprises at least one of:
bonding adjacent battery cells of the plurality of battery cells to each other; attaching the battery cell block to a bottom plate, wherein the bottom plate is a thermal plate and the battery cell block is connected to the thermal plate by means of a thermal filler material; and attaching an electrical connector to the battery cell block top side to electrically contact the one or more electrical contacts.

10 . The method as claimed in claim 4 , wherein providing the release layer on or in the mold comprises:
equipping the mold with a thermoformable lid blank, wherein the lid blank comprises a PET material, a PP material or a PEF material; thermoforming the lid blank to obtain the lid; and cooling the lid so that the lid temperature drops to a second threshold value or below.

11 . The method as claimed in claim 1 , wherein the foaming adhesive is at least one of: a flame-retardant adhesive and has an open time of less than 60 seconds.

12 . A battery assembly for a battery module, comprising
a battery cell block having a plurality of battery cells, wherein a battery cell block top side has one or more electrical contacts of the plurality of battery cells; and a foaming adhesive which at least partially covers the battery cell block top side and at least partially encloses the one or more electrical contacts in order to provide contact protection for the battery cell block top side.

13 . The battery assembly as claimed in claim 12 , wherein an electrically insulating outer layer is arranged on the foaming adhesive.

14 . The battery assembly as claimed in claim 12 , wherein the outer layer and the foaming adhesive together form a composite material, which is formed from layers bonded together over their entire surface.

15 . The battery assembly as claimed in claim 12 , wherein the one or more electrical contacts are connected by means of an electrical connector and the foaming adhesive at least partially encloses the electrical connector.

16 . The battery assembly as claimed in claim 12 , wherein at least one of: at least two adjacent battery cells of the plurality of battery cells are bonded together by means of adhesive beads; and the battery cell block is attached to a base plate, wherein the base plate is a thermal plate and the battery cell block is connected to the thermal plate by means of a thermal filling material.

Assignees

• Webasto SE

Inventors

• Sacher Martin
• Müller Arne
• Barth Rosemarie

Classifications

• H01M10/6554

  Rods or plates · CPC title

• H01M10/613

  Cooling or keeping cold · CPC title

• H01M10/653

  characterised by electrically insulating or thermally conductive materials · CPC title

• H01M10/643

  Cylindrical cells · CPC title

• H01M50/588 Primary

  outside the batteries, e.g. incorrect connections of terminals or busbars · CPC title