Method and apparatus for manufacturing a cell stack for a battery cell

Abstract

The invention relates to a method and a device for manufacturing a battery stack for a battery unit, in particular to a method for manufacturing a battery stack for a battery unit, having at least the following steps: a) supplying at least one first material web composed of a first material; b) carrying out a first cutting at the at least first material web (3) in the context of constructing at least one tensile-resistant strip-shaped transport section; c) gathering the first material web with at least one second material web composed of a second material into a sub-stack; d) fastening the thus produced sub-stack at a first fastening location by means of a movable first clamping device, e) supplementing the at least one material web and fastening the thus produced sub-stack at a second fastening location by means of a movable second clamping device, f) carrying out a second cutting of the fastened sub-stack, wherein the transport section is detached; g) releasing the clamping devices, h) arranging the at least two sub-stacks into one battery stack.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for manufacturing a battery stack for battery cells. Background Technology

[0002] In the prior art, it is known that battery stacks for battery cells are manufactured in such a manner that individual facilities are used to separate the cathode layer, anode layer, and separator layer. The layers manufactured in this manner are then provided individually and separately in a sump and, in the case of a single-layer stack, individually positioned and oriented during stacking. This process of manufacturing battery stacks requires a very high cycle time.

[0003] Another known method is the so-called Z-fold, in which a separator layer is wound around the individual electrode layers, which, in turn, must be pre-separated and positioned in the upstream process steps. Similarly, the Z-fold enables only relatively slow cycle times.

[0004] Furthermore, it is known that the layers are stacked using a lamination process. For this, it is necessary to laminate the cathode and anode layers with a separator film. However, the required laminateable separator film is relatively expensive.

[0005] Current designs have various drawbacks. Therefore, battery stacking is currently a very slow process in the production of battery cells. Similarly, maintaining the necessary positional tolerances is currently only achievable with considerable difficulty in the short cycle time of stacking. Furthermore, the separate preparation, subsequent storage, aggregation, stacking, and connection of the individual layers for the battery stack require a series of process steps, which correspondingly demand complex handling of materials. In addition, the large number of process steps necessitates greater costs in facility technology and allows for only relatively slow cycle times. Summary of the Invention

[0006] Therefore, the object of this invention is to at least partially solve the problems arising from the prior art. In particular, a method and apparatus for manufacturing battery stacks for battery cells, which can be done particularly quickly, should be described. Furthermore, the positional accuracy of the material webs used should be improved and the cost of the facility technology should be reduced.

[0007] The features listed individually in this invention may be combined with each other in a technically meaningful manner and may be supplemented by the facts described in the specification and / or by the details in the drawings, wherein further embodiments of the invention are described.

[0008] This document proposes a method for manufacturing a battery stack for battery cells, comprising at least the following steps:

[0009] a) Supply at least one first material sheet made of the first material;

[0010] b) In the case of constructing at least one tensile strip-shaped transport section, a first cut is performed at least on the first material width;

[0011] c) Assemble the first material sheet with at least one second material sheet made of the second material into a sub-stapel;

[0012] d) Secure the resulting sub-pile in the first fastening position by means of a movable first clamping device.

[0013] e) Supplement at least one material sheet and secure the resulting sub-pile at a second fastening position by means of a movable second clamping device, thereby automatically securing the protrusion of one material from another.

[0014] f) Perform a second trimming of the secured sub-staples, in which the transport section is disassembled.

[0015] g) Release the clamping device.

[0016] h) Arrange at least two sub-piles into a battery pile.

[0017] Steps a) through g) may be performed at least once in the order described herein: a), b), c), d), e), f), and g). It is possible that these steps may be performed at different frequencies and / or at least partially overlapping in time.

[0018] Here, in method steps a) and b), at least one first material sheet with a first material and a second material sheet with a second material are first supplied. The corresponding material sheets can be selected, for example, for use as an anode, cathode, or separator in a battery cell. For the anode, for example, a substrate made of a copper-containing material and an anode active layer coated thereon are provided. Correspondingly, an aluminum-containing material is suitable as a substrate for a cathode active layer coated thereon. For the separator, for example, flexible microporous plastic or felt is considered.

[0019] The material width can preferably be supplied by a storage device (e.g., a reel or roll) with a large width length, thereby enabling continuous and uninterrupted operation of the method over a longer period of time.

[0020] If, for example, a first material web suitable for the manufacture of anodes is supplied, this web can undergo a first cut at a first cutting device, wherein the cut is performed such that at least one tensile conveying section is retained. Here, the conveying section should be constructed such that it can withstand tensile forces in the longitudinal direction of the material web. This allows the material web to be processed as a continuous material web in an immediate step, because the force necessary for continued conveying can be introduced into the conveying section.

[0021] Simultaneously, a second cut is performed on the second material section, thereby forming a conveyor section on that material section, suitable for bearing the forces required for continued conveying and further processing. Here, however, the conveyor section of the second material section is formed such that it is arranged laterally, that is, laterally and transversely to the longitudinal direction of the material section, offset relative to the conveyor section of the first material section, immediately after the material section is assembled. This makes it possible to perform the cutting of different material sections independently.

[0022] In a further step of the method, the first and second material sheets (e.g., partitions) cut in this way are then assembled into sub-piles. In particular, the second material sheet of the partition is also pre-reserved in a storage device (e.g., as a partition roll), thereby allowing the first cutting process and the assembly of the first and second material sheets to be performed at a high speed. Besides the optional lateral offset arrangement of the dividing cuts, these cutting cuts can also be positioned at different locations along the longitudinal direction of the material sheets according to the invention. This makes it possible to cut material sheets of different lengths in a continuous manufacturing process.

[0023] In step d), the sub-piles, which are still being supplied indefinitely, are first clamped by a first clamping device and then by a second clamping device. Here, the first clamping device prevents relative movement of the material webs within the clamping area. The second clamping device similarly clamps the material webs together. In the case of the second clamping device, however, at least one additional material web is added in step e) of the method for this purpose. That is, the extra length of this material web is extracted from the storage device, so that the material web is processed with a length greater than that of the unadded material web. This allows the manufacture of sub-piles from multiple material webs, in which different material webs may have different lengths when viewed in their transport direction.

[0024] After gathering, clamping, and replenishing, the sub-pile thus secured by the clamping device in step f) is then supplied for a second cut.

[0025] Therefore, a second cutting of the sub-stacking device can be achieved at the second cutting device, wherein the corresponding conveying section is then separated or laterally cut by the sub-stacking, thereby producing complete separation of the sub-stacking in the lateral direction.

[0026] The two sub-stacking layers thus generated and separated have, for example, an anode and a separator, and can be arranged, for example, with another two sub-stacking layers consisting of a cathode and a separator to form a battery stack.

[0027] Alternatively, multiple material sheets, as an alternative to the two material sheets described, can also be assembled after the first cut and then subjected to a second cut. In particular, the use of four material sheets in the order of anode, separator, cathode, separator or cathode, separator, anode, separator is advantageous here, because the sub-stacking of these four layers can be directly stacked on top of each other so frequently that the battery stack has the required number of anodes and cathodes.

[0028] In step g), the first and second clamping devices are then released to release the resulting sub-piles that are now separated from each other. Preferably, the second clamping device is released first, and then either the first or second clamping device. This has the advantage that the first clamping device prevents unintentional movement of the material webs relative to each other until the second clamping device is released and the material webs clamped therein are once again placed flat on top of each other. In the case of the material webs clamped by the second clamping device returning, the rear cutting edges, such as supplementary partitions, then move backward in their conveying direction beyond the ends of the sub-piles, when they are once again placed flat on the material webs below them.

[0029] Thus, the partitions extend beyond the outer edges of the cathode and anode and can be reliably electrically insulated from each other. It is equally possible, if needed, to design a second clamping device that, in addition to the partitions, can also supplement an electrode, such that one electrode is longer than the other. Therefore, for example, a four-layer sub-stacking structure can be manufactured, in which the anode is larger than the cathode. Simultaneously, the two partitions can be larger than not only the anode but also the cathode.

[0030] In step h), the finally separated sub-piles are arranged to overlap each other until they have a battery pile with the desired height.

[0031] The described method allows for the very rapid and precisely positioned fabrication of battery stacks with significantly shorter manufacturing times compared to known methods. Furthermore, the defined material profiles (e.g., separators) can extend not only laterally but also longitudinally along the edges of the anode and cathode, and despite this, fabrication can be carried out at very high speeds in a continuous, uninterrupted manufacturing process.

[0032] In particular, the second clamping device can be arranged longitudinally between the first clamping device and the supplied material web. This ensures that the length of the supplementary material web is supplied either from the supplied material web or from its storage device.

[0033] In particular, it is possible to observe the supply longitudinally as follows, i.e., the front and rear edges of at least one material sheet produced in the first cut extend beyond the front and rear edges of the adjacent material sheet.

[0034] In particular, it is equally advantageous that the second clamping device is released in time before the first clamping device in order to release the clamping device, thereby avoiding unintentional supplementation of the material width from its front end in the conveying direction.

[0035] For this purpose, it is particularly advantageous when the first and second clamping devices move together with the sub-staples in a synchronized motion. Thus, a continuous manufacturing process can be achieved while maintaining the same conveying speed.

[0036] For reliable insulation of the anode and cathode, it is also advantageous when the first and second material widths are cut to different sizes.

[0037] In particular, it is possible to use material sheets of different sizes, at least in the lateral direction. Here, for example, the first and second material sheets can be cut to different sizes or already have the desired width in the provided state. For the safety of the battery cell, it is necessary that the separator extends sufficiently beyond the anode or cathode to be insulated in all directions to reliably prevent current from flowing between the two material sheets. Here, the separator should extend approximately 3 mm beyond the cathode and approximately 1.5 mm beyond the anode. This, for example, means that the separator should be approximately 6 mm larger than the cathode and approximately 3 mm larger than the anode.

[0038] These different dimensions can preferably be produced in the first cut using a first cutting device that performs a separate cut for each material web. For this purpose, for example, the cathode is cut to the desired width plus the required width of the conveying section. Simultaneously, the anode is cut to the desired width plus a 3mm allowance, as the anode should preferably be larger than the cathode. Finally, the partition is cut to the desired width plus an allowance of about 6mm for the cathode width. It should be noted that transverse cuts can also be incorporated into all three material webs. It is important that at least one conveying section is always retained, suitable for bearing and / or transmitting tensile forces acting in the longitudinal direction of the material web. In all width dimensions, the width of the conveying sections to be separated again is considered accordingly. If the sides of the material webs are oriented relative to each other at this point, these material webs can be aggregated and a second cutting device can be supplied for a second cut to obtain subsequently spaced sub-piles that can be stacked together.

[0039] Particularly advantageously, a window section can be created in at least one material sheet, selected such that the dividing cut of the conveyor section of at least one other material sheet is located within this window. This is preferably already achieved in the case of the first cut, where, for example, a smaller window or hole is brought into the material sheet, where the drive subsequently used for continued conveying can act or engage with a pin, drive wheel, or the like. If the position of the window of one material sheet and the dividing cut of the conveyor section of another material sheet are selected such that they are located within the window of the other material sheet, the strip-shaped conveyor section in the window area and the material sheet to which it is attached can be separated independently from the other material sheet at that position. For this purpose, for example, an existing but not yet continuous transverse dividing cut only needs to be extended to the edge of the material sheet. This feature thus creates the possibility of cutting two material sheets that are indirectly or directly overlapped with each other independently. Here, the position of the dividing cut can be different not only in the transverse direction of the material sheet but also in the longitudinal direction.

[0040] In particular, as previously described, after the second trimming, at least two sub-piles can be arranged (together) into a single battery pile.

[0041] In particular, the sub-stacking can be composed of at least four material webs. Here, a combination of material webs in the form of two electrodes and two separators is especially advantageous. If possible combinations of these material webs are formed, the sub-stackings thus produced can be arranged stacked on top of each other up to the required height of the battery stack, where only the addition of a separator as the first or last material web is necessary.

[0042] If, for example, a combination of anodes, partitions, cathodes, and partitions arranged on top of each other is chosen, then a single partition must be placed at the beginning of the sub-stacking arrangement, because otherwise the anodes at the bottom will not be insulated.

[0043] Conversely, if a combination of material width partitions, anodes, partitions, and cathodes arranged in an overlapping order is chosen, then a single partition is placed at the end of the sub-stacking arrangement, because otherwise the cathode at the top is not insulated.

[0044] In particular, in this cutting case, conductive markings can be constructed at at least two material sections. This is especially true at the anode and cathode material sections. It is possible here that the conductors are constructed completely and without additional cost in the first and second cuts in such a way that only the appropriate cut contours are selected.

[0045] In particular, the battery stacks manufactured according to the current method can be connected into a battery pack in an immediate method step using connecting devices (such as straps or tapes). This additional step can be readily incorporated into the current method as an additional method step.

[0046] For automated arrangement, it is particularly advantageous to arrange at least one additional material sheet in the battery stack when the sub-staples are arranged into a battery stack. As previously described, this material sheet may be brought into the battery stack at the bottom of the battery pack and thus at the start of the sub-staple arrangement, or at the top of the battery pack and thus at the end of the sub-staple arrangement.

[0047] Battery cells with manufactured battery stacks have the advantages of being able to be manufactured at low cost and having their individual material sections precisely positioned relative to each other due to automated and continuous processing. This reduces costs and improves the lifespan or reliability of the battery cells.

[0048] In particular, this also applies to motor vehicles with at least one battery unit.

[0049] According to another aspect, an apparatus for manufacturing a battery stack is proposed, comprising at least two storage devices for at least one first material web and a second material web, at least one first and a second cutting device for cutting the material web, a conveying device for conveying the material web, a device for aggregating the material web, and a stacking device. Here, a first fastening device is disposed at a first fastening position and a second fastening device is disposed at a second fastening position, wherein the fastening device is additionally configured as a supplementary device for at least one material web.

[0050] In particular, it is also possible to configure the second fastening device as a supplementary device and arrange it between the first fastening device and the storage device.

[0051] Furthermore, it is more advantageous to configure the fastening device to be connected to the drive unit and to be moved synchronously with the material width.

[0052] In particular, the fastening device and at least the second cutting device can be configured such that the fastening device can pass through the second cutting device in the closed state. This ensures reliable fastening of the material webs to each other at every moment and, consequently, high positioning accuracy of the material webs.

[0053] A particularly simple implementation can be made by means of at least three guide elements that can be moved in groups.

[0054] Furthermore, the first cutting device can be configured to split at least one material sheet into multiple material sheets parallel to the longitudinal direction. This allows for the processing of wider material sheets, for example, within the first cutting device. Preferably, a first cut is performed first, followed by the material sheets being divided to the desired width. Thus, a material sheet, for example, twice the width of the desired partition, can be cut. If this wider material sheet is divided into two material sheets for the partition during the first cut, these two material sheets can be processed continuously and uninterruptedly, for example, immediately in the case of a sub-stacking assembly, along with the two electrodes and the two partitions.

[0055] The description of the apparatus or method above and / or the suitability described therefor may be applied selectively or in coordination with each other.

[0056] It should be noted that the numerals used herein (“first,” “second,” …) are preferably used (only) to distinguish multiple similar objects, dimensions, or processes, i.e., especially when the relationship and / or order of these objects, dimensions, or processes to each other is not necessarily given in advance. If such relationship and / or order is necessary, it is described in detail herein or is clearly derived by a professional in the context of a study of the specific design scheme described. Attached Figure Description

[0057] The invention and its technical scope will be further described below with reference to the accompanying drawings. It should be noted that the invention should not be limited to the listed embodiments. In particular, it is equally possible, as will be shown without exhaustive detail, to extract certain aspects of the actual situation illustrated in the drawings and combine them with other components and knowledge according to this specification. It should be noted in particular that the dimensions shown in the drawings are merely illustrative. Wherein, illustratively:

[0058] Figure 1 : Shows a cross-sectional view of the side of the first cutting device for the anode;

[0059] Figure 2 : Shows the orientation according to Figure 1 A top view of the cutting device;

[0060] Figure 3 : Shows a top view of the anodized surface after the first cut;

[0061] Figure 4 : Shows a top view of the cathode after the first cut;

[0062] Figure 5 : Shows a cross-sectional view of the side of the first cutting device for the partition;

[0063] Figure 6 : Shows a top view of two possible cuts for the partition;

[0064] Figure 7 This shows the possible combinations of the four material sheets;

[0065] Figure 8 : Shows a side view of the process from the gathering of the material sheet;

[0066] Figure 9 : Shows a top view of the four gathered material sections;

[0067] Figure 10 This demonstrates the operation of the first clamping device;

[0068] Figure 11 This shows the closure of the first clamping device;

[0069] Figure 12 This demonstrates the operation of the second clamping device;

[0070] Figure 13 This shows the closing of the second clamping device;

[0071] Figure 14 : Shows a side view of the cam driver;

[0072] Figure 15 : Shows a cross-sectional view of the cam passing through the cam driver;

[0073] Figure 16 The top and side views show the first, second, and third clamping devices.

[0074] Figure 17 : Shows a top view of the second cutting device;

[0075] Figure 18 : Shows a perspective view of the first roller of the second cutting device;

[0076] Figure 19 This shows a cross-sectional view of the side of the second cutting device;

[0077] Figure 20 The top and side views show the second cutting device and two hoppers.

[0078] Figure 21 The side view shows the third clamping device, the holding device, and the material magazine.

[0079] Figure 22 The image shows a top view of a conveyor belt carrying both completed and uncompleted battery packs.

[0080] Figure 23 : Shows a side view of the first step in attaching the battery stack;

[0081] Figure 24 This shows a side view of the second step in attaching the battery stack;

[0082] Figure 25 : Shows a side view of the third step used to attach the battery stack;

[0083] Figure 26 This shows a side view of the fourth step in attaching the battery stack;

[0084] Figure 27 : Shows a side view of the storage of battery packs on the conveyor belt;

[0085] Figure 28 : Shows a top view of the completed battery pack; and

[0086] Figure 29 This shows an alternative implementation of the second cutting device. Detailed Implementation

[0087] exist Figure 1 The first cutting device 1 is shown in a side view. Figure 1On the left side, there is a first storage device 2, which stores a first material web 3. The first storage device 2 may be, for example, a prefabricated unit comprising, for example, a calendered master roll with the first material web 3 for the anode 7 of the battery cell 8. The calendered and wound first material web 3 has a particularly uniform layer thickness, and the first cutting device 1 is supplied under a defined tension that is as constant as possible to avoid folds in the first material web 3. The first cutting device 1 consists of a lower roller 4, an upper roller 5, and a punching unit 6. The cutting performed in the first cutting device 1 will be further described below. In the embodiment shown here, the first material web 3 has a width selected such that the material web 3 can be split longitudinally during cutting, thereby simultaneously forming two first material webs 3a, 3b in the first cutting device 1, which can then be further processed. An alternative embodiment shown here, in which the first material sheet 3 has a width corresponding to twice the width of the cut first material sheets 3a, 3b, can also be readily used, corresponding to a single or multiple times the width of the cut first material sheets 3a, 3b. In the second case, the corresponding plurality of dividing cuts must be arranged longitudinally on the material sheet 3. For performing the cutting, the lower roller 4 can be made of, for example, a hardened material, such as tungsten carbide or chromium steel. The punching unit 6 is constructed in a stamping form, suitable for punching holes into the corresponding separate first material sheets 3a, 3b.

[0088] exist Figure 2 The image is shown in top view format according to Figure 1 The first cutting device 1. A first storage device 2 arranged on the left, from which a first material web 3 is supplied to the right to the lower roller 4 shown. The first material web 3 has an anode region 9 and an edge 10. The anode region 9 is coated with a material suitable for use as a subsequent anode 7 in the battery cell 8 (the so-called anode active layer). The substrate of the anode is preferably copper. It can be well recognized here that the first material web 3 is twice as wide as the first material webs 3a, 3b after the first cut. The lower roller 4 has a rotating blade 11 that brings a longitudinal cut 12 into the material web 3 in the middle. Immediately afterwards, a punching unit 6 produces receiving holes 13, which form the defined starting positions of the material web 3 or the separate material webs 3a, 3b.

[0089] Figure 3An alternative embodiment of the invention is shown, in which the first cutting device 1 performs a more complex cut on the first material web 3. In this embodiment, in addition to the longitudinally extending longitudinal slit 12, the laterally extending dividing slit 14, window slit 15, two-piece conductive slit 16, and conveying hole 17 are brought into the first material web 3 by the first cutting device 1 during the first cut. For this, it is only necessary that the rotating blade 11 arranged in the lower roller 4 is designed with a corresponding cutting profile.

[0090] It is important here that edge 10 is not completely cut off in the transverse direction. Only through continuous connection can edge 10 function as a conveying section 18 and bear and transmit tension in the longitudinal direction of the first material web 3. Such conveying force can be transmitted to the conveying section 18, for example, by means of rollers. Alternatively, mechanical elements can also be engaged in the conveying holes 17, and thus the first material web 3 is conveyed continuously, rapidly, uninterruptedly, and with high precision.

[0091] Furthermore, the window 19 brought in by the window cutout 15 is important to the present invention because the material sheet below or above it can be cut through the window 22.

[0092] The slit 14, which has been brought in at this location, is brought in longitudinally at a spacing of X+Δ1. This means that the anode 7, which is subsequently completed, has a length of X+Δ1. Accordingly, the width 21 of the anode 7 has a dimension of Y+Δ1, which roughly corresponds to the width of the section of the conductor slit 16 that is away from the edge 10 and located inside it. The two transverse sections of the conductor slit 16, arranged side by side in the transport section 18, define the width of the conductor 25 to be produced from the electrode (in this case, the anode 7). While the receiving hole 13 is only needed when the material web 3 is initially provided, the transport hole 17 is continuously, that is, throughout the entire manufacturing process, used not only to transmit driving force but also for very precise positioning of the material web 3.

[0093] Figure 4 This shows the second material sheet 22 that has undergone the first cut, which is approximately the same as the previous one. Figure 3The cutting is consistent with that described in the figure. The difference in the embodiment shown in the figure is that it is the cathode 23. For this purpose, the second material web 22 is first supplied to the first cutting device 1 of the second storage device 26. It is particularly efficient here when multiple first cutting devices are used in parallel so that, for example, the first cutting is performed simultaneously at the first material web 3 of the anode 7 and the second material web 22 of the cathode 23. In order to be used as the cathode 23, the transport section 18 with the edge 10 and the cathode region 24 are made of a material suitable for the cathode 23 of the battery cell 8. For this purpose, for example, an aluminum-containing substrate is considered as a carrier for the cathode active material. Another difference from the anode 7 is that the length and width 21 of the cathode 23 in the longitudinal direction 20 are slightly smaller than the length and width 21 in the longitudinal direction 20. Figure 3 The width 21 of the anode 7. In the embodiment shown, the anode 7 is larger than the cathode 23 by a difference dimension Δ1. This applies not only in the longitudinal direction 20 but also in the direction of the width 21.

[0094] The separate second material sheets 22a and 22b formed after the first cut can then be processed directly and separately from each other.

[0095] exist Figure 5 The diagram shows another first cutting device 1, which is supplied with a third material web 27 by a third storage device 28. The third material web 27 is a partition 29, which has insulating properties and is suitable for electrically insulating the anode 7 and cathode 23 from each other. The third material web 27 is then subjected to a first cut by means of a lower roller 4 and an upper roller 5. Similarly, a punching unit 6 is provided for constructing receiving holes 13.

[0096] Figure 6 A lower view towards the lower roller 4 is shown in the upper region, where the punching unit 6 is not shown. In this embodiment, the lower roller 4 is equipped with a rotating blade 11 configured to bring in a transverse dividing cut 14 at a defined location on the third material web 27. However, this dividing cut 14 does not extend across the entire width of the third material web 27, but instead leaves an edge 10. Thus, tensile-resistant conveying sections 18 are formed on both sides of the third material web 27 in the edge 10, thereby enabling further machining of the third material web 27 in a continuous and uncut state. Furthermore, receiving holes 13 are brought into the third material web 27 by the punching unit 6 (not shown in the figure).

[0097] exist Figure 6A variant configuration is shown in the lower region, in which the third material width 27 is twice the width required for the separator 29 in the battery cell 8. In this case, the lower roller 4 can be constructed, for example, such that it makes longitudinally extending longitudinal cuts 12 in addition to the transverse dividing cuts 14, and the third material width 27 is divided into two halves according to length. For the safe operation of the battery cell 8, it is advantageous when the separator 29 is larger than the anode 7 or cathode 23 to be insulated. Thus, the separator 29 is cut from the previously described basic dimensions X and Y of the cathode 23 to a width of Y+Δ2 and a length of X+Δ2. Here, Δ2 is the excess that the separator 29 should have when it is larger than the cathode 23.

[0098] exist Figure 7 The diagram shows four material sheets that should be stacked on top of each other to form a sub-pile. Here, from bottom to top, they are anode 7, partition 29, cathode 23, and another partition 29. All material sheets have undergone their first trimming in the shown configuration.

[0099] exist Figure 8 The following method steps are shown in a side view. From the left, correspondingly after the first cut, the first material sheet 3, the second material sheet 22, and two third material sheets 27 are supplied in such a manner that the third material sheets 27 are arranged between the first material sheet 3 and the second material sheet 22, and the additional third material sheets are on top of the second material sheet 22. Here, the four material sheets 3, 27, 22 are gathered into a sub-pile 31 via a guide device 30. A first clamping device 32 operates at the right end of the sub-pile 31, and a second clamping device 33 operates at the left end. The operating principles of the clamping devices 32 and 33 will be described in more detail below. Continued transport of the sub-pile 31 in the longitudinal direction 20 is achieved by a transport pin 34, which engages with the transport holes 17 of the first material sheet 3 and the second material sheet 22. The transport pin 34 is driven by a drive device (not shown) and applies driving force to the corresponding transport section 18. For the initial supply of the material sheet, a receiving pin 35 is provided, which engages in the receiving hole 13 and is thus coordinated, i.e., the newly supplied material sheet and its cut profile are precisely supplied in the defined position by the first cut. In a further process, a cam drive 36 is coupled thereto, which is designed on the one hand to drive the delivery pin 34 or the receiving pin 35 and on the other hand to allow easy passage of the first clamping device 32 and the second clamping device 33 to the position shown further to the right, where the third clamping device 37 is provided to the sub-staple 31.

[0100] As shown above Figure 9 Shown again in top view format according to Figure 8The sub-stacking unit 31. Here, the first clamping device 31 and the second clamping device 33 can be clearly identified. It can also be clearly identified here that the conveying section 18 of the anode 7, cathode 23 and partition 29 is arranged in a transverse direction, that is, offset in the transverse direction. This causes in particular that the conveying section 18 of partition 29 is completely within the window 19 in the anode 7 or in the cathode 23. To persistently ensure the correct transverse orientation of the material width, a monitoring device 38 is provided, which may be configured, for example, for position recognition of the width control of partition 29 or optical width edge adjustment.

[0101] Figure 10 The first clamping device 32 is shown in a cross-sectional view along the longitudinal direction 20 of the sub-staple 31. In the case where the first clamping device 31 is provided, two clamps 39 are brought into position above and below the sub-staple 31.

[0102] exist Figure 11 The diagram shows the first clamping device 32 in the closed state, in which the clamps 39 move relative to each other and securely clamp the sub-staples 31. This ensures that, in the case of subsequent processing, no relative movement occurs between the material webs 3, 22, 27.

[0103] Figure 12 The second clamping device 33 is shown on the upper left in the open state and on the upper right in the closed state. When the second clamping device 33 is in place, a plurality of clamps 39 are pushed in from the side between the material webs 3, 22, 27. After this is achieved, the clamps 39 are moved relative to each other to close the second clamping device 33.

[0104] As in Figure 13 As shown, the clamps 39 are constructed differently in this embodiment of the second clamping device 33. Therefore, there are clamps 39 with a circular cross-section and clamps 39 with a rectangular cross-section. If the clamps 39 are moved relative to each other, the circular clamps 39 are surrounded by the corresponding material webs (in this case, the two third material webs 27 of the partition 29) to an increasing degree. This results in the additional travel length of the third material webs 27 required for this enclosure being supplemented externally. If the first clamping device 32 is closed first, followed immediately by the second clamping device 33, the loose end of the third material web 27 located at the rear left end of the sub-stacking 31 is supplemented longitudinally 20 and then pulled forward or to the right in the image plane.

[0105] Figure 14The sub-pile 31 with the supplemented partition 29 is shown after passing through the cam drive 36. Here, the conveying pin 34 is removed and engaged with the opposing cam 40 and the sub-pile 31. The sub-pile 31 continues to be conveyed longitudinally 20 by the rotation of the two cams 40 of the cam drive 36. The second conveying pin 34 is shown in a retracted state in the upper cam 40 and is not yet engaged with the sub-pile 31.

[0106] exist Figure 15 The cam 40 of the cam driver 36 is shown in cross-sectional view. The cam 40 has a removable feed pin 34 and a groove 41. When the feed pin 34 is engaged in the feed hole 17 of the material web, the groove 41 allows the first clamping device 32 and the second clamping device 33 to easily pass through the cam 40. The movement of the feed pin 34 can be controlled in a particularly simple manner by means of a bend 42, in which the plate 43 connected to the feed pin 34 is pressed against the bend 42 by means of a spring 44. Here, the bend 42 is constructed such that the feed pin 34 is only moved out precisely when there is a possibility of engagement with the feed hole 17 during the rotational movement of the cam 40.

[0107] Figure 16 The sub-stacking 31 in the case of passing the cam drive 36 is shown in top and side view form. A first clamping device 32 and a second clamping device 33 are placed here. Here, the transverse dividing cut 18 in the partition 29 is shown both as a dashed line and as a solid line. The dashed line shows the position of the dividing cut 18 before the first clamping device 32 and the second clamping device 33 are provided. Here, the first clamping device 32 is provided first, followed immediately by the second clamping device 33. Thus, the additional stroke length required for the partition 29 in the case of providing the second clamping device 33 can be supplemented only by the left side, that is, by the third storage device 28. Based on this additional supplemented stroke length, the dividing cut 18 shown as a dashed line is shifted to the right to the position of the dividing cut 18 shown as a solid line. This means that a larger length of the third material web 27 is given in the continuous manufacturing process, compared to the lengths given by the first material web 3 and the second material web 22 by the first storage device 2 and the second storage device 26. This makes it possible that, in its completed state, the partition 29 extends not only laterally over the anode 7 and cathode 23, but also longitudinally over the longitudinal direction 20, thus ensuring safe and reliable insulation. Figure 16The lower region again shows a side view of the section shown above. Here it is evident how the second clamping device 33 increases the stroke length of the partition 29 when in its positioned state. Similarly, it is clearly evident in this view that the conveying sections 18 of the three material webs 3, 22, 27 are arranged clearly separated from each other laterally. Furthermore, the conveying sections 18 of the partition 29 are positioned so internally, that is, away from the edge 10, that is, within the window 19. This laterally offset arrangement of the conveying sections 18 has several advantages. Therefore, the conveying pin 34 can engage with the conveying hole 17 of the anode 7 on one side and with the conveying hole 17 of the cathode 22 on the opposite side. The two material webs 3, 22 can thus be driven synchronously in such a way that the necessary driving force, generally introduced as tension, is transmitted to the material webs 3, 22.

[0108] Another advantage of the lateral offset arrangement of the conveyor section 18 can be obtained when the conveyor section 18 of the material webs 3, 22, 27, such as the conveyor section 18 of the partition 29, is arranged such that the conveyor section is located above at least one window 19 of the adjacent material webs 3, 22, such as the anode 7 or the cathode 23. In this embodiment, it is possible to separate the partition 29 at any position within the window 19. More precisely, for this purpose, its conveyor section 18 is cut laterally at a freely selectable position within the window 19. For this purpose, the dividing cut 14 brought into the partition 29 by the first cutting device 1 in the first cut must be positioned accordingly within the window 19. If this is achieved as shown in the figures, the conveyor section 18, which is still present in the partition at this time, can be very easily cut laterally in such a way that the dividing cut 18 is extended to the side edge of the partition 29. This can be very easily performed by means of a second cutting device 45, which is configured, for example, as a rolling stamping device or a rolling cutting device. In the case of this second cut, it is also possible to perform other cuts, such as free cutting of the conductor 25 by extending the conductor cut 16 to the edge, or separation of the side conveying sections 18 of the anode 7 and cathode 23 by cutting in the longitudinal direction of the sub-staple 31.

[0109] exist Figure 17The second cutting device 45 is shown in top view. A second cut is performed by means of this second cutting device 45, in which the sub-staples 31 are also separated laterally. Here, the conveyor section 18 used up to this point is separated. In the state shown here, the sub-staples 31 are simultaneously held by first, second, and third clamping devices 32, 33, 37 (not shown). Here, the dividing cut 14 is moved to the right from the starting position shown by the dashed line to the position shown by the solid line due to the second clamping device 33.

[0110] The second cutting device 45 has a first roller 46 and a second roller 47, which work together with a mating roller 48. Here, the first roller 46 cuts one side of the anode 7 and the partition 29. The second roller 47 cuts the other side of the cathode 23 and the partition 29. The cutting of the partition 29 is achieved by extending the dividing cut 14 laterally through the partition 29 in the area of ​​the window 19, thereby forming individual partitions 29 divided longitudinally by the endless partition 29. It is only through the window 19 that the partition 29 can be cut separately from the electrode.

[0111] Furthermore, the anode 7 and cathode 23 are cut in such a manner that the corresponding conductive cut 16 is extended laterally outward toward the edge 10 by the first roller 46 or the second roller 47, or is cut by a longitudinal cut extending in the longitudinal direction. The strip 49 is then separated by the longitudinal cut. Both cuts (that is, both laterally and longitudinally) can also be made simultaneously.

[0112] Figure 18 The first roller 46 is shown in enlarged view. Here, the roller 46 has a groove 41, through which the first and second clamping devices can easily pass. Furthermore, a separating blade 50 for extending the dividing slit 14 into the partition 29 and a conductive blade 50 for extending the conductive slit 16 are provided.

[0113] In addition, a radially arranged blade may be provided at one of the rollers 46, 47, 48 to facilitate separating the strip 49 in the same working process.

[0114] exist Figure 19The image again shows a first roller 46 together with the mating roller 48, with a sub-staple 31 between them. Not only the mating roller 48 but also the first roller 46 has a groove 41 to facilitate easy passage of the first clamping device 32 and the second clamping device 33. Furthermore, the first roller 46 has a conveying pin 34 that engages with the conveying section 18 of the anode 7 or cathode 23 and is used for safe conveying, provided the conveying section 18 has not been separated. For performing a second cut, the first roller 46 has a separating blade 50 and two conductive blades 51, with a dividing slit 14 that can be extended into the partition 29 and the conductor 25 can be removed.

[0115] exist Figure 20 The image shows a top view of the second cutting device 45. Here, viewed from left to right, the third clamping device 37 is activated simultaneously with the first clamping device 32 and the second clamping device 33. During the further movement of the sub-staple 31 to the right, the second clamping device 33 is released first, followed by the first clamping device 32, allowing the supplemented partition 29 to move from its enclosed position in the second clamping device 33 to a flat position and move parallel to the anode 7 or cathode 22. Here, the rearward cutting notch 14 of the partition 29, viewed longitudinally 20, is then removed by the corresponding conductor 25, thereby safely extending the anode 7 or cathode 22 longitudinally as well.

[0116] After the first clamping device 32 and the second device 33 are released, the device is then moved back to its initial position by means of the conveyor belt 52, where it can be repositioned to the sub-staple 31. Simultaneously, the clamping device 53 is provided to the sub-staple 31 so that it can continue to be conveyed to the hopper 54 and stacked there after the third clamping device 37 is released. Similarly, the clamping device 53 operates in a cyclical manner, like the clamping devices 32, 33, and 37, to enable rapid and continuous manufacturing of the battery stack 57.

[0117] Figure 21 The third clamping device 37 is shown in side view. Similarly, the third clamping device 37 has multiple clamping elements 55 fixed to a second conveyor belt 56, which moves the sub-pile 31 at the same speed at which it is delivered by the first clamping device 32 and the second clamping device 33. After the sub-pile 31 is delivered to the clamping device 53, the clamping elements 55 are then moved downwards or upwards and to the left in the opposite direction to be repositioned thereto to the immediately following sub-pile 31. As a next step, the clamping device 53 supplies the sub-pile 31 to a hopper 54, where multiple sub-piles 31 are stacked on top of each other to form a battery stack 57.

[0118] Because the sub-stacking unit 31 consists of four material sections, including an anode 7, a separator 29, a cathode 23, and another separator 29, arranged in this order from bottom to top, individual separators 29 are first placed into an empty hopper 54. This is to prevent the anode 7, located at the bottom of the sub-stacking unit 31, from making electrical contact with another component through these individual separators 29. For this purpose, a reserve of individual separators 29 is provided in the receiving section 58 at the hopper 54. Here, the supply device 59 places the separator 29 into the hopper 54 each time it begins to fill an empty hopper 54, for example by means of a siphon as the first material section. Once the battery stack 57 is completed, the hopper 54 is moved and replaced by another empty hopper 54. When the second hopper 54 is filled, the battery stack 57 can be connected to the battery pack 60 in the first hopper 54 and then transported away. Multiple hoppers 54 can also be used in cases of higher manufacturing speeds. For this purpose, two additional material bins 54 can be arranged, parallel to the first two bins, and filled with sub-piles 31 by means of a continuing clamping device 53. The additional material bins 54, when empty, can also be pre-equipped with partitions 29 by a supply device 59. Thus, manufacturing can continue uninterruptedly and at a high speed.

[0119] Figure 22 A top-view view on the left shows a filled hopper 54 with battery stacks 57 on conveyor belt 61. A completed battery pack 60 on conveyor belt 61, ready for transport, is shown on the right. A slider 62 is used to securely attach the battery stacks 57 into a battery pack 60 using tape 63. Here, the battery stacks 57 are held at their end faces 64 within the hopper 54, where the conductors 25 are also located.

[0120] exist Figure 23 The first step for applying the adhesive is shown. Here, slider 62 first moves outward from the side and four strips 63 are pulled out by tape roller 66 using adhesive puller 65.

[0121] exist Figure 24 The second step is shown, in which slider 62 is moved to battery stack 57 and tape 63 is pressed against the battery stack from the side. Here, tape 63 is simultaneously cut by a cutter 67 arranged at slider 62. During cutting, adhesive puller 65 also acts as a mating support for cutter 67.

[0122] Figure 25 The diagram shows how the slider 62 is then moved further in the direction of the battery stack 57 and the cut tape 63 is pressed onto the battery stack 57 to form the battery pack 60.

[0123] Immediately afterwards Figure 26 As shown, the battery pack 60 thus produced is placed on conveyor belt 61 and transported away.

[0124] Figure 27 This shows how the bottom 71 of this silo 54 opens by swinging down and the slider 62 lowers the battery pack 60 onto the conveyor belt 61.

[0125] Figure 28 The completed battery pack 60 is shown with a conductor 25 and surrounding tape 63.

[0126] Finally, Figure 29 An alternative embodiment is shown, which performs the functions of the first and second clamping devices 32, 33 and the second cutting device 45. The sub-pile 31, having passed through the first cutting device 1 and now being conveyed by the cam drive 36 to the second cutting device 45, is shown. Here, a lower roller 4 is used, which can be configured, for example, as a cam-driven mating roller with a forming punch 68 made of rubber. The forming punch 68 is designed such that, when the cutting slit 14 of the partition 29 enters the second cutting device 45, the sub-pile 31 is forced into a curved motion track 69 via the approximately elliptical, non-circular forming punch 68. The resulting curvature is further enhanced by the additional deformation of the forming punch 68 in this position in the direction of the sub-pile 31 via a pin 70. This results in curvature of the material webs 3, 22, 27, which in this state also causes relative movement of these material webs 3, 22, 27 relative to each other. If the partition 29 is separated in this position by the separating blade 50 arranged on the upper roller 5, a partition 29 longer than the anode 7 or cathode 23 below is obtained. Immediately thereafter, the conductor cut 16 can be made using the immediately following conductor blade 51, wherein the sub-pile 31 does not bend in this rotational position of the upper roller 5 and lower roller 4 because the forming punch 68 is not against the sub-pile 31 in this immediate rotational position. This means that the conductor cut 16 is made with the conductor blade 51 at a straight and extended sub-pile 31.

[0127] With this invention, it is possible to perform four work steps in one facility. These work steps include longitudinal cutting, transverse cutting, stacking, and gluing or binding of the battery pack. Furthermore, very high stacking speeds can be achieved, wherein preferably, the four material webs are continuously secured by clamping devices 32, 33, 37 or by holding devices 53, thereby achieving very high positional and manufacturing accuracy.

[0128] The material planes do not need to be separated and then gathered, so very little material handling is required and very good material utilization is achieved, for example, in Z-shaped folding.

[0129] Due to the high positional accuracy, the necessary excess of the relative cathode 23, such as 6 mm, for the partition 29 can also be reliably ensured.

[0130] Finally, the lamination process commonly used in general can also be eliminated, thereby eliminating the need for the more expensive laminated partition 29.

[0131] List of reference numerals

[0132] 1. First cutting device

[0133] 2 First storage device

[0134] 3 First material sheet

[0135] The first material sheet divided into 3a and 3b

[0136] 4 lower roller

[0137] 5 upper roller

[0138] 6 Drilling Units

[0139] 7 Anode

[0140] 8 battery cells

[0141] 9 Anode region

[0142] 10 Edges

[0143] 11 Rotary blade

[0144] 12. Longitudinal incision

[0145] 13 Receiving Holes

[0146] 14 Cutting Incision

[0147] 15 Window cut

[0148] 16 Conductor cut

[0149] 17 Conveyor Hole

[0150] 18 Conveyor Section

[0151] 19 windows

[0152] 20 Vertical

[0153] 21 width

[0154] 22 Second Material Width

[0155] The second material sheet divided into 22a and 22b

[0156] 23 Cathode

[0157] 24 Cathode Region

[0158] 25 Conductors

[0159] 26 Second storage device

[0160] 27 Third Material Sheet

[0161] 28 Third storage device

[0162] 29 partitions

[0163] 30 Guiding Devices

[0164] 31 sub-heaps

[0165] 32 First clamping device

[0166] 33 Second clamping device

[0167] 34 Conveyor pins

[0168] 35 Support pin

[0169] 36 Cam Driver

[0170] 37 Third clamping device

[0171] 38. Monitoring devices

[0172] 39 Grippers

[0173] 40 Cam

[0174] 41 Groove

[0175] 42 bends

[0176] 43 boards

[0177] 44 Springs

[0178] 45 Second cutting device

[0179] 46 First Roller

[0180] 47 Second Roller

[0181] 48 Paired Rollers

[0182] 49 ribbons

[0183] 50 Separating Blade

[0184] 51 Conductor Knife

[0185] 52 Conveyor Belts

[0186] 53 Clamping Devices

[0187] 54 Material Warehouse

[0188] 55 Clamping elements

[0189] 56 Second Conveyor Belt

[0190] 57 Battery Stack

[0191] 58. Accommodation Department

[0192] 59. Supply device

[0193] 60 battery pack

[0194] 61 Conveyor Belt

[0195] 62 sliders

[0196] 63 Tape

[0197] 64 end face

[0198] 65 Adhesive Puller

[0199] 66 Belt Roller

[0200] 67 knives

[0201] 68 Forming punch

[0202] 69. Motion Track

[0203] 70 pins

[0204] 71. Ground.

Claims

1. A method for manufacturing a battery stack (57) for a battery cell (8), comprising at least the following steps: a) Supply at least one first material sheet (3) made of the first material; b) In the case of constructing at least one tensile strip-shaped conveying section (18), a first cut is performed at least on the first material width (3); c) Gather the first material sheet (3) and at least one second material sheet (22, 27) made of the second material into a sub-pile (31); d) The resulting sub-pile (31) is secured in the first fastening position by means of a movable first clamping device (32). e) Supplement at least one second material web (22, 27) and secure the resulting sub-pile (31) at a second fastening position by means of a movable second clamping device (33), wherein the second clamping device (33) is configured as a supplementing device and arranged between the first clamping device (32) and the storage device (2, 26, 28), wherein the additional length of the second material web (22, 27) is extracted from the storage device, thereby allowing the second material web (22, 27) to be processed with a length greater than that of the unsupplemented material web. f) Perform a second trimming of the secured sub-pile (31), wherein, The conveyor section (18) was disassembled; g) Release the first clamping device (32) and the second clamping device (33), h) Arrange at least two sub-piles (31) into a battery pile (57).

2. The method according to claim 1, characterized in that, The second clamping device (33) is arranged in the longitudinal direction (20) of the material width (3,22,27) between the first clamping device (32) and the supplied material width (3,22,27).

3. The method according to claim 1 or 2, characterized in that, With regard to the supply, viewed in the longitudinal direction (20), the front and rear edges of at least one second material sheet (22, 37) produced in the first cut extend beyond the front and rear edges of the adjacent first material sheet (3).

4. The method according to claim 1 or 2, characterized in that, In order to release the first clamping device (32) and the second clamping device (33), the second clamping device (33) is released in time before the first clamping device (32).

5. The method according to claim 1 or 2, characterized in that, The first clamping device (32) and the second clamping device (33) move together with the sub-pile (31) in a synchronized motion.

6. The method according to claim 1 or 2, characterized in that, The first material sheet (3) and the second material sheet (22, 27) are cut to different sizes.

7. The method according to claim 1 or 2, characterized in that, In the case of the first cut, create window sections or transport joints in the material sheet.

8. The method according to claim 1 or 2, characterized in that, The sub-pile (31) consists of at least four material sheets (3, 22, 27).

9. The method according to claim 1 or 2, characterized in that, In the case of cutting, conductive markings (25) are constructed at at least two material sections (3, 22).

10. The method according to claim 1 or 2, characterized in that, The battery stack (57) is connected into a battery pack (60) by a connecting device (63).

11. The method according to claim 1 or 2, characterized in that, In the case where the sub-pile (31) is arranged as the battery pile (57), at least one additional material sheet (29) is arranged in the battery pile (57).

12. A battery cell (8) having a battery stack (57) manufactured according to any one of the preceding claims.

13. A motor vehicle having at least one battery cell (8) according to the preceding claims.

14. An apparatus for manufacturing a battery stack (57), comprising at least two storage devices (2, 26, 28) for at least one first material web (3) and a second material web (22, 27), at least one first cutting device (1) and a second cutting device (45) for cutting the first material web (3) and the second material web (22, 27), a conveying device for conveying the material web (3, 22, 27), a device for gathering the material web, and a stacking device (54), wherein, A first clamping device (32) is provided at a first fastening position and a second clamping device (33) is provided at a second fastening position, wherein the second clamping device (33) is additionally configured as a supplementary device for at least one second material web (22, 27) and is arranged between the first clamping device (32) and the storage device (2, 26, 28), wherein an additional length of the second material web (22, 27) is extracted from the storage device, thereby allowing the second material web (22, 27) to be processed with a length greater than that of the unsupplemented material web.

15. The apparatus according to claim 14, characterized in that, The first clamping device (32) and the second clamping device (33) are connected to the driving device and can move synchronously with the material width (3,22,27).

16. The apparatus according to claim 14 or 15, characterized in that, The first clamping device (32) and the second clamping device (33) and at least the second cutting device (45) are configured such that the first clamping device (32) and the second clamping device (33) can pass through the second cutting device (45) in the closed state.

17. The apparatus according to claim 14 or 15, characterized in that, The supplementary device is constructed by means of at least three guide elements (39) that can move in groups.

Images