Method for manufacturing battery element for battery cell and application thereof

Abstract

The invention relates to a method for producing a battery element (10, 12) for a battery cell, comprising the following method steps: a) applying a first electrode material (14) to a first separator (18) coated with a ceramic material (16); b) applying a second separator (20) coated with the ceramic material (16) to the structure according to method step a); c) producing at least one fastening connection (22) between the first separator and the second separator (18, 20) in an edge region (24) of the first electrode material (14); and d) producing at least one main connection (26) between the first separator and the second separator (18, 20) and spaced from the at least one fastening connection (22), and forming a recess (28) for the first electrode material (14).

Description

Technical Field

[0001] The present invention relates to a method of manufacturing a battery element for a battery unit used in a vehicle. Background Art

[0002] JP 2016-038995 A relates to an energy storage device and a method for manufacturing the energy storage device. According to the solution, an energy storage device is proposed, in which electrodes are positioned with reference to separators and electrodes that are not correctly positioned can be detected very simply. In addition, a method for manufacturing such an energy storage device is proposed. The energy storage device comprises a positive electrode and a negative electrode inside an electrode group, which are coated with separators and arranged between the separators. Each pair of separators is welded so that the four corners of the positive electrode are positioned between a pair of separators in a sandwich structure with four corners.

[0003] Battery cells for vehicles are currently wound into cylindrical structures, for example. In the future, such lithium-ion battery cells should be constructed in a stacking concept according to a stacking method. With such a stack of battery cells, a higher volume utilization can first be achieved compared to wound battery cells. In addition, thicker electrode layers can be used compared to wound battery cells. In addition, the electrochemical performance and periodic aging are significantly better in battery cells produced using a stacking method.

[0004] Battery cells are usually constructed from alternating layers of anode, separator and cathode. Materials such as PE (polyethylene) or PP (polypropylene) are used as base films in the separator, which can be coated on one side or both sides with a thin ceramic layer made of Al2O3 or boehmite or the like. During the stacking process, there is always one ceramic side facing the cathode of the battery element. This ensures that the cathode is always surrounded by ceramic on both sides, thereby improving stability, especially when high battery cell voltages occur. In the case of a separator coated on both sides, the anode is also surrounded by ceramic layers on both sides.

[0005] In order to increase the stacking speed, ie to speed up the cell production, it may also be expedient for functional and safety reasons to insert the cathode into the separator recess.

[0006] The production of battery cells according to the stacking method is associated with a number of technical challenges. This applies, for example, to the splicing process of the splicing method by material fusion, whether it is produced manually or mechanically. When the battery cells are produced according to the stacking method, the width of the anode usually exceeds the width of the cathode, while the separator and the anode are designed to have the same width. Therefore, there is a possibility that the first electrode material used to produce the cathode may slide from the position where it is placed on the first separator. In addition, the first electrode material for producing the cathode is placed on the first separator with tolerances during manual or mechanical production. Due to the movement or sliding of the first electrode material for producing the cathode from a predefined position, the cathode may be damaged during the subsequent splicing method, such as ultrasonic welding. This may, for example, lead to a collision between the cathode and the ultrasonic oscillator that establishes the material fusion connection. In addition, due to the movement or sliding of the first electrode material for producing the cathode from a predefined position, the minimum overlap required for the second battery material for producing the anode with respect to the first electrode material for producing the cathode may be not exceeded, which may significantly hinder the electrochemical functionality of the battery cell. Therefore, the higher volume utilization inside the battery cell achieved by the stacking method compared to a wound battery cell brings about problems in manufacturing technology. Summary of the invention

[0007] According to the invention, a method for producing a battery element for a battery cell is proposed, the method comprising the following method steps:

[0008] a) applying a first electrode material to a first separator coated with a ceramic material;

[0009] b) applying a second separator coated with a ceramic material to the structure according to method step a);

[0010] c) producing at least one secure connection between the first and second separators in an edge region of the first electrode material; and

[0011] d) producing at least one main connection between the first and second separators, which is spaced apart from the at least one fastening connection and forms a recess for the first electrode material.

[0012] The method proposed according to the invention has the outstanding advantage that, for example, the first electrode material forming the cathode is positioned in a defined position in the recess by a two-stage joining process. The distance to the actual main connection that is implemented later is kept uniform with reference to the edges of the first electrode material. By forming the actual main connection that is produced in the second stage as a fastening connection, the first electrode material forming the cathode is ensured to move from the nominal position or nominal location that is necessary and maximally permissible for fulfilling the function of the battery cell.

[0013] In an embodiment of the method proposed according to the invention, method steps c) and d) are performed by means of a material-fusion joining method, in particular by ultrasonic welding. In an embodiment of the method proposed according to the invention, after carrying out method steps a) to d), a second electrode material for the anode is applied to the previously produced recess and a four-component stack suitable for stacking is produced.

[0014] The at least one fastening connection produced according to method step c) is a continuously constructed ultrasonic weld, which can be applied in a semicircular or L-shaped manner. In addition, points or point geometries or oscillating wobble geometries are also conceivable as embodiments of the at least one fastening connection.

[0015] The at least one main connection produced according to method step d) is also a seam produced by means of an ultrasonic welding method, which can be designed as a continuous main connection, can be designed as a line or an oscillating oscillating motion or as a point-interrupted or other interrupted main connection. When the at least one main connection extends along the edge of the first electrode material, at least one semicircular or L-shaped fastening connection is respectively located in the corner region of the first electrode material for producing the cathode.

[0016] The first partition and / or the second partition for forming the recess is a material coated on one side or on both sides with a ceramic material. In the simplest case, an uncoated partition made of a polymer can also be used. The ceramic layer is a ceramic such as Al2O3 or also boehmite. If at least one fastening connection is produced by means of an ultrasonic welding method, in particular a first ultrasonic oscillation unit is used, the head of which has a diameter between 1 mm and 2 mm, wherein the at least one fastening connection produced has a width between 0.1 mm and 0.3 mm. At least one fastening connection is preferably designed in a semicircular or L-shaped manner in the corner area of ​​the first electrode material and the first electrode material is fastened to the upper side of the first partition.

[0017] Accordingly, the method according to the invention then produces at least one main connection according to method step d) using a second sonotrode. The head of the second sonotrode has a diameter of between 4 mm and 8 mm and the at least one main connection has a width of between 0.3 mm and 1.2 mm. The method according to the invention for producing a battery element furthermore shows that the distance between the inner edge of the at least one fastening connection and the edge of the electrode material in the recess corresponds to the difference between the second dimension and the first dimension. The distance between the inner edge of the at least one main connection and the edge of the first electrode material in the recess corresponds to the difference between the third dimension and the first dimension.

[0018] Furthermore, the invention relates to the use of a battery element produced according to the proposed method in a power battery for an electric vehicle (EV = electric vehicle), a hybrid vehicle (HEV = hybrid electric vehicle) or a PHEV (plug-in hybrid electric vehicle).

[0019] The solution proposed according to the invention has the advantage that the first electrode material for the cathode is pre-positioned in a defined manner in a recess formed by interconnected separators by means of an ultrasonic welding method before at least one actual main connection is established at a distance from at least one fastening connection. In the solution proposed according to the invention, the main connection is kept constant by at least one fastening connection with reference to the spacing between the edges of the first electrode material for the cathode. The at least one main connection designed as an ultrasonic weld ensures the maximum permissible movement of the first electrode material for the cathode from its nominal position on the first separator, which is preferably constructed in a track shape, required to meet the function of the battery cell. By fastening the position of the first electrode material for the cathode with at least one fastening connection, the first electrode material is kept in its initial position during the manufacture of the battery element. Along the contour of the first electrode material for the cathode, at least one main connection is established either as an interrupted connection (e.g., a point-break connection) or as a continuous weld so that at least one main connection is further away from the edge of the first electrode material for the cathode than at least one fastening weld.

[0020] The at least one secure connection subsequently produced by means of an ultrasonic welding method is a permanent connection which already provides resistance in the event of damage, such as in the event of an exothermic reaction due to, for example, overheating due to mechanical damage. In the worst case, the separator is pulled back, which can cause the cathode to come into electrical contact with the anode, which can further accelerate the situation. The at least one secure connection produced by means of an ultrasonic welding method is already a great resistance in these cases.

[0021] When producing the actual main connection, an ultrasonic weld is produced, which simultaneously limits the maximum displacement of the first electrode material used to produce the cathode from its desired position. This advantageously reduces the overlap between the anode and cathode, which in turn results in a higher volume utilization for the battery cell.

[0022] In the ultrasonic welding method, a rod-shaped ultrasonic oscillator is used to produce at least one fastening seam between the first electrode material of the cathode and the first separator, and the head diameter of the ultrasonic oscillator is between 1 mm and 2 mm. For this reason, the rod-shaped ultrasonic oscillator can be guided very close to the first cathode material without damaging the rod-shaped ultrasonic oscillator. This in turn provides the possibility that at least one fastening seam is constructed very close to the edge of the first electrode material and reaches a very thin seam width for preparing at least one fastening connection. But this is sufficient to fix the first electrode material for preparing the cathode for further processing. The ultrasonic welding method can also be used for separators coated on both sides. Because the first electrode material for preparing the cathode is now fixed in two separators, the following risk is reduced, that is, the second ultrasonic oscillator used later to produce at least one main connection collides with the first electrode material for preparing the cathode. The first electrode material can now be kept in its position even more accurately, which improves the robustness of the manufacturing method. Whether the at least one fastening connection or the at least one main connection is a spliced ​​connection between the separators, the first electrode material for preparing the cathode is located in the formed recess.

[0023] In order to produce at least one main connection between the first and second separators on the one hand and to form a recess for producing the first electrode material of the cathode on the other hand, a second ultrasonic oscillator, in particular a rod-shaped ultrasonic oscillator, is used, which has a head diameter of between 4 mm and 8 mm. The at least one main connection designed as an ultrasonic weld is produced with a width of between 0.3 mm and 1.2 mm by the second ultrasonic oscillator. A sufficient width is thus produced. The width provides a resistance against shrinkage of the separator in the event of a puncture, and a sufficient resistance against metallic or electrically conductive particles penetrating from the outside into the produced recess that could cause a short circuit. The at least one main connection can be designed either continuously or interrupted, for example, in a dotted manner, wherein the at least one fastening seam is designed continuously because the length of the at least one fastening connection is relatively small compared to the at least one main connection.

[0024] When producing the recess for the first electrode material for producing the cathode, the distance between the inner edge of at least one fastening edge relative to the outer edge of the first electrode material for producing the cathode is advantageously selected such that a highly precise cathode fastening occurs in the separator recess.

[0025] If the spacing is minimized, the overlap between the first electrode material for the cathode and the second electrode material for the anode can be reduced, thereby improving the volume utilization. In addition, with reference to the outer edges of the first electrode material for the cathode, the spacing between the inner edges of at least one main connection is obtained in such a way that, in the event of a possible failure of at least one fastening connection, a maximum permissible gap of the first electrode material is present in the produced recess.

[0026] The method proposed according to the invention can prevent the first electrode material for the cathode from shifting or sliding when producing at least one main connection. This significantly reduces waste caused by collisions between the sonotrode and the electrode material. The at least one main connection, which is preferably produced by ultrasonic welding, serves to limit the maximum permissible shift of the first electrode material for the cathode in the event of failure of at least one fastening connection.

[0027] If, as proposed by the invention, the first electrode material forming the cathode is fastened to the first separator, the long tolerance chain that has hitherto occurred during the stacking process is shortened, since the cathode position is very accurate due to the proposed fastening and is independent of the at least one main connection that is subsequently produced. The process of producing the at least one main connection as an ultrasonic weld can be designed to be more robust. The production of the at least one main connection can be triggered from the tolerance chain by the manufacturing method proposed by the invention, since the first electrode material for producing the cathode is retained in its defined position between the separators due to the pre-fastening.

[0028] The method proposed according to the invention can in particular avoid the rotation of the first electrode material used to form the cathode. This in turn can significantly reduce electrochemical degradation mechanisms such as electrolyte aging and lithium deposition in the pores due to uneven current density, especially in the edge regions of the anode and cathode corners themselves that are affected by the rotation of the first electrode material used to form the cathode. Rotating the cathode reduces the distance to the second electrode material used to form the anode. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will now be described in more detail with the aid of the accompanying drawings.

[0030] Figure 1 A battery element, the separator of which is coated with a ceramic material on one side;

[0031] Figure 2 A battery element having a first separator and a second separator, wherein the first separator and the second separator are coated with a ceramic material on both sides;

[0032] Figure 3is a first electrode material applied to the first separator coated on one side;

[0033] Figure 4 is a cross-sectional view of a composite structure consisting of a first electrode material, a first separator, a second separator, and a fastening connection;

[0034] Figure 5 yes Figure 4 A top view of the cross-sectional structure shown in ;

[0035] Figure 5.1 It is a detailed view of the fastening connection;

[0036] Figure 6 is a cross-sectional view of a recessed portion created by a first separator, a second separator, and a first electrode material;

[0037] Figure 7 yes Figure 6 A top view of the structure shown in cross section;

[0038] Figure 7.1 is a magnified view of an edge region of a first electrode material; and

[0039] Figure 8 A four component stack is shown with a second electrode material forming the anode. DETAILED DESCRIPTION

[0040] Depend on Figure 1 Shown is a battery cell 10 which comprises separators 18 , 20 which are coated on one side with a ceramic material 16 .

[0041] according to Figure 1 The battery element 10 of FIG. 1 comprises a first separator 18 and a second separator 20. However, both separators 18, 20 are coated on one side with a ceramic material 16, such as Al2O3 or boehmite. The separators 18, 20 are oriented so that the ceramic material 16 faces the first electrode material 14, which forms the cathode. The second electrode material 38, i.e., the anode, is located above the second separator 20.

[0042] Figure 2 Another battery element 12 is shown, which also includes a first separator 18 and a second separator 20, but in this embodiment variant, they are coated on both sides with a ceramic material 16. The first and second separators 18, 20, which are coated on both sides with a ceramic material 16, accommodate between them a first electrode material 14 for forming a cathode. A second electrode material 38 for forming an anode is arranged above the second separator 20.

[0043] Figure 3A first separator 18 is shown coated on one side with a ceramic material 16. A first electrode material 14 of the cathode is located above the ceramic material 16. x1 or -x1 refers to a first dimension, which represents the width of the first electrode material 14 and refers to Figure 3 The center line shown is defined as the nominal position of the first electrode material.

[0044] What works is: |-x1| = |x1|.

[0045] Figure 4 A first electrode material 14 for producing a cathode is shown, as well as separators 18 , 20 , which are coated with a ceramic material 16 and are connected to one another via a fastening connection 22 .

[0046] Depend on Figure 4 As can be seen from the cross-sectional view of , the first separator 18 receives the ceramic material 16 on its upper side and points to the first electrode material 14 forming the cathode. The second separator 20 covers the first electrode material 14 with a layer of ceramic material 16 that forms the cathode. The first separator 18 and the second separator 20 are made of plastic, such as PE (polyethylene) or PP (polypropylene). Figure 4 As shown, the fastening connection portion 22 extends substantially vertically through the Figure 4 The composite structure shown is created with the aid of a first ultrasonic oscillator 44. The diameter 46 of the head of the first ultrasonic oscillator 44 is between 1 mm and 2 mm, and the width 48 is between 0.1 mm and 0.3 mm, within which at least one fastening connection 22 is designed as an ultrasonic weld. Due to the small diameter 46 of the first ultrasonic oscillator 44, this first ultrasonic oscillator can be guided very closely past the first electrode material 14 forming the electrode without damaging it. Figure 4 It can be seen that at least one fastening connection 22 extends in the edge region 24 of the first electrode material 14 close to the edge 36 of the first electrode material 14. The width 48 of the at least one fastening connection 22 is very thin, but sufficient to fix the first electrode material 14 in place for further processing. Figure 4 The separators 18 or 20 shown in the figure are coated on one side, but also can be used according to Figure 2 A separator 18 or 20 is shown which is coated on both sides.

[0047] Depend on Figure 4As can be seen from the figure, the first electrode material 14 for producing the cathode is now fixed and the risk that the second sonotrode 52 to be used later for forming at least one main connection 26 will collide with and possibly damage the first electrode material 14 is reduced. The first electrode material 14 for producing the cathode is now even more precisely defined in its position than only by the main connection 26. Significantly smaller gaps occur.

[0048] By Figure 5 From the top view, we can see that the cross section runs along IV-IV. Figure 5 As can be seen from the top view of FIG. 1 , the stacked first and second separators 18 and 20 completely cover the first electrode material 14 for preparing the cathode. The outline 34 of the first electrode material 14 is shown by the dotted line. Figure 4 The fastening connection 22 shown in the cross-sectional view of FIG. 2 extends in the corner region of the first electrode material 14. The fastening connection can be as follows Figure 5.1 As shown, it is designed as a semicircle 30 or can also be designed as an L-shape. The fastening connection 22 surrounds the corner area of ​​the edge 36 of the first electrode material 14 that forms the cathode. The contact projection of the first electrode material 14 that forms the cathode is marked with the reference numeral 50, which protrudes laterally from the composite structure composed of the first separator 18, the first electrode material 14 and the second separator 20 and is used for the subsequent contacting of the first electrode material 14. It also applies here that |-x1|=|x1|.

[0049] Depend on Figure 6 It can be seen from the illustration that the recess 28 is formed by producing at least one main connection 26 by means of an ultrasonic welding method.

[0050] At least one main connection 26 is established using a second ultrasonic oscillator 52, which is in particular designed as a rod-shaped ultrasonic oscillator. The second ultrasonic oscillator 52 has a diameter 54 at the head, which is between 4 mm and 8 mm. With the aid of the second ultrasonic oscillator 52, at least one main connection 26 can be produced, the width 56 of which is between 0.3 mm and 1.2 mm. The width 56 of the at least one main connection 26 is selected in such a way that it is wide enough and meets the conditions required for the function of the battery element 10, 12 to be produced, such as counteracting the shrinkage of the separator and counteracting conductive metal particles that penetrate from the outside into the recess 28 and may cause a short circuit. The main connection 26, which is preferably designed as an ultrasonic weld, can be designed both continuously and interrupted, so for example in a punctuated manner, while the at least one fastening connection 22 is designed continuously, which is related to the small gap length of the at least one fastening connection 22, see the press Figure 5 Top view of the .

[0051] In addition, by Figure 6 As can be seen from the cross-sectional view of FIG. 5 , there is a second spacing 60 between the edge 36 of the first electrode material 14 for preparing the cathode and the inner edge 66 of the fastening connection 22. The first spacing 58 refers to the distance between the first electrode material 14 for preparing the cathode and the inner edge 68 of at least one main connection 26. Reference numeral 56 marks the width of at least one main connection 26, which is preferably established as an ultrasonic weld.

[0052] In addition, by Figure 6 The sectional view of the recess 28 of FIG. 2 shows that on the outer side of each main connecting part 26 , the first partition 18 and the second partition 20 have a projection 62 . The projection 62 is in the order of magnitude of 0 mm and 1 mm.

[0053] Figure 7 Shows the Figure 6 The section goes along VI-VI.

[0054] Depend on Figure 7 As can be seen from the top view, the first electrode material 14 for the cathode is completely covered by the two separators 18, 20, which each have a layer of ceramic material 16, as shown in its nominal position |-x1| = |x1|, and is therefore located in the recess 28. The contact projection 50 of the first electrode material 14 protrudes laterally beyond the first and second separators 18, 20 connected to each other. The first electrode material 14 for the cathode is fixed in its position by the fixing connection 22 formed in the corner area of ​​the first electrode material 14, whereas in the press Figure 7 In the illustration of FIG. , the main connection 26 is shown as a continuous ultrasonic weld. Figure 7.1 In the detailed view of FIG. 4 , at least one main connection 26 is shown interrupted. The interrupted main connection 42 can be formed, for example, by spot welding or short build-up welding. Figure 7.1 As can be seen from the detailed view of FIG. 1 , the interrupted main connection 42 is laterally away from the contour 34 of the first electrode material 14. Reference numeral 24 denotes the edge region of the first electrode material 14, see the reference numeral 24. Figure 7 Top view of the .

[0055] Figure 8 A fully constructed four-component stack 64 is shown to produce a battery element 10 or 12 .

[0056] Figure 8 The second electrode material 38 for preparing the anode is placed in the press Figure 6The upper side of the recess 28 is formed. Figure 8 A four-component stack 64 is shown in cross section in FIG. 1 , which is distinguished by highly accurate positioning and is particularly suitable for stacking. Figure 8 As can be seen, the following relationships apply to the positioning of the first electrode material 14, or the position of the inner edge 66 of at least one fastening connection, and the corresponding positioning of the inner edge 68 of the main connection 26, which is preferably configured as an ultrasonic weld: x2 - x1 or x3 - x1.

[0057] If the conditions are met with respect to the first dimension x1 , the second dimension x2 and the third dimension x3 , a highly precisely manufactured four-component stack 64 is present, which can be used to construct a battery cell made of a plurality of battery elements 10 or 12 .

[0058] The difference between the second dimension x2 and the first dimension x1 is formed in the separator recess for the distance between the inner edge 66 of at least one fastening connection 22 and the edge 36 of the first electrode material 14. The distance between the inner edge 68 of at least one main connection 26 and the edge 36 of the first electrode material 14 used to prepare the cathode is used to limit the maximum permissible gap of the first electrode material 14 in the recess 28 in the event of a possible failure of at least one fastening seam, and to maintain the minimum permissible overlap between the first electrode material 14 and the second electrode material 38 that is required for the function. The distance is obtained by the difference between the third dimension x3 and the first dimension x1.

[0059] The method proposed by the present invention shows a two-stage ultrasonic welding method, which fixes the first electrode material 14 forming the cathode and realizes the formation of the recess 28 for accommodating the first electrode material 14. The risk of slipping of the first electrode material 14 for preparing the cathode is greatly reduced. As a result, the waste generated by the collision between the first electrode material 14 and the second ultrasonic oscillation unit 52 can be greatly reduced. In addition, for the case where at least one fixing connection 22 may fail, at least one main connection 26 is used to limit the maximum allowable movement of the first electrode material 14 in the recess 28. However, the main functional task of at least one main connection 26 is to form a resistance to the shrinkage of the separator and the conductive metal particles that appear. At least one fixing connection 22 realizes the precise positioning of the first electrode material 14 for preparing the cathode. By fixing the first electrode material 14 for preparing the cathode, a much more accurate and robust manufacturing process for battery cells 10, 12 is provided. The recess 28 can be trimmed or further processed as required in a subsequent process, so that, for example, the volume utilization of the battery cell to be manufactured can be further improved by trimming the edges of the recess 28. This is possible because the first electrode material 14 forming the cathode can be positioned very accurately by fastening by means of at least one fastening connection 22, and is independent of the actual main connection 26 that is externally located with reference to the at least one fastening connection 22. The establishment of the connection can be constructed more robustly, because it is now ensured that the first electrode material 14 for preparing the cathode is held in its position by at least one fastening connection 22 during the manufacturing process of the recess 28. However, since the establishment of at least one main connection 26 in the ultrasonic welding method can be constructed more robustly and independently of the establishment of at least one fastening connection 22, the tolerance becomes larger and the process can be generally simplified. The establishment of at least one main connection 26 is triggered from the tolerance chain. The entire manufacturing process can be simplified accordingly, and in addition, a higher service life of the first and second ultrasonic oscillation units 44 or 52 used is achieved.

[0060] The invention is not limited to the embodiments described here and the aspects emphasized in the embodiments. Rather, a number of modifications are possible within the scope of the claims, which are within the scope of a person skilled in the art.

Claims

1. A method for producing a battery element (10, 12) of a battery cell, comprising the following method steps: a) applying a first electrode material (14) to a first separator (18) coated with a ceramic material (16); b) applying a second separator (20) coated with the ceramic material (16) to the structure according to method step a); c) producing at least one fastening connection (22) between the first separator and the second separator (18, 20) in an edge region (24) of the first electrode material (14); and d) creating at least one main connection (26) between the first and second separators (18, 20) and spaced from the at least one fastening connection (22), and forming a recess (28) for accommodating the first electrode material (14), The at least one fastening connection (22) is designed to pre-position the first electrode material (14) in a defined manner in its position within the recess (28).

2. The method according to claim 1, characterized in that Method steps c) and d) are carried out by means of a material-fusion joining method.

3. The method according to claim 1, characterized in that After carrying out the method steps a) to d), a second electrode material (38) is applied to the recess (28) and a four-component stack (64) is produced for stacking.

4. The method according to claim 1, characterized in that The at least one fastening connection (22) is designed as a point in a semicircular (30) or L-shaped (32) shape.

5. The method according to claim 1, characterized in that The at least one main connection (26) is designed as a continuous main connection (40) or as an interrupted main connection (42).

6. The method according to claim 1, characterized in that The at least one main connection (26) is at a first distance (58) from an edge (36) of the first electrode material (14), the first distance exceeding a second distance (60) between the edge (36) of the first electrode material (14) and the at least one fastening connection (22).

7. The method according to claim 1, characterized in that The first separator (18) and / or the second separator (20) are coated on one side or both sides with the ceramic material (16).

8. The method according to claim 1, characterized in that The at least one fastening connection (22) is produced by means of a first ultrasonic oscillation unit (44), the head of which has a diameter (46) between 1 mm and 2 mm, and the width (48) of the at least one fastening connection (22) is between 0.1 mm and 0.3 mm.

9. The method according to claim 1, characterized in that The at least one main connecting portion (26) is produced by a second sonotrode (52), the head of which has a diameter (54) between 4 mm and 8 mm, and the width (56) of the at least one main connecting portion (26) is between 0.3 mm and 1.2 mm.

10. The method according to claim 1, characterized in that A second distance (60) exists between an inner edge (66) of the at least one fastening connection (22) and an edge (36) of the first electrode material (14) in the recess (28).

11. The method according to claim 1, characterized in that A first distance (58) exists between an inner edge (68) of the at least one main terminal (26) and an edge (36) of the first electrode material (14) in the recess (28).

12. The method according to claim 2, characterized in that Method steps c) and d) are performed by an ultrasonic welding method.

13. Use of a battery element (10, 12) manufactured according to the method according to any one of claims 1 to 12 in a power battery of an electric vehicle or a hybrid vehicle.

14. The use according to claim 13, characterized in that The hybrid vehicle is a plug-in hybrid vehicle.

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