Electrochemical device

Abstract

An electrochemical device comprises at least one enclosure (10A) for a stack (24) of sheets of electrochemical device shaping material, the stack comprising at least one sheet of first type electrode, at least one sheet of second type electrode, and at least one separator sheet located between the sheets of two types electrode, where the enclosure comprises a plurality of parts, the components include a first component (12A) and a second component (14), which are joined to each other using welding, crimping, crimping or stamping, for forming an internal volume containing the stack (24).

Description

Technical Field

[0001] The present invention relates to an electrochemical device. Background Art

[0002] Electrochemical devices (i.e., devices that use electrodes and / or membranes for transporting and / or storing electrical energy in an electrolyte, such as batteries) have gained attention in a wide range or field due to the increasing use of renewable energy. For this reason, sheets of electrochemical materials such as electrode sheets and separator sheets are placed in a capsule or housing. Therefore, the way in which such a capsule is formed has also gained attention.

[0003] Today, this enclosure is usually made of flexible or rigid parts to protect the interior of the enclosure from moisture and electrolyte leakage. Common cell formats include bag-type enclosures, rigid cylindrical cans, and rigid prismatic cans. The advantage of rigid cell enclosures is that they are easier to integrate into modules or battery packs, and have a higher level of safety to withstand internal gasification, expansion, and external mechanical influences. The safety of rigid structures is also increased, with the attendant higher manufacturing complexity and cost.

[0004] Additionally, many cell chemistries require that the cells be compressed when assembled in a module or pack. This approach is inaccurate, resulting in a complex and fault-prone system that can cause poor or unpredictable aging of the entire module or individual cells within a module due to inaccurate compression conditions.

[0005] However, there is interest in improving the cell enclosure by providing a rigid enclosure or a semi-rigid enclosure that is easy to manufacture, while extending the useful life of the cell.

[0006] A type of enclosure is known from US9831474, in which a battery cell (including an electrode assembly of a cathode / separator / anode structure) is impregnated with an electrolyte and mounted in a battery case made of aluminum or an aluminum alloy. Furthermore, an aluminum oxide coating is applied to at least a portion of the outer surface of the battery case by an anodic oxidation process.

[0007] There is interest in ways to improve electrochemical devices, such as achieving a stack of sheets with electrochemical device forming materials, wherein such a stack can be used for battery cells and / or fuel cells. Summary of the invention

[0008] It is an object of the present invention to provide an improved electrochemical device which is easier to produce.

[0009] According to a first aspect, the object is achieved by an electrochemical device, the electrochemical device comprising:

[0010] at least one enclosure for a stack of sheets of electrochemical device forming material comprising at least one sheet of a first type of electrode, at least one sheet of a second type of electrode and at least one separator sheet between the sheets of the two types of electrodes,

[0011] The enclosure includes a plurality of components including a first component and a second component, and the components are joined to each other using welding, crimping, crimping or stamping for forming an internal volume for accommodating the stack.

[0012] The first component and the second component may each have a first edge, wherein the first edge of the first component may be engaged with the first edge of the second component for forming a first mechanical connection. The first edge of the first component may additionally be folded around the first edge of the second component, or the first edge of the second component may additionally be folded around the first edge of the first component.

[0013] The components may also include a third component including a first edge, and the second component may include a second edge. In this case, the first edge of the third component may additionally engage with the second edge of the second component for forming a second mechanical connection, wherein the first edge of the third component may additionally be folded around the second edge of the second component, or the second edge of the second component may additionally be folded around the first edge of the third component.

[0014] Furthermore, there may be a sealant between at least one of the mechanically connected edges.

[0015] The enclosure may include a top and a bottom separated by at least one sidewall.

[0016] The stack may have a first end with a bottom sheet, the first end facing the bottom of the capsule. The stack may also have a second end with a top sheet, the second end facing the top of the capsule.

[0017] The top, bottom and at least one side wall may be made of a metallic material, and the metallic material may be coated with an electrically insulating material on the surface of the metallic material facing the inner volume. As an alternative, at least one wall, and possibly the lid and bottom may be a polymer.

[0018] The stack may be placed in the internal volume. In this case, the stack may be compressed by a pressure applied through the top and bottom or the first side wall and the other opposing side wall of the enclosure. This may be achieved by the height of the enclosure being less than the original stack height in the axial direction of the stack, wherein the original stack height is the stack height before the stack is placed in the internal volume. Pressing the top or the first side wall in the axial direction towards the bottom or the other side wall may compress the stack. Of course, the bottom or the other side wall may be pressed additionally or instead towards the top or the first side wall. In this case, the compression activity is initiated before the individual components are engaged with each other.

[0019] The enclosure may additionally comprise at least one flexible compression element.The flexible compression element may be arranged on the exterior of at least one side wall.As an alternative, each of the top and bottom parts may be provided with a flexible compression element.

[0020] The bottom and / or top of the capsule may additionally be corrugated. There may also be a corrugation adapter element in the inner volume which flattens the grooves on the inner surface of the bottom and / or lid facing the stack so that the corrugations do not change the shape of the sheets of the stack during compression.

[0021] The enclosure may further comprise at least one pre-tensioning element, wherein each pre-tensioning element may be arranged at one end of the stack and facing the top or bottom sheet of the stack.

[0022] The at least one pre-tensioning element may include an internal pre-tensioning element, which is placed in the internal volume between the stack and the top or bottom of the capsule. There may also be an adhesive element between the top or bottom of the capsule and the internal pre-tensioning element. Such an adhesive element may be implemented as an internal glue or adhesive caulk.

[0023] The at least one pretensioning element may additionally or instead comprise an external pretensioning element, the external pretensioning element being provided as the top or bottom of the enclosure. In this case, there may be a foam element on the external pretensioning element facing away from the laminate.

[0024] At least one pre-tensioning element may be concave with a focal point. In this case, the pre-tensioning element may additionally be placed between the stack and the focal point.

[0025] The enclosure may also include at least one ventilation element located in the top, bottom or in at least one wall.

[0026] The enclosure may also include a first electrical connection to the first type of electrode and a second electrical connection to the second type of electrode.

[0027] The first electrical connection and the second electrical connection may be provided via a first mechanical connection. As an example, the first electrical connection may be provided at a sidewall of the second component provided at one side of the stack between first edges of the first component and the second component, and the second electrical connection may be provided at another opposite sidewall of the second component provided on an opposite side of the stack between first edges of the first component and the second component.

[0028] Alternatively, one electrical connection may be provided through a side wall of the enclosure, while the other electrical connection may be provided through an opposite side wall of the enclosure. As a further alternative, one electrical connection may be provided via the top of the enclosure, while the other electrical connection may be provided via the bottom of the enclosure. The two electrical connections may also be provided via the same surface. Thus, they may be provided via the top, the bottom, or the same side wall.

[0029] The at least one electrical connection may also include a tab extending from within the enclosure to an outside of the enclosure, the tab including a conductor surrounded by insulation.

[0030] The electrochemical device may also include two or more capsules stacked on each other by cooperation of a first mechanical connection of a capsule with a second mechanical connection of an adjacent capsule.

[0031] This mating can be achieved through a first mechanical connection, in which the inner diameter or side defined by the first edge of the first part of the first mechanical connection is aligned with the outer diameter or side defined by the first edge of the third part of the second mechanical connection, or the outer diameter or side defined by the first edge of the third part of the second mechanical connection is aligned with the inner diameter or side defined by the first edge of the first part of the first mechanical connection.

[0032] The first part of the enclosure may be electrically insulating, or the enclosure may further comprise electrical insulation between the first and third parts of adjacent enclosures.

[0033] A first component of an enclosure may be in electrical contact with a third component of an adjacent enclosure, and in each enclosure a second edge of a second component may be electrically isolated from a first edge of the third component and / or a first edge of the second component may be electrically isolated from a first edge of the first component.

[0034] The second component may be a container and the first component may be a lid of the container. As an alternative, the first component may form one half of a capsule and the second component may form the other half of the capsule.

[0035] At least one of the plurality of components may be rigid and at least one of the other components may be rigid or semi-rigid.

[0036] The invention has several advantages. It provides a capsule having a high safety level and can be mass-produced at a competitive cost and high speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention is described below with reference to the accompanying drawings, in which

[0038] 1a and 1b show cross-sectional views of a first type of battery cell casing and a first variation of a second type of battery cell casing;

[0039] Figure 2a A cross-sectional view of a first type of cell package is shown having a stack of sheets of electrochemical device forming material used to form a cell;

[0040] Figure 2b A cross-sectional view of a first variation of a second type of cell package having a stack of sheets of electrochemical device forming material used to form a cell;

[0041] Figure 2c to Figure 2d showing cross-sectional views of second and third variations of a second type of cell package having a stack of sheets of electrochemical device forming material used to form a cell;

[0042] Figure 2e A cross-sectional view showing a first variation of a third type of cell package having a stack of sheets of electrochemical device forming material used to form a cell;

[0043] Figure 2f schematically illustrates various possible cross-sectional areas of the first component, the second component and the optional third component;

[0044] Figures 3a to 3e Different implementations of compression and pretensioning elements for a first type of cell package and a first variant of a second type of cell package are shown, all of which are combined with a stack of sheets of electrochemical device forming material;

[0045] Figures 4a to 4d Different ways of achieving electrical connection with electrode sheets in a first type of battery cell casing, a first variation of a second type of battery cell casing, and a first variation of a third type of battery cell casing are shown;

[0046] Figure 5a to Figure 5c An alternative solution for providing electrical connection to the electrode sheet in a first variant of the third type of cell casing is shown;

[0047] 6a and 6b show alternative solutions for providing electrical connections to electrode sheets in a fourth type of cell casing and a fifth type of cell casing; and

[0048] Figures 7a to 7cDifferent stacks of a first variation of a third type of cell casing, a second variation of the third type of cell casing and a third variation of the third type of cell casing are shown in which electrodes are electrically interconnected using the casing or not. DETAILED DESCRIPTION

[0049] The present invention relates to an electrochemical device, such as a battery cell or a fuel cell, comprising an electrochemical device shaped sheet stack including at least one sheet of a first type electrode, at least one sheet of a second type electrode and at least one separator sheet between the sheets of the two types of electrodes.

[0050] Various aspects of the present disclosure propose solutions to provide rigid or semi-rigid cell enclosures and casings or casings with high safety levels that can be mass-produced at competitive costs and high speeds.

[0051] The electrochemical device may include at least one enclosure, wherein such enclosure is formed using a plurality of components including a first component and a second component. Sheets of electrochemical device forming material (such as sheets of a first type of electrode, sheets of a second type of electrode, and one or more separators) may be placed in the enclosure. Thus, the stack may include at least one sheet of a first type of electrode, at least one sheet of a second type of electrode, and at least one separator between the sheets of the two types of electrodes. The stack may additionally be a laminate, wherein the sheets form different layers of the laminate.

[0052] The multiple parts are then joined together to form the inner volume of the shell, in which joining the enclosure techniques used for cans and cans can be used, such as any kind of welding (such as laser welding, traditional welding) or any type of crimping, crimping or stamping (such as gluing).

[0053] At least one of the plurality of components may be rigid and at least one of the other components may be semi-rigid.

[0054] The sheets may also be pre-soaked in the electrolyte. Alternatively, the electrolyte may be filled into the enclosure before or after the stack has been placed in the enclosure.

[0055] Fig. 1a shows a cross-sectional view of a first type of enclosure 10A, which is formed as a box with a lid and comprises a first part 12A and a second part 14A, wherein the second part 14A can be formed as a box or a cylinder, and the first part 12A can be formed as a rectangular lid or a circular lid for the box or cylinder. Thus, the second part 14A is a container, and the first part 12A is a lid of the container.

[0056] More specifically, the second component 14A may have a bottom 14AB surrounded by at least one side wall 14AW, wherein the side wall 14AW is at a right angle or inclined at a certain angle to the bottom 14AB. Additionally, the first component 12A is parallel to the bottom 14AB of the second component 14A. Thus, a capsule having an internal volume 1VA 22A is formed by the first component 12A and the second component 14A, and the stack can be placed in the volume 22A. The first component 12A may have a first edge 12AE, and the second component 14A may have a first edge 14AE. Thus, the first component 12A and the second component 14A each have a first edge 12AE and 14AE. The first edge 12AE of the first component 12A may be arranged at the periphery of the cover so as to extend beyond the wall 14AW of the second component 14A, and the first edge 14AE of the second component 14A may be at a certain angle, such as 90 degrees, to the wall 14AW of the second component 14A. The first edge 14AE of the second component 14A may be parallel and aligned with the first edge 12AE of the first component 12A.

[0057] Moreover, it can also be seen that the enclosure includes a top (in this case, a top provided by the cover 12AL of the first component 12A) and a bottom (in this case, a bottom formed by the bottom 14AB of the second component 14A), wherein the top and bottom are separated by at least one side wall, which is formed by the wall 14AW of the second component 14A.

[0058] The first component 12A and the second component 14A may further comprise a metal layer ML 16 and an insulating layer IL 18, respectively, wherein the insulating layer 18 is provided on the inside of the enclosure, i.e. facing inwardly towards the inner volume 22A, and the metal layer 16 is provided on the outside of the components, i.e. facing away from the inner volume 22A. Thus, the first component 12A and the second component 14A may be substantially metallic, wherein the surfaces of the first component 12A and the second component 14A facing inwardly towards the inner volume 22A of the enclosure are coated or provided with the insulating material 18. Thus, the surface of the cover 12AL of the first component 12A facing the bottom of the second component 14A is covered with insulating material, as is the surface of the second component 14A facing the bottom 14AB of the first component 12A. Furthermore, the inner surface of the wall 14AW facing inwardly towards the inner volume 22A of the enclosure is covered with the insulating material 18. Furthermore, the surfaces of the edge 12AE of the first component 12 and the edge 14AE of the second component facing each other may also be provided with insulating material, which may extend all the way to the edge or end of the corresponding edge, or may partially extend beyond the edge or end, such as extending halfway beyond the edge or end.

[0059] The metal layer 16 may be made of, for example, aluminum, and the electrically insulating inner layer 18 may be, for example, a polymer or ceramic (cold sprayed) fixed to the outer metal layer by bonding or lamination. The stiffness of the first and second components may be fine-tuned by material selection and shaping (e.g., embossing, etc.).

[0060] Then, the first edge 12AE of the first component 12A can be joined with the first edge 14AE of the second component 14A to form a first mechanical connection MCA 20A between the first and second components, which seals the enclosure. As mentioned before, the joining can be performed using welding (such as laser and resistance welding), crimping, stamping or any kind of crimping.

[0061] FIG. 1 b shows a first version of a second type of enclosure 10B1, which also includes a first part 12B and a second part 14B, wherein the second part 14B can be implemented in the same way as the second part 14A of the first type of enclosure 10A. In this case, the second part 14B has the same shape as the second part 14A of the first type of enclosure and forms half of the shell, i.e., it has a bottom 14BB, at least one side wall 14BW and a first edge 14BE. Moreover, the first part 12B has the same shape as the second part and forms the other half of the shell. The first part 12B has a lid or top 12BL enclosed by at least one side wall 12BW, wherein the side wall 12BW is at right angles to the lid or top 12BL, and the lid or top 12BL of the first part 12B is parallel to and faces the bottom 14BB of the second part 14B, and at least one wall 12BW of the first part 12B is aligned with at least one wall 14BW of the second part 14B. The edges 12BE and 14BE of the first part 12A and the second part 14A are joined together here in the same way as in the enclosure of the first type, so as to form a mechanical connection MCA 20A of the first type.

[0062] Figure 2a A first type of capsule 10A is schematically shown, wherein a stack ST24 comprising sheets forming a first electrode, a second electrode and a separator sheet is provided in the internal space of the capsule, and a first component 12A and a second component 14B are joined with a first type of first mechanical connection 20A, which can be achieved using any kind of welding (such as laser welding or conventional resistance welding) or bonding.

[0063] The stack here has a first end with a bottom sheet, which faces the bottom of the capsule. The stack also has a second end with a top sheet, which faces the top of the capsule.

[0064] Figure 2bA first variant of a second type of capsule 10B1 is schematically shown, in which a stack ST 24 comprising sheets forming a first electrode, a second electrode and a separator sheet is provided in the inner volume of the capsule, which is again sealed using a first mechanical connection 20A of the first type. The same joining techniques as used in the first type of capsule can be used.

[0065] Figure 2c A second variant of a second type of capsule 10B2 is schematically shown, which includes a stack ST 24 of sheets forming electrodes and separations, wherein in this case, a second type of first mechanical connection 20B is used. The joint can additionally be formed by stamping (such as bonding the first edges of the first and second components to each other) or by crimping. The second type of first mechanical connection 20B is thus obtained by folding the first edge of the first component 12B around the first edge of the second component 14B. The second type of first mechanical connection 20B can additionally be airtightly sealed by providing a sealant or a sealing-adhesive between the first edges of the first component 12B and the second component 14B. Here, it should be recognized that, as an alternative, the first edge of the second component 14B may be folded around the first edge of the first component 12B. Alternatively, the two edges can be rotated 180 degrees together (not shown in the schematic diagram).

[0066] Figure 2d A third variation of the second type of enclosure 10B3 is shown in which there is a third type of first mechanical connection 20C, which is similar to the first type 20A. Thus, the first edges of the first component and the second component are aligned with each other, but no edge is folded over the other edge. However, in this case, the first edge of the second component 14B is provided with a sealing groove, and a sealant is placed in the groove and between the first edges of the first component 12B and the second component 14B for airtight sealing of the first mechanical connection 20C. The advantage of doing so is that the coating position of the sealant in the first mechanical connection 20C can be better controlled. It should be appreciated that a sealing groove can also be provided in the first edge of the first component. This sealing variation can be combined with any of the bonding mechanisms previously mentioned (e.g., crimping).

[0067] Figure 2eA first version of a third type of capsule 10C1b is shown. In this type, there is a first component 12C and a second component 14C, each of which is provided with a first edge. However, there is also a third component 28, which also includes a first edge. Further, the second component 14C also includes a second edge. In this case, the first component 12C forms the lid or top of the capsule, the third component 28 forms the bottom of the capsule, and the second component 14C forms at least one wall placed between the top and the bottom of the capsule. In this case, the first component 12C and the third component 28 are arranged at opposite ends of the stack 24, and the second component 14C surrounds the stack. In this case, the first edge of the second component 14C is arranged at the periphery of one end of at least one wall, so as to extend out of the lid of the first component 12C; and the second edge of the second component 14C is arranged at the periphery of the other end of at least one wall, so as to extend out of the bottom of the third component 28. In this case, there is a first mechanical connection 20B of the second type obtained by folding the first edge of the first part 12C around the first edge of the second part 14C, and a second mechanical connection MCB in which the first edge of the third part 28 engages the second edge of the second part. In this variant of the third type of enclosure 10C, the second mechanical connection is of the first type 30A, which is identical to the second type of the first mechanical connection and is obtained by folding the first edge of the third part 28 around the second edge of the second part.

[0068] It can be seen that the second mechanical connection MCB may also be of the second type 30B, in which the second edge of the second component 14C is folded around the first edge of the third component 28. Similarly, the first edge of the second component 14C may be folded around the first edge of the first component 12C, rather than the first edge of the first component 12C being folded around the first edge of the second component 14C. A sealant may also be placed in the first mechanical connection and the second mechanical connection. Thus, a sealant may be used between the edges of at least one mechanical connection of the enclosure, or may be used between all mechanical connections of the enclosure.

[0069] An advantage of the third type of enclosure is that it is suitable for stacking enclosures on top of each other.

[0070] according to Figure 2f , it can be seen that the shapes of the first and third components and the cross-section of the second component can have a rectangular form or a circular form, with different aspect ratios of the x and y combinations. The rectangular shape can have or have no fillet radius.

[0071] The first component, the second component and the optional third component may additionally be made of a single aluminum layer or a hybrid polymer aluminum layer.

[0072] Figures 3a to 3eDifferent ways of providing pre-tensioning of the capsule in order to compress the capsule are shown.

[0073] Figure 3a A first type of capsule is schematically shown, in which an external pretensioning element 32A is placed on the side wall of the second part. The pretensioning element 32A is flexible in the axial direction of the stack (i.e. in the direction between the top and bottom of the capsule), thus allowing the bottoms of the first and second parts to be pressed against each other.

[0074] Figure 3b A second type of external pretensioning element of a first version of a second type of enclosure is shown. In this case, the side wall of the first component leads to a first edge of the component via a first angled portion 32B1 and the side wall of the second component leads to a first edge of the component via a second angled portion 32B2, wherein the angled portions 32B1 and 32B2 are at an angle of approximately 0 to 45 degrees to the corresponding wall and together form a second type of external pretensioning element. The angled portions are flexible and will allow the bottom and top of the first and second components to be pressed against each other, which will increase the angle with the side walls. Additionally, the compressive force can be increased after the external compressive force is released. This can be done if, for example, the angled portions 32B1 and 32B2 are provided with adhesive material on their inner surfaces (i.e. on their surfaces facing inwards towards the inner volume). Pressing the angled portions against each other may cause them to adhere, thereby increasing the compressive force.

[0075] Thus, it can be seen that there is at least one flexible compression element on the exterior of at least one side wall.

[0076] As an alternative, both the top and the bottom portion may be provided with rigid or flexible compression elements.

[0077] The enclosure may further comprise at least one pre-tensioning element arranged at one end of the stack and facing the top or bottom sheet of the stack.

[0078] The at least one pretensioning element may additionally comprise an internal pretensioning element, which is placed in the inner volume between the stack and the top or bottom of the enclosure. The at least one pretensioning element may additionally or instead comprise an external pretensioning element, which is provided as the top or bottom of the enclosure.

[0079] Figure 3cA first version of a second type of enclosure is shown, wherein one end of the stack inside the enclosure is provided with such an internal pretensioning element in the form of a concave flexible pretensioning element 34. The pretensioning element 34 is more specifically arranged in the inner volume of the enclosure, here between the top or cover 12BL of the rigid first part and the top of the stack. Furthermore, in this example, the bottom 14BB of the second part is provided as an external pretensioning element with a concave shape, which is arranged at the opposite end of the stack, i.e. the bottom of the stack. The concave sidewall or internal concave element can be a uniaxial concave element or a biconcave (offset by 90°) element. The concave shapes of the left and right sides can be aligned on the concave axis or offset by 90°.

[0080] The concave pretensioning element has a focal point. It will be appreciated that the pretensioning element is placed between the stack 24 and the focal point.

[0081] Pressing the top 12BL of the first component toward the bottom 14BB of the second component using the first edges of the first and second components compresses the stack.

[0082] Figure 3d shows some additional elements that have been added to Figure 3c The first version of the second type of enclosure may be provided with a pretensioning element. For example, there may be an adhesive element between the top or bottom of the enclosure and the internal pretensioning element. In this case, there is an adhesive element implemented as an internal glue or adhesive caulk 12 between the pretensioning element 34 and the top 3BL of the first component. There may also be a foam element on the external pretensioning element in the direction away from the stack. In this example, there is foam 14 on the outside of the bottom 40BB of the second component. These elements 38 and 40 can be used to adjust a uniform pretensioning.

[0083] Here, it should be recognized that only Figure 3c and Figure 3d One of the pre-tensioning elements shown, either the internal pre-tensioning element 34 or the external pre-tensioning element, is provided at either end of the stack. Furthermore, if two pre-tensioning elements are used, they may also be of the same type, either the internal pre-tensioning element or the external pre-tensioning element or part of the cell enclosure itself.

[0084] Figure 3e A first version of the second type of enclosure is schematically shown, wherein corrugated indentations are provided on the top 12BL of the first component and the bottom 14BB of the second component. It can be seen that the top 12BL of the first component and / or the bottom 14BB of the second component are corrugated.

[0085] A corrugated adapter element aligned with the corrugations of the corresponding bottom or top can be used in the inner volume, which corrugated adapter element flattens the grooves on the inner surface of the bottom and / or lid facing the stack. Figure 3d Similarly, a corrugation adapting element 44 is provided by glue or caulking, such as bonding between the two layers. Here, such glue or caulking 44 is present between the bottom of the first component and the adjacent bottom sheet of the bottom of the stack. By providing a corrugation adapting element, it can be ensured that the corrugations do not change the shape of the sheet during compression, such as creating indentations.

[0086] Here, it should be recognized that it is also possible to Figure 3c and Figure 3d The pre-tensioning elements shown are combined with the corrugation indentations. Thus, one or two concave pre-tensioning elements can be combined with the corrugation top and / or bottom. Thus, concave elements can be combined with localized corrugations to increase stiffness and compression.

[0087] It should also be appreciated that, instead of or in addition to using a different type of pre-tensioning element, the height of the capsule in the axial direction of the stack can also be made smaller than the original stack height, where the original stack height is the stack height before the stack is placed in the internal volume. Then, pressing the first component in the axial direction towards the second component and / or the third component may compress the stack. In this case, the compression activity begins before the various components are engaged with each other, and the engagement occurs when the 3 components mentioned above are pressed against each other. Therefore, the top and bottom of the capsule may compress the stack. In this case, no additional compression adjustment element is required, but it can be optionally integrated.

[0088] Thus, the stack may be compressed by the pressure applied through the top and bottom or the first side wall and the other opposing side wall of the capsule. Pressing the top or first side wall toward the bottom or the other side wall in the axial direction may compress the stack. Of course, the bottom or the other side wall may additionally or conversely be pressed toward the top or first side wall.

[0089] Furthermore, there may also be a first electrical connection to a first type of electrode and a second electrical connection to a second type of electrode.

[0090] Figures 4a to 4d Different ways of providing such electrical connections for different types of electrodes in different types of enclosures are disclosed.

[0091] exist Figures 4a to 4dIn the embodiment, all electrodes of the first type are connected to a first connecting strip 46 arranged on one side of the stack, and all electrodes of the second type are connected to a second connecting strip 48 arranged on the opposite side of the stack, wherein the first connecting strip 46 is in turn connected to a first conductor leaving the capsule, and the second connecting strip 48 is connected to a second conductor leaving the capsule. The connecting strips can be realized as separate tab parts, and can also be formed partially or completely by uncoated electrode foil sections.

[0092] Figure 4a One implementation of a first type of enclosure 10A is shown in which a first connecting bar 46 is disposed along a wall of the second component on one side of the stack, and a first conductor 50A exits or leaves the enclosure through a first mechanical connection on that side of the stack. A second connecting bar 48 is disposed along a wall of the second component on an opposite side of the stack, and a second conductor 52A exits the enclosure through a first mechanical connection on the same side of the stack.

[0093] Thus, the first electrical connection and the second electrical connection are provided via the first mechanical connection. More specifically, the first electrical connection is provided at a side wall of the second component on one side of the stack between the first edges of the first component and the second component, and the second electrical connection is provided at another opposite side wall of the second component on the opposite side of the stack between the first edges of the first component and the second component.

[0094] Figure 4b A first variant implementation of the second type of enclosure 10B1 is shown, in which a first connecting strip 46 is arranged along the wall of the first and second parts on one side of the stack, and a first conductor 50B exits the enclosure through a first mechanical connection on this side of the stack. A second connecting strip 48 is arranged along the wall of the first and second parts on the other side of the stack, and a second conductor 52B exits the enclosure through a first mechanical connection on the same side of the stack. It can be seen that in Figure 4a In the first type of capsule in , the side of the stack where the first connecting bar 46 is located is the same as the side where the second connecting bar 48 is located.

[0095] Here, it should be mentioned that two insulating material tabs may be provided in the mechanical connection. The first conductor and the second conductor then leave the inner volume via these two tabs. If the first edge of the first component and the second component is provided with an insulating layer, this insulating layer can provide additional insulation. The use of tabs will be in Figure 4c and Figure 4d A more detailed description is given in .

[0096] Still further, one electrical connection may be provided through a side wall of the enclosure and another electrical connection may be provided through an opposing side wall of the enclosure.

[0097] Figure 4cA first implementation of a first variant of the third type of enclosure 10C1 is shown to illustrate this. In this case, the first conductor 50C exits the enclosure via a first portion of the wall of the second component and the second conductor 52C exits the enclosure via a second portion of the wall of the second component, wherein one portion may be a side of the wall having a rectangular cross-section. In this case, the first conductor 50C may be surrounded by insulating material 56, and the conductor and insulating material may be provided in the form of a tab passing through the wall; and the second conductor 52C may be surrounded by insulating material 54, and the conductor and insulating material may be provided in the form of a tab passing through the wall. It can be seen that in Figure 4b In the first variant of the second type of enclosure in FIG. 1 , the side of the stack along which the first connecting strip 46 is arranged is the same as the side along which the first connecting strip 46 is arranged. It can be seen that the first conductor and the second conductor are connected to the wall through which they leave the enclosure. Figure 4b The same as in.

[0098] As an alternative, one electrical connection may be provided via the top of the enclosure and the other electrical connection may be provided via the bottom of the enclosure.

[0099] Figure 4d A second version of the implementation of a third type of enclosure 10C1 is shown illustrating this. In this case, the first conductor 50D exits the enclosure via the first component, while the second conductor 52D exits the enclosure via the third component. Both conductors are arranged in tabs, with insulation 54 and 56 surrounding the conductors 50d, 52d, and these tabs pass through the corresponding components.

[0100] As a further alternative, the two electrical connections may be provided via the same surface. Thus, they may be provided via the top, the bottom or the same side wall.

[0101] Figure 5a A second part 14C of an enclosure according to the third type is shown in a side view before being folded into a box-like shape and in a side view from above. In this case, there is a first tab 58 for a first electrical connection through the first wall and a second tab 60 for a second electrical connection through the wall, wherein the first tab 58 comprises a first conductor 52C surrounded by insulation 54 and the second tab 60 comprises a second conductor 50C surrounded by insulation 56. Ventilation elements 62 in the form of ventilating discs are provided in the second and fourth walls of the second part 14C to relieve pressure in the enclosure in the event of, for example, thermal runaway.

[0102] Although the ventilation element is shown as being arranged in the second wall and the fourth wall of the second component, it should be appreciated that the ventilation element may be placed in the first wall and / or the third wall instead or in addition. It is also possible that there is only one ventilation element in the second component. The ventilation element may also be arranged on the first component and / or the third component. Therefore, it should be appreciated that the ventilation element may be arranged on the top, the bottom or at least one wall.

[0103] Figure 5b From left to right are shown: a top view of an empty second part 14C of a third type according to a first type of enclosure, wherein the first and second tabs are composed of a first conductor 50C surrounded by insulation 56 and a second conductor 52C surrounded by insulation 54 passing through the first wall and the third wall, and the second part can be composed of a bent and welded / bonded metal sheet or a directly extruded polymer; a stack 46 of sheets, wherein a first connecting strip 46 is provided on the first side of the stack and a second connecting strip 48 is provided on the second side of the stack; and a stack 24, wherein the connecting strips 46 and 48 are placed in the enclosure in contact with the first conductor 56 and the second conductor 54 of the two tabs.

[0104] Figure 5c From left to right, schematically shown are: a side view of the connection between the stack 24 provided by the second part 14C of the first version of the third type of enclosure and the first conductor 50C and the second conductor 52C via the first and second connecting strips; a side view of the connection between the first conductor 50C and the second conductor 52C via the first and second connecting strips provided by the second part 14C of the first version of the third type of enclosure when the second part 14C is engaged with the first part 12C and the third part 28; and a side view of the connection between the first conductor 50C and the second conductor 52C via the first and second connecting strips provided by the second part 14C of the first version of the third type of enclosure when the first wall and the third wall are corrugated for pre-tensioning purposes and when the first part and the second part are pressed against each other.

[0105] according to Figure 5a to Figure 5c As can be seen, at least one electrical connection may include a tab extending from inside the enclosure to outside the enclosure, the tab including a conductor surrounded by insulation.

[0106] 6a and 6b show alternative solutions for providing electrical connection to electrode tabs in the fourth type of cell package 1D and the fifth type of cell package 10E.

[0107] The fourth type of enclosure 10D comprises a first component and a second component 14D, the first component comprising a lid or top 12DL, a bottom 14DW and a bottom 12DB joined by a wall 12DW, and the second component 14D is formed by a first wall 14DW1, a second wall 14DW2 and a third wall 14DW3. The first wall 14DW1 and the third wall 14DW3 of the second component are parallel to each other, while the second wall 14DW2 of the second component is perpendicular to the two walls and joined thereto. The first wall 14DW1 and the third wall 14DW3 are also provided with the previously mentioned tabs. During assembly of the cell, the stack 24 is first connected with the tabs of the first wall 14DW1 and the second wall 14DW3, and the second component is then slid between the top 12DL and the bottom 12DB of the first component until the first wall 14DW1 and the second wall 14DW3 of the second component abut against the wall 12DW of the first component, so that the first wall 14DW1, the second wall 14DW2 and the third wall 14DW3 of the second component together with the wall 12DW of the first component form the side walls of the enclosure between the lid 12DL and the bottom 12DB. The two components can then be joined to each other using any of the previously mentioned techniques, such as gluing, welding, crimping, crimping, etc.

[0108] In the fifth type of enclosure 10E, the bottom 14EB is instead part of the second component perpendicular to and joined to the first wall 14EW1, the second wall 14EW2 and the third wall 14EW3. Here, too, the first wall 14EW1 and the third wall 14EW3 are provided with the previously mentioned tabs. In this case, the second component can be slid under and below the top 12EL of the first component until the first wall 14EW1 and the third wall 14EW3 of the second component abut against the wall 12EW of the first component.

[0109] Here, it should be appreciated that this structure is equally applicable to the stacking of the tabs engaging with the top and bottom of the capsule. In this case, the first and second parts of the capsule of the fourth type and the fifth type can be regarded as the second and first parts of the capsule of the sixth type and the seventh type, respectively.

[0110] Different enclosures can be stacked on top of each other. Thus, the electrochemical device can include two or more enclosures. Additionally, if the enclosures are of the third type, the enclosures can be stacked on top of each other by cooperating between a first mechanical connector of one enclosure and a second mechanical connector of an adjacent enclosure.

[0111] Figures 7a to 7c It is shown how this can be achieved for a third type of enclosure.

[0112] Figure 7aA stack of enclosures 10C1A, 10C1B and 10C1C according to a first version of the third type is shown. According to the figures, here, it can be seen that the inner diameter or side of the first mechanical connection defined by the first edge of the first component is aligned with the outer diameter or side of the second mechanical connection defined by the first edge of the third component. More specifically, a portion of the first edge of the first component resting on the inner surface of the first edge of the second component can be adapted to and rest on a portion of the first edge of the third component resting on the outer surface of the second edge of the second component.

[0113] Additionally, the first part of each enclosure may be electrically insulating, or the enclosure may further include electrical insulation between the first part of the enclosure and the third part of an adjacent enclosure with which it mates.

[0114] Figure 7b A stack-up of capsules 10C2A, 10C2B and 10C2C according to a second version of the third type is shown, in which this case is exemplified. Figure 7b , it can be seen that the first part 12C can also be made electrically insulating, or electrical insulation 64 can be placed between the first part 12C of a capsule in the capsule stack and the third part of the next capsule, where insulation must also be placed around the first mechanical connection. The insulation 64 can be provided as an additional layer on the outside of the first part 12C of each capsule 10C2. As an alternative, this treatment can also be applied to the third part.

[0115] Additionally, a first component of one capsule may be in electrical contact with a third component of an adjacent mating capsule, and in each capsule a second edge of a second component may be electrically isolated from a first edge of the third component and / or a first edge of a second component may be electrically isolated from a first edge of a first component.

[0116] Figure 7c A stack-up of capsules 10C3A, 10C3B and 10C3C according to a third version of a third type is shown, in which this case is exemplified. Figure 7cIt can be seen that electrical interconnection of stacked enclosures can be achieved when the first electrical connection and the second electrical connection are provided via the first component 12C and the third component 28. In this case, the first component 12C and the third component 28 are used to electrically connect one enclosure 10C3B in the enclosure stack to an adjacent enclosure 10C3A. In order to avoid short circuits, the second edge of the second component of the second mechanical connection and in particular the second mechanical connection for said one enclosure 10C3B can be isolated 68 from the first edge of the third component in the same enclosure and the first edge of the first component of the adjacent enclosure 10C3A on which the second mechanical connection rests or is adjacent. Here, it should be recognized that, as an alternative, the first edge of the second component of the first mechanical connection and in particular the second mechanical connection can also be isolated in a similar manner from the first edge of the first component or the first edge of the third component to which the first component is adjacent.

[0117] Therefore, it is possible to achieve this by using only mechanical coupling ( Figure 7a ), mechanical isolation and direct mechanical coupling ( Figure 7b ) and direct electrical coupling ( Figure 7c ) Combine cells into modules, strings and packs. Crimped or bonded cell areas can also be used to fix to the mechanical structure of the module or pack.

[0118] The various aspects of the present disclosure provide solutions to provide rigid cell enclosures and casings with high safety levels at competitive costs, high speeds, and mass production. In addition, many cell chemistries require compression of the cells when assembled in a module or battery pack. This approach is not accurate and results in a complex and failure-prone system with low or unpredictable aging of the entire module or individual cells in the module due to inaccurate compression conditions.

[0119] The main points of this disclosure are as follows:

[0120] Cost-effective half-shell molding with multiple options for subsequent closing of the lid.

[0121] • Embodiments of encapsulating the cell stack in a hybrid housing consisting of a mechanically rigid part and an electrically isolating layer.

[0122] • Combining rigid elements with pre-determined flexible elements to tailor cell compression. These embodiments with pre-tensioned can or can sections allow compression of the electrode stack without compression at the module or pack level (tension-free assembly at module and pack level).

[0123] Use existing large-scale production processes from the food packaging industry that are suitable for the given cell enclosure conditions.

[0124] Case or housing shapes for simple and cost-effective stacking of cells into modules and packs

[0125] From the above discussion, it can be seen that the present invention can be varied in many ways. The schematic diagrams shown represent only exemplary embodiments, and the list of embodiments given is to be regarded as non-limiting. Therefore, it should be recognized that the present invention is limited only by the following claims.

Claims

1. An electrochemical device comprising at least one capsule (10A; 10B1; 10B2; 10B3, 10C1; 10C2; 10C3; 10D; 10E), the at least one enclosure is for a stack (24) of sheets of electrochemical device forming material, the stack comprising at least one sheet of a first type of electrode, at least one sheet of a second type of electrode, and at least one separator sheet located between the sheets of the two types of electrodes, The enclosure comprises a plurality of parts, including a first part (12A; 12B; 12C) and a second part (14A; 14B; 14C), which are joined to each other using welding, crimping, pressing or stamping to form an internal volume (22A; 22B) for accommodating the stack.

2. The electrochemical device of claim 1 , wherein the first component and the second component each have a first edge (12AE, 14AE; 12BE, 14BE), wherein the first edge (12AE; 12BE) of the first component (12A; 12B) engages with the first edge (14AE; 14BE) of the second component (12A; 14A) to form a first mechanical connection (20A; 20B; 20C). 3 . The electrochemical device according to claim 2 , wherein the first edge of the first component is folded around the first edge of the second component, or the first edge of the second component is folded around the first edge of the first component.

4. An electrochemical device according to claim 2 or 3, wherein the components further comprise a third component (28), the third component comprising a first edge, wherein the second component comprises a second edge, and the first edge of the third component engages with the second edge of the second component to form a second mechanical connection (30A; 30B). 5 . The electrochemical device according to claim 4 , wherein the first edge of the third component is folded around the second edge of the second component, or the second edge of the second component is folded around the first edge of the third component.

6. An electrochemical device according to any one of the preceding claims, wherein the enclosure comprises a top (12AL; 12BL; 12DL; 12EL) and a bottom (14AB; 14BB; 28; 12DB; 14EB), the top and the bottom being separated by at least one side wall (14AW; 12BW, 14BW; 12DW, 14DW1, 14DW2, 14DW3; 12EW, 14EW1, 14EW2, 14EW3).

7. The electrochemical device of claim 6, further comprising the stack (24) located in the interior volume, the stack being compressed by pressure applied through the top and the bottom or the first side wall and the other opposing side wall of the enclosure.

8. An electrochemical device according to claim 6 or 7, wherein the top (12AL; 12BL), the bottom (14AB; 14BB) and the at least one side wall (14AW; 12BW, 14BW) are made of a metal material (16) and an electrically insulating material (18) (or a polymer) is coated on the surface of the metal material (16) facing the internal volume.

9. The electrochemical device according to any one of claims 6 to 8, further comprising at least one flexible compression element (32A; 32B1, 32B2), the at least one flexible compression element being on the outside of at least one side wall or on the outside of each of the top and the bottom.

10. The electrochemical device according to any one of claims 6 to 9, wherein the bottom portion (14BB) and / or the top portion (12BL) is corrugated.

11. The electrochemical device according to any one of claims 6 to 10, further comprising at least one pre-tensioning element (34; 14BB), each pre-tensioning element being provided at one end of the stack (24) and facing the top or bottom sheet of the stack (24).

12. The electrochemical device of claim 11, wherein the at least one pre-tensioning element comprises an internal pre-tensioning element (34) placed in the interior volume (22B) between the stack (24) and the top (12BL) or the bottom (14BB) of the enclosure.

13. An electrochemical device according to claim 11 or 12, wherein the at least one pre-tensioning element comprises an external pre-tensioning element (14BB) provided as the top or the bottom of the enclosure.

14. The electrochemical device according to any one of claims 11 to 13, wherein the at least one pre-tensioning element (34, 14BB) is concave with a focal point, and the pre-tensioning element (34; 14BB) is placed between the stack (24) and the focal point.

15. The electrochemical device according to any one of claims 6 to 14, further comprising at least one ventilation element (62) located in the top, the bottom or at least one wall (14C).

16. An electrochemical device according to any preceding claim, further comprising a first electrical connection to an electrode of the first type and a second electrical connection to an electrode of the second type.

17. An electrochemical device according to claim 16 when dependent on claim 2, wherein the first electrical connection and the second electrical connection are provided via the first mechanical connection (20A).

18. An electrochemical device according to claim 16 when dependent on claim 6, wherein one electrical connection is provided through a side wall of the enclosure and the other electrical connection is provided through an opposite side wall of the enclosure.

19. An electrochemical device according to claim 16 when dependent on claim 6, wherein one electrical connection is provided via the top of the enclosure and another electrical connection is provided via the bottom of the enclosure.

20. The electrochemical device of any one of claims 17 to 19, wherein at least one electrical connection comprises a tab (58, 60) extending from inside the enclosure to outside the enclosure, the tab comprising a conductor (52C, 50C) surrounded by insulation (54, 56).

21. An electrochemical device according to any of the preceding claims when dependent on claim 4, comprising two or more capsules, the capsules (10C1A, 10C1B, 10C1C; 10C2A, 10C2B, 10C2C; 10C3A, 10C3B, 10C3C) being stacked on each other by cooperating between the first mechanical connection (20C) of a capsule (10C1A; 10C2A; 10C3A) and the second mechanical connection (30A) of an adjacent capsule (10C1B; 10C2B; 10C3B).

22. An electrochemical device according to claim 21, wherein the mating is achieved by the first mechanical connection, the first mechanical connection has an inner diameter or side defined by the first edge of the first component, the inner diameter or side defined by the first edge of the first component of the first mechanical connection is aligned with the outer diameter or side defined by the first edge of the third component of the second mechanical connection, or the outer diameter or side defined by the first edge of the third component of the second mechanical connection is aligned with the inner diameter or side defined by the first edge of the first component of the first mechanical connection.

23. An electrochemical device according to claim 21 or 22, wherein the first part (12C) of the capsule (10C2A) is electrically insulating, or further comprises electrical insulation (64) between the first part (12C) of the capsule (10C2A) and the third part (28) of the adjacent capsule (10C2B).

24. An electrochemical device according to claim 21 or 22, wherein the first part (12C) of the enclosure (10C3A) is in electrical contact with the third part (28) of the adjacent enclosure (10C3B), and in each enclosure, the second edge of the second part is electrically isolated (68) from the first edge of the third part, and / or the first edge of the second part is electrically isolated from the first edge of the first part.

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