Electrochemical cell comprising electrically conductive layer and method of making same

Abstract

The invention relates to an electrochemical cell comprising an electrically conductive layer and a method of making the same. A method for manufacturing a battery cell includes: disposing an electrode assembly within a battery can; assembling the top cap assembly to the battery can to form a battery cell having at least a first fill hole and a second fill hole; disposing a first portion of a liquid solution within the battery cell via the first fill hole, the liquid solution including an organic solvent, a crosslinkable polymer, and a crosslinking agent; converting a first portion of the liquid solution into a first conductive layer disposed between the electrode assembly and the battery can; disposing a second portion of the liquid solution within the battery cell via a second filling hole; converting a second portion of the liquid solution into a second conductive layer disposed between the electrode assembly and the battery can; and filling the battery cell with a liquid electrolyte through the electrolyte filling hole.

Description

Technical Field

[0001] The concepts described herein generally relate to electrochemical battery cells, including but not limited to prismatic battery cells and cylindrical battery cells having a metal casing or "can," and including heat dissipation paths for efficient and consistent heat dissipation over the life of the battery cell. Background Art

[0002] A lithium-ion battery is an electrochemical device that operates by transferring lithium ions between a negative electrode (or anode) and a positive electrode (or cathode). Typically, in most prismatic battery cells, the negative electrode and the positive electrode are located on opposite sides of a porous polymer separator to form an electrode stack. The electrode stack may be part of an electrode assembly and may include a protective wrap. The electrode stack or assembly is disposed within a hollow, rectangular, metal battery housing or "can" and is soaked or "wetted" with an electrolyte solution suitable for conducting lithium ions.

[0003] In most cylindrical battery cells, a jelly roll (JR) design is used. Typically, in a JR design, an insulating substrate is laid, followed by an anode layer, a separator layer, and a cathode layer to form an electrode stack. The electrode stack is then rolled up into a cylinder and inserted into a hollow metal cylindrical case or battery can and soaked or "wetted" with an electrolyte solution suitable for conducting lithium ions.

[0004] A DC power source such as a lithium-ion battery can be used to store and release electrical power, which can be used by a circuit or motor to perform work, such as for communication, display, or propulsion. Heat can be generated by the process of converting electrical power into chemical potential energy (i.e., battery charging) and the process of converting chemical potential energy into electrical power (i.e., battery discharging).

[0005] Lithium-ion battery cells (such as, but not limited to, lithium-ion battery cells used in rechargeable energy storage systems (RESS)) are typically packaged into battery modules or battery packs. Each lithium-ion battery module or battery pack may include multiple lithium-ion battery cells. Therefore, each lithium-ion module or battery pack may generate even greater amounts of heat than a single lithium-ion battery cell.

[0006] Individual lithium-ion battery cells (including but not limited to prismatic battery cells and cylindrical battery cells) may include void space between the sidewalls of the metal battery can and the electrode assembly contained within the metal battery can. The void space may include air, which may reduce thermal performance within the individual battery cells.

[0007] Current cooling or heat dissipation strategies for lithium-ion battery modules or battery packs may include cooling plates disposed within the lithium-ion battery module or battery pack (e.g., but not limited to, between the lithium-ion battery cells as a unit and the battery module or battery pack and / or between individual lithium-ion battery cells within the battery module or battery pack). These cooling or heat dissipation strategies are external to the lithium-ion battery cell units within the battery module or battery pack, and / or external to the individual lithium-ion battery cells themselves. Summary of the invention

[0008] In view of the above discussion, it is useful to develop a battery cell with improved thermal performance within the battery cell. A heat dissipation path may be provided herein by including a conductive layer disposed within the battery cell between the electrode assembly and the battery can. The conductive layer may be more effective than current cooling or heat dissipation strategies (such as, but not limited to, those currently used in battery cells used in rechargeable energy storage systems (RESS)) without compromising existing thermal runaway characteristics.

[0009] The electrochemical battery cell may include an electrode assembly, a battery can, and a top cap assembly. The battery can may include a first side wall and a second side wall.

[0010] The electrode assembly may be disposed within the battery can. The top cap assembly may be assembled to the battery can to form a battery cell having a first filling hole and a second filling hole.

[0011] The first portion of the liquid solution may be disposed within the battery cell via the first filling hole. The first portion of the liquid solution may be converted into a first conductive layer disposed between the first sidewall of the battery can and the electrode assembly.

[0012] A second portion of the liquid solution may be disposed within the battery cell via the second filling hole. The second portion of the liquid solution may be converted into a second conductive layer disposed between the second sidewall of the battery can and the electrode assembly.

[0013] The liquid solution may include an organic solvent, a cross-linkable polymer, and a cross-linking agent.

[0014] Vacuum filling can be used to facilitate the introduction of liquid electrolyte into the battery cell.

[0015] A reaction product is formed by reacting a cross-linkable polymer and a cross-linking agent in each of the first part and the second part of the liquid solution so that an organic solvent can be contained in the reaction product, and each of the first part and the second part of the liquid solution can be converted into a first conductive layer and a second conductive layer, respectively.

[0016] Reacting the cross-linkable polymer and the cross-linking agent of each of the first and second portions of the liquid solution may include applying heat to the liquid solution.

[0017] A first portion of a liquid solution disposed within the battery cell may be converted into a first electrically conductive layer by applying heat to at least a first sidewall of the battery can when the battery cell is in the first position.

[0018] A second portion of the liquid solution disposed within the battery cell may be converted into a second conductive layer by applying heat to at least a second sidewall of the battery can when the battery cell is in the second position.

[0019] The first conductive layer may be in contact with the first side wall of the battery can and the first side portion of the electrode assembly. The second conductive layer may be in contact with the second side wall of the battery can and the second side portion of the electrode assembly.

[0020] According to one aspect of the present disclosure, at least one of the first filling hole and the second filling hole may be provided in the top hat assembly.

[0021] According to another aspect of the present disclosure, the at least one of the first filling hole and the second filling hole may be provided in the battery can.

[0022] The battery can may be preheated prior to disposing at least one of the first portion and the second portion of the liquid solution within the battery cell.

[0023] According to another aspect of the present disclosure, vacuum filling may be used to facilitate the placement of liquid electrolyte within the battery cell.

[0024] The liquid solution may include an alkyl phosphate mixed solution.

[0025] According to one aspect of the present disclosure, a method for manufacturing a battery cell may include: disposing an electrode assembly in a battery can; assembling a top cap assembly to the battery can to form a battery cell having at least a first filling hole and a second filling hole; disposing a first portion of a liquid solution in the battery cell via the first filling hole, the liquid solution comprising an organic solvent, a cross-linkable polymer, and a cross-linking agent; converting the first portion of the liquid solution into a first conductive layer disposed between the electrode assembly and the battery can; disposing a second portion of the liquid solution in the battery cell via the second filling hole; converting the second portion of the liquid solution into a second conductive layer disposed between the electrode assembly and the battery can; and filling the battery cell with a liquid electrolyte via the electrolyte filling hole.

[0026] Converting at least one of the first and / or second parts of the liquid solution into at least one of the first and / or second conductive layers, respectively, may include: reacting a cross-linkable polymer and a cross-linking agent of at least one of the first and / or second parts of the liquid solution to form a reaction product, such that an organic solvent is contained in the reaction product.

[0027] Reacting the cross-linkable polymer and the cross-linking agent of each of the first and second portions of the liquid solution may include applying heat to the liquid solution.

[0028] When the first portion of the liquid solution is converted into the first conductive layer, the battery cell can be in a first position. Before converting the second portion of the liquid solution into the second conductive layer, the battery cell can be rotated to a second position. The angle between the first position and the second position can be 180 degrees.

[0029] Converting the first portion of the liquid solution into the first conductive layer may include applying heat to at least a first sidewall of the battery can, and converting the second portion of the liquid solution into the second conductive layer may include applying heat to at least a second sidewall of the battery can.

[0030] The first conductive layer may contact a first sidewall of the battery can and a first side portion of the electrode assembly, and the second conductive layer may contact a second sidewall of the battery can and a second side portion of the electrode assembly.

[0031] According to one aspect of the present disclosure, at least one of the first filling hole and the second filling hole may be provided in the top hat assembly.

[0032] According to another aspect of the present disclosure, at least one of the first filling hole and the second filling hole may be provided in the battery can.

[0033] Prior to disposing at least one of the first portion and / or the second portion of the liquid solution within the battery cell, the battery can may be preheated.

[0034] According to another aspect of the present disclosure, filling the battery cell with electrolyte includes vacuum filling.

[0035] According to one aspect of the present disclosure, a method for manufacturing a battery cell may include: disposing an electrode assembly in a battery can; assembling a top cap assembly to the battery can to form a battery cell having two filling holes; disposing a liquid solution in the battery cell via at least one of the two filling holes, the liquid solution comprising an organic solvent, a cross-linkable polymer and a cross-linking agent; converting the liquid solution into at least one conductive layer disposed between at least one side portion of the electrode assembly and the battery can, wherein converting the liquid solution into the at least one conductive layer comprises reacting the cross-linkable polymer and the cross-linking agent of the liquid solution to form a reaction product, wherein the organic solvent is contained in the reaction product; and filling the battery cell with a liquid electrolyte using vacuum filling.

[0036] Disposing the liquid solution within the battery cell may include: disposing a first portion of the liquid solution within the battery cell via one of the two fill holes; and disposing a second portion of the liquid solution within the battery cell via the other of the two fill holes.

[0037] The method may include rotating the battery cell from the first position to the second position prior to disposing the second portion of the liquid solution within the battery cell.

[0038] The method may include storing the battery cell in the first position for a predefined period of time before rotating the battery cell to the second position.

[0039] According to one aspect of the present disclosure, the at least one conductive layer may include two conductive layers. When the battery cell is in a first position, a first portion of the liquid solution may be converted into one of the two conductive layers, and when the battery cell is in a second position, a second portion of the liquid solution may be converted into the other of the two conductive layers.

[0040] One of the two conductive layers may be disposed between the battery can and one side portion of the electrode assembly, and the other of the two conductive layers may be disposed between the battery can and the other side portion of the electrode assembly.

[0041] One of the two conductive layers may contact one side portion of the battery can and the electrode assembly, and the other of the two conductive layers may contact the other side portion of the battery can and the electrode assembly.

[0042] According to one aspect of the present disclosure, reacting the cross-linkable polymer and the cross-linking agent of the liquid solution to form a reaction product includes applying heat to the battery can.

[0043] According to another aspect of the present disclosure, the method may include preheating the battery can prior to disposing the liquid solution within the battery cell.

[0044] Therefore, by including a conductive layer disposed inside the battery cell between the electrode assembly and the battery can, a heat dissipation path can be provided. The conductive layer can be more effective than current cooling or heat dissipation strategies (such as, but not limited to, those currently used in battery cells used in rechargeable energy storage systems (RESS)) without compromising existing thermal runaway characteristics.

[0045] The present invention provides the following technical solutions.

[0046] Technical Solution 1. A method for manufacturing a battery cell, comprising:

[0047] placing the electrode assembly in the battery can;

[0048] Assembling a top cap assembly to the battery can to form the battery cell having at least a first fill hole and a second fill hole;

[0049] disposing a first portion of a liquid solution in the battery cell via the first filling hole, the liquid solution comprising an organic solvent, a cross-linkable polymer, and a cross-linking agent;

[0050] converting the first portion of the liquid solution into a first conductive layer disposed between the electrode assembly and the battery can;

[0051] disposing a second portion of the liquid solution into the battery cell via the second filling hole;

[0052] converting the second portion of the liquid solution into a second conductive layer disposed between the electrode assembly and the battery can; and

[0053] The battery cell is filled with a liquid electrolyte via an electrolyte filling hole.

[0054] Technical Solution 2. A method for manufacturing a battery cell according to Technical Solution 1, wherein converting at least one of the first part and / or the second part of the liquid solution into at least one of the first and / or second conductive layers, respectively, comprises: reacting the cross-linkable polymer of at least one of the first and / or second parts of the liquid solution and the cross-linking agent to form a reaction product, wherein the organic solvent is contained in the reaction product.

[0055] Technical Solution 3. A method for manufacturing a battery cell according to Technical Solution 1, wherein the battery cell is in a first position when the first part of the liquid solution is converted into the first conductive layer, and further comprising: rotating the battery cell to a second position before converting the second part of the liquid solution into the second conductive layer.

[0056] Technical Solution 4. A method for manufacturing a battery cell according to Technical Solution 1, wherein converting the first portion of the liquid solution into the first conductive layer includes applying heat to at least a first side wall of the battery can; and wherein converting the second portion of the liquid solution into the second conductive layer includes applying heat to at least a second side wall of the battery can.

[0057] Technical Solution 5. A method for manufacturing a battery cell according to Technical Solution 1, wherein the first conductive layer is in contact with the first side wall of the battery can and the first side portion of the electrode assembly; and wherein the second conductive layer is in contact with the second side wall of the battery can and the second side portion of the electrode assembly.

[0058] Technical Solution 6. The method for manufacturing a battery cell according to Technical Solution 1, wherein at least one of the first filling hole and the second filling hole is arranged in the top cap assembly.

[0059] Technical Solution 7. The method for manufacturing a battery cell according to Technical Solution 1, wherein at least one of the first filling hole and the second filling hole is disposed in the battery can.

[0060] Technical Solution 8. The method for manufacturing a battery cell according to Technical Solution 1 further includes preheating the battery can before disposing at least one of the first part of the liquid solution and / or the second part of the liquid solution in the battery cell.

[0061] Technical Solution 9. The method for manufacturing a battery cell according to Technical Solution 1, wherein filling the battery cell with the liquid electrolyte comprises vacuum filling.

[0062] Technical Solution 10. A method for manufacturing a battery cell, comprising:

[0063] placing the electrode assembly in the battery can;

[0064] Assembling a top cap assembly to the battery can to form a battery cell having two filling holes;

[0065] Disposing a liquid solution in the battery cell through at least one of the two filling holes, the liquid solution comprising an organic solvent, a cross-linkable polymer, and a cross-linking agent;

[0066] converting the liquid solution into at least one conductive layer disposed between at least one side portion of the electrode assembly and the battery can, wherein converting the liquid solution into the at least one conductive layer comprises reacting the cross-linkable polymer and the cross-linking agent of the liquid solution to form a reaction product, wherein the organic solvent is contained in the reaction product; and

[0067] The battery cell is filled with liquid electrolyte using vacuum filling.

[0068] Technical Solution 11. A method for manufacturing a battery cell according to Technical Solution 10, wherein disposing the liquid solution in the battery cell further comprises: disposing a first portion of the liquid solution in the battery cell via one of the two filling holes; and disposing a second portion of the liquid solution in the battery cell via the other of the two filling holes.

[0069] Technical Solution 12. The method for manufacturing a battery cell according to Technical Solution 11 further includes: rotating the battery cell from a first position to a second position before disposing the second part of the liquid solution in the battery cell.

[0070] Technical Solution 13. The method for manufacturing a battery cell according to Technical Solution 12 further includes: storing the battery cell in the first position for a predefined period of time before rotating the battery cell to the second position.

[0071] Technical Solution 14. The method for manufacturing a battery cell according to Technical Solution 13 further includes: after rotating the battery cell from the first position to the second position, storing the battery cell in the second position.

[0072] Technical Solution 15. A method for manufacturing a battery cell according to Technical Solution 12, wherein the at least one conductive layer includes two conductive layers, when the battery cell is in the first position, the first part of the liquid solution is converted into one of the two conductive layers, and when the battery cell is in the second position, the second part of the liquid solution is converted into the other of the two conductive layers.

[0073] Technical Solution 16. A method for manufacturing a battery cell according to Technical Solution 15, wherein one of the two conductive layers is disposed between the battery can and one side portion of the electrode assembly, and the other of the two conductive layers is disposed between the battery can and another side portion of the electrode assembly.

[0074] Technical Solution 17. A method for manufacturing a battery cell according to Technical Solution 16, wherein one of the two conductive layers is in contact with one side portion of the battery can and the electrode assembly, and the other of the two conductive layers is in contact with another side portion of the battery can and the electrode assembly.

[0075] Technical Solution 18. A method for manufacturing a battery cell according to Technical Solution 10, wherein the organic solvent of the liquid solution includes one of an alkyl phosphate ester or a fluorinated alkyl phosphate ester, and reacting the cross-linkable polymer and the cross-linking agent of the liquid solution to form the reaction product includes applying heat to the battery cell.

[0076] Technical Solution 19. The method for manufacturing a battery cell according to Technical Solution 10 further includes preheating the battery can before placing the liquid solution in the battery cell.

[0077] Technical Solution 20. A battery cell, comprising:

[0078] Battery cans;

[0079] an electrode assembly disposed in the battery can;

[0080] a top cap assembly assembled to the battery can to form a battery cell having at least a first fill opening and a second fill opening;

[0081] A first conductive layer disposed between the first side wall of the battery can and the electrode assembly;

[0082] A second conductive layer disposed between the second side wall of the battery can and the electrode assembly; and

[0083] A liquid electrolyte is disposed within the battery cell.

[0084] The above features and advantages of the present disclosure and other features and attendant advantages will become apparent from the following detailed description of illustrative examples and modes for carrying out the present disclosure when taken in conjunction with the accompanying drawings and appended claims. In addition, the present disclosure expressly includes combinations and sub-combinations of the elements and features presented above and below. BRIEF DESCRIPTION OF THE DRAWINGS

[0085] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate implementations of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0086] Figure 1 is a schematic diagram of a cross section of an example battery cell in an upright position without liquid solution.

[0087] Figure 2A is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present disclosure rotated to position 1 prior to liquid solution conversion.

[0088] Figure 2B is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present disclosure rotated to Position 1 after conversion of a liquid solution to a conductive layer.

[0089] Figure 3A is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present disclosure rotated to position 2 prior to liquid solution conversion.

[0090] Figure 3B is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present disclosure rotated to position 2 after conversion of a liquid solution to a conductive layer.

[0091] Figure 4 is a schematic illustration of a cross-section of an example battery cell constructed in accordance with the present disclosure in an upright position, including a conductive layer and a liquid electrolyte solution.

[0092] Figure 5A is a flow chart describing a method for manufacturing a battery cell according to the present disclosure.

[0093] Figure 5Bis a flow chart describing a method for manufacturing a battery cell according to the present disclosure.

[0094] The drawings are not necessarily drawn to scale and may present somewhat simplified representations of various preferred features of the present disclosure disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes. The details associated with these features will be determined in part by the specific intended application and use environment. DETAILED DESCRIPTION

[0095] The present disclosure allows for many different forms of embodiments. Representative examples of the present disclosure are shown in the accompanying drawings and are described in detail herein as non-limiting examples of the disclosed principles. For this reason, elements and limitations described in the abstract, introduction, summary of the invention, and detailed description of the embodiments but not explicitly set forth in the claims should not be incorporated into the claims individually or collectively by implication, inference, or otherwise.

[0096] For the purpose of this specification, unless otherwise stated, the use of the singular includes the plural and vice versa, the terms "and" and "or" shall be conjunctive and disjunctive, and the words "including", "comprising", "containing", "having", etc. shall mean "including but not limited to". In addition, approximate words such as "about", "almost", "substantially", "substantially", "approximately", etc. may be used herein in the sense of "at, close to, or nearly at", or "within 0-5% of...", or "within an acceptable manufacturing tolerance", or their logical combinations.

[0097] Referring now to the drawings, wherein like numerals indicate like parts throughout the several views, there are shown and described herein a battery cell including a liquid solution that is converted to a conductive layer and a method for making a battery cell including a liquid solution that is converted to a conductive layer.

[0098] like Figure 1 1 , an electrochemical battery cell 100 is shown in an upright position. The battery cell 100 generally includes a battery can 110, an electrode assembly 120, and a top cap assembly 130. The battery can 110 includes a first side wall 112, a second side wall 114, and a bottom 116.

[0099] The battery can 110 includes a metal material, such as but not limited to aluminum.

[0100] Electrode assembly 120 includes electrode tabs 122 and 124, each of which extends through top cap assembly 130 to terminals 122A and 124A. Electrode tab 122 extends upward from first side portion 120A of electrode assembly 120. Electrode tab 124 extends upward from second side portion 120B of electrode assembly 120.

[0101] The top hat assembly 130 includes a first fill hole 132 , a second fill hole 134 , and an electrolyte fill hole 136 .

[0102] The electrode assembly 120 is disposed within the battery can 110 .

[0103] Air gaps 115A and 115B are formed between the first side portion 120A of the electrode assembly 120 and the inner surface 112A of the first side wall 112 of the battery can 110 , and between the second side portion 120B of the electrode assembly 120 and the inner surface 114A of the second side wall 114 of the battery can 110 , respectively.

[0104] The top cap assembly 130 is assembled to the battery can 110 to form the battery cell 100 .

[0105] like Figure 2A and Figure 2B As shown in the figure, continue to refer to Figure 1 , the battery cell 100 is shown in the first position P1.

[0106] In the first position P1, the battery cell 100 is Figure 1 The upright position shown in FIG. 1 is rotated 90 degrees counterclockwise so that the first side wall 112 of the battery cell 100 is horizontal.

[0107] The first portion 142 of the liquid solution is disposed within the battery cell 100 via the first fill hole 132 disposed in the top cap assembly 130, as shown in FIG. Figure 2A As shown in the figure.

[0108] The first portion 142 of the liquid solution is converted into a first conductive layer 142A disposed between the first side wall 112 of the battery can 110 and the first side portion 120A of the electrode assembly 120, such as Figure 2B As shown in the figure.

[0109] The first conductive layer 142A contacts the inner surface 112A of the first side wall 112 of the battery can 110 and the first side portion 120A of the electrode assembly 120 , filling the air gap 115A between the inner surface 112A of the first side wall 112 of the battery can 110 and the first side portion 120A of the electrode assembly 120 .

[0110] like Figure 3A and Figure 3B As shown in the figure, continue to refer to Figure 1 , the battery cell 100 is shown to be in the second position P2.

[0111] In the second position P2, the battery cell 100 is Figure 2A and Figure 2B The first position P1 shown in the figure is rotated 180 degrees clockwise, or from Figure 1 The upright position illustrated in FIG. 1 is rotated 90 degrees clockwise so that the second side wall 114 is horizontal.

[0112] The second portion 144 of the liquid solution is disposed within the battery cell 100 via the second fill hole 134 disposed in the top cap assembly 130, as shown in FIG. Figure 3A As shown in the figure.

[0113] The second portion 144 of the liquid solution is converted into a second conductive layer 144A disposed between the second side wall 114 of the battery can 110 and the second side portion 120B of the electrode assembly 120, such as Figure 3B As shown in the figure.

[0114] The second conductive layer 144A contacts the inner surface 114A of the second side wall 114 of the battery can 110 and the second side portion 120B of the electrode assembly 120 , filling the air gap 115B between the inner surface 114A of the second side wall 114 of the battery can 110 and the second side portion 120B of the electrode assembly 120 .

[0115] The liquid solution includes an organic solvent, a cross-linkable polymer and a cross-linking agent, wherein a non-limiting example may include an alkyl phosphate ester mixed solution having a carbonate or ester-based organic solvent (such that the content of the alkyl phosphate ester mixed solution is between 5 wt % and 100 wt %), a cross-linkable oligomer (or monomer) and a cross-linking agent activated by an increase in temperature.

[0116] forming a reaction product by reacting the cross-linkable polymer and the cross-linking agent of each of the first part 142 and the second part 144 of the liquid solution so that the organic solvent is contained in the reaction product, Figure 2A and Figure 3A Each of the first portion 142 and the second portion 144 of the liquid solution shown in FIG. 1 is converted into Figure 2B and Figure 3B The first conductive layer 142A and the second conductive layer 144A are shown in FIG.

[0117] By applying heat to at least the first sidewall 112 of the battery can 110 , the first portion 142 of the liquid solution is converted into a first conductive layer 142A.

[0118] The shape of the first conductive layer 142A is defined by the inner surface 112A of the first sidewall 112 of the battery can 110 and the outer surface 126 of the electrode assembly 120 .

[0119] The size of the first conductive layer 142A is defined by a predetermined amount of the liquid solution included in the first portion 142 .

[0120] By applying heat to at least the second sidewall 114 of the battery can 110 , the second portion 144 of the liquid solution is converted into a second conductive layer 144A.

[0121] The shape of the second conductive layer 144A is defined by the inner surface 114A of the second sidewall 114 of the battery can 110 and the outer surface 126 of the electrode assembly 120 .

[0122] The size of the second conductive layer 144A is defined by a predetermined amount of the liquid solution included in the second portion 144 .

[0123] Figure 2B and Figure 3B Each of the first conductive layer 142A and the second conductive layer 144A illustrated in FIG. 1 includes a gel that does not flow freely under zero shear force after the cross-linking process is completed.

[0124] when Figure 2B and Figure 3B Each of the first conductive layer 142A and the second conductive layer 144A illustrated in FIG. 1 is filled with, for example but not limited to, an alkyl phosphate in the form of a gel. Figure 1 When the air gaps 115A, 115B are formed as shown in the figure, the thermal performance is improved by increasing the thermal conductivity between the electrode assembly 120 and the battery can 110.

[0125] Although the first fill hole 132 and the second fill hole 134 are illustrated as being disposed in the top cap assembly 130 , it should be understood that at least one or both of the first fill hole 132 and the second fill hole 134 may be disposed in the battery can 110 .

[0126] According to one aspect of the present disclosure, the battery can 110 may be preheated before disposing at least one of the first portion 142 and the second portion 144 of the liquid solution within the battery cell 100 .

[0127] like Figure 5A , an electrochemical battery cell 200 according to the present disclosure is shown in an upright position. The battery cell 200 generally includes a battery can 210, an electrode assembly 220, and a top cap assembly 230. The battery can 210 includes a first side wall 212, a second side wall 214, and a bottom 216.

[0128] The battery can 210 includes a metal material, such as but not limited to aluminum.

[0129] Electrode assembly 220 includes electrode tabs 222 and 224, each of which extends through top cap assembly 230 to terminals 222A and 224A. Electrode tab 222 extends upward from first side portion 220A of electrode assembly 220. Electrode tab 224 extends upward from second side portion 220B of electrode assembly 220.

[0130] The top hat assembly 230 includes a first fill hole 232 , a second fill hole 234 , and an electrolyte fill hole 236 .

[0131] The electrode assembly 220 is disposed within the battery can 210 .

[0132] The first conductive layer 242A is disposed between the first side wall 212 of the battery can 210 and the first side portion 220A of the electrode assembly 220, filling the air gap 115A ( Figure 1 ).

[0133] The first conductive layer 242A contacts the inner surface 212A of the first sidewall 212 of the battery can 210 and the first side portion 220A of the electrode assembly 220 .

[0134] The second conductive layer 244A is disposed between the second side wall 214 of the battery can 210 and the second side portion 220B of the electrode assembly 220, filling the air gap 115B ( Figure 1 ).

[0135] The second conductive layer 244A is disposed between the inner surface 214A of the second sidewall 214 of the battery can 210 and the second side portion 220B of the electrode assembly 220 .

[0136] A top cap assembly 230 including a first filling hole 232 and a second filling hole 234 is assembled to the battery can 210 to form the battery cell 200 .

[0137] A liquid electrolyte 250 is disposed within the battery cell 200 .

[0138] like Figure 5A As shown in FIG. 1 , a method 1000 for manufacturing a battery cell 200 includes: disposing 1100 an electrode assembly 220 in a battery can 210; assembling 1200 a top cap assembly 230 to the battery can 210 to form a battery cell 200 having at least a first filling hole 232 and a second filling hole 234; disposing 1300 a first portion 242 of a liquid solution in the battery cell 200 via the first filling hole 232, the liquid solution comprising an organic solvent, a cross-linkable polymer, and a cross-linking agent; and disposing 1400 a first portion 242 of the liquid solution in the battery cell 200 via the first filling hole 232. The first embodiment of the present invention is to convert 1400 the first conductive layer 242 of the liquid solution into a first conductive layer 242A disposed between the electrode assembly 220 and the battery can 210; dispose 1500 the second portion 244 of the liquid solution in the battery cell 200 via the second filling hole 234; convert 1600 the second portion 244 of the liquid solution into a second conductive layer 244A disposed between the electrode assembly 220 and the battery can 210; and fill 1700 the battery cell 200 with the liquid electrolyte 250 in the battery cell 200 via the electrolyte filling hole 236.

[0139] Converting 1400, 1600 at least one of the first part 242 and / or the second part 244 of the liquid solution into at least one of the first conductive layer 242A and / or the second conductive layer 244A, respectively, may include: reacting 1450, 1650 a cross-linkable polymer and a cross-linking agent of at least one of the first part 242 and / or the second part 244 of the liquid solution to form a reaction product, such that the organic solvent is contained in the reaction product.

[0140] When the first portion 242 of the liquid solution is converted 1400 into the first conductive layer 242A, the battery cell 100 is in the first position P1. Before converting 1600 the second portion 244 of the liquid solution into the second conductive layer 244A, the battery cell 200 is rotated 180 degrees into the second position P2.

[0141] According to one aspect of the present disclosure, converting 1400 the first portion 142 of the liquid solution into the first conductive layer 242A includes applying 1390 heat to at least the first sidewall 212 of the battery can 210, and converting the second portion 244 of the liquid solution into the second conductive layer 244A may include applying 1590 heat to at least the second sidewall 214 of the battery can 210.

[0142] The first conductive layer 242A contacts the first sidewall 212 of the battery can 210 and the first side portion 220A of the electrode assembly 220 , and the second conductive layer 244A contacts the second sidewall 214 of the battery can 210 and the second side portion 220B of the electrode assembly 220 .

[0143] Converting 1400 first portion 242 of the liquid solution into first conductive layer 242A may include storing 1410 battery cell 200 at a predefined temperature for a predetermined period of time.

[0144] Converting 1600 second portion 244 of the liquid solution into second conductive layer 244A may include storing 1610 battery cell 200 at a predefined temperature for a predetermined period of time.

[0145] In one example according to the present disclosure, at least one of the first filling hole 232 and the second filling hole 234 may be provided in the top hat assembly 230 .

[0146] In another example according to the present disclosure, at least one of the first filling hole 232 and the second filling hole 234 may be provided in the battery can 210 .

[0147] Prior to disposing at least one of the first portion 242 and / or the second portion 244 of the liquid solution within the battery cell 200 , the battery can 210 may be preheated.

[0148] According to one aspect of the present disclosure, filling 1700 the battery cell 200 with the liquid electrolyte 250 includes using vacuum filling.

[0149] like Figure 5B As illustrated in , a method 2000 for manufacturing a battery cell 200 may include: disposing 2100 an electrode assembly 220 within a battery can 210; assembling 2200 a top cap assembly 230 to the battery can 210 to form a battery cell 200 having two filling holes 232, 234; disposing 2300 a liquid solution 242, 244 within the battery cell 200 via at least one of the two filling holes 232, 234, the liquid solution 242, 244 comprising an organic solvent, a cross-linkable polymer, and a cross-linking agent; converting 2400 the liquid solution 242, 244 into at least one conductive layer 242A, 244A disposed between at least one side portion 220A, 220B of the electrode assembly 220 and the battery can 210; and filling 200 the battery cell 200 with a liquid electrolyte 250 using vacuum filling.

[0150] Converting 2400 the liquid solution 242 , 244 into the at least one conductive layer 242A, 244A includes reacting 2450 a cross-linkable polymer and a cross-linking agent of the liquid solution 242 , 244 to form a reaction product, wherein an organic solvent is contained within the reaction product.

[0151] Disposing 2300 the liquid solution 240 within the battery cell 200 includes disposing a first portion 242 of the liquid solution within the battery cell 200 via one of the two filling holes 232 , 234 , and disposing a second portion 244 of the liquid solution within the battery cell 200 via the other of the two filling holes 232 , 234 .

[0152] The method 2000 also includes rotating 2330 the battery cell 200 from the first position P1 to the second position P2 before disposing 2340 the second portion 244 of the liquid solution within the battery cell 200 .

[0153] The method 2000 may include storing 2320 the battery cell 200 in the first position P1 for a predefined period of time before rotating 2330 the battery cell 200 to the second position P2.

[0154] According to one aspect of the present disclosure, at least one conductive layer 242A, 244A may include two conductive layers 242A and 244A. When the battery cell 200 is in the first position P1, the first portion 242 of the liquid solution is converted into one of the two conductive layers 242A, 244A, and when the battery cell 200 is in the second position P2, the second portion 244 of the liquid solution is converted into the other of the two conductive layers 242A, 244A.

[0155] One of the two conductive layers 242A, 244A is disposed between the battery can 210 and one side portion 220A, 220B of the electrode assembly 220 , and the other of the two conductive layers 242A, 244A is disposed between the battery can 210 and the other side portion 220A, 220B of the electrode assembly 220 .

[0156] One of the two conductive layers 242A, 244A contacts one side portion 220A, 220B of the battery can 210 and the electrode assembly 220 , and the other of the two conductive layers 242A, 244A contacts the other side portion 220A, 220B of the battery can 210 and the electrode assembly 220 .

[0157] According to one aspect of the present disclosure, reacting 2450 the cross-linkable polymer and the cross-linking agent of the liquid solutions 242 , 244 to form a reaction product includes applying heat 2455 to the battery can 210 .

[0158] By including at least one conductive layer disposed between an electrode assembly of a battery cell and a battery can, a heat dissipation path is provided within the battery cell that is more effective than an air gap disposed between the electrode assembly and the battery can and / or other cooling strategies currently used to dissipate heat, without compromising existing thermal runaway characteristics.

[0159] These and other attendant benefits of the present disclosure will be appreciated by those skilled in the art in view of the foregoing disclosure.

[0160] The detailed description and the accompanying drawings or figures are support and description of the present teaching, but the scope of the present teaching is limited only by the claims. Although some best modes and other embodiments for implementing the present teaching have been described in detail, there are various alternative designs and embodiments for implementing the present teaching defined in the appended claims.

Claims

1. A method for manufacturing a battery cell, comprising: placing the electrode assembly in the battery can; Assembling a top cap assembly to the battery can to form the battery cell having at least a first fill hole and a second fill hole; disposing a first portion of a liquid solution in the battery cell via the first filling hole, the liquid solution comprising an organic solvent, a cross-linkable polymer, and a cross-linking agent; converting the first portion of the liquid solution into a first conductive layer disposed between the electrode assembly and the battery can; disposing a second portion of the liquid solution into the battery cell via the second filling hole; converting the second portion of the liquid solution into a second conductive layer disposed between the electrode assembly and the battery can; and The battery cell is filled with a liquid electrolyte via an electrolyte filling hole.

2. The method for manufacturing a battery cell according to claim 1, wherein: Converting at least one of the first part and / or the second part of the liquid solution into at least one of the first and / or second conductive layers, respectively, comprises: reacting the cross-linkable polymer of at least one of the first and / or second parts of the liquid solution and the cross-linking agent to form a reaction product, wherein the organic solvent is contained in the reaction product.

3. The method for manufacturing a battery cell according to claim 1, wherein: The battery cell is in a first position when the first portion of the liquid solution is converted to the first conductive layer, and further comprising: rotating the battery cell to a second position before converting the second portion of the liquid solution to the second conductive layer.

4. The method for manufacturing a battery cell according to claim 1, wherein: Converting the first portion of the liquid solution into the first conductive layer comprises applying heat to at least a first sidewall of the battery can; and wherein converting the second portion of the liquid solution into the second conductive layer comprises applying heat to at least a second sidewall of the battery can.

5. The method for manufacturing a battery cell according to claim 1, wherein: The first conductive layer contacts a first side wall of the battery can and a first side portion of the electrode assembly; and wherein the second conductive layer contacts a second side wall of the battery can and a second side portion of the electrode assembly.

6. The method for manufacturing a battery cell according to claim 1, wherein: At least one of the first fill hole and the second fill hole is disposed in the top hat assembly.

7. The method for manufacturing a battery cell according to claim 1, wherein: At least one of the first filling hole and the second filling hole is provided in the battery can.

8. The method of manufacturing a battery cell according to claim 1, further comprising preheating the battery can before disposing at least one of the first portion of the liquid solution and / or the second portion of the liquid solution within the battery cell.

9. A method for manufacturing a battery cell, comprising: placing the electrode assembly in the battery can; Assembling a top cap assembly to the battery can to form a battery cell having two filling holes; Disposing a liquid solution in the battery cell through at least one of the two filling holes, the liquid solution comprising an organic solvent, a cross-linkable polymer, and a cross-linking agent; converting the liquid solution into at least one conductive layer disposed between at least one side portion of the electrode assembly and the battery can, wherein converting the liquid solution into the at least one conductive layer comprises reacting the cross-linkable polymer and the cross-linking agent of the liquid solution to form a reaction product, wherein the organic solvent is contained in the reaction product; and The battery cell is filled with liquid electrolyte using vacuum filling.

10. A battery cell comprising: Battery cans; an electrode assembly disposed in the battery can; a top cap assembly assembled to the battery can to form a battery cell having at least a first fill opening and a second fill opening; A first conductive layer disposed between the first side wall of the battery can and the electrode assembly; a second conductive layer disposed between the second side wall of the battery can and the electrode assembly; and A liquid electrolyte is disposed within the battery cell.

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