Ultraviolet (UV) assisted stacking system for battery cell stacking mechanism

Abstract

The cell stack includes an electrically insulating material formed as a series of folds that create a plurality of foil support surfaces. The battery foil is disposed between adjacent folds of the series of folds. An amount of ultraviolet (UV)-activated adhesive, the amount of ultraviolet (UV)-activated adhesive disposed between the adjacent foil support surfaces of the plurality of foil support surfaces. The amount of UV-activated adhesive joins adjacent foil support surfaces of the plurality of foil support surfaces to each other to form a consolidated battery pack.

Description

Technical Field

[0001] The present disclosure relates to the field of battery cell stacking mechanisms, and more particularly, to an ultraviolet (UV) assisted stacking system for a battery cell stacking mechanism. Background Art

[0002] Manufacturing speed and product reliability are important factors in battery cell production. Many soft packaged lithium-ion batteries rely on insulating members located between adjacent battery components. Typically, the insulating member takes the form of a continuous sheet of electrically insulating material that is folded over the battery components to form a battery stack. In one example, the electrically insulating material passes through a mechanism that creates alternating layers. In one example, the alternating layers are folded and pressed against the battery electrodes to form a "Z-fold battery stack." Other systems can manipulate this structure to form a "jelly roll battery stack."

[0003] Once the selected number of electrodes are separated and formed, the battery stack is removed, secured and stored for transport. Given the nature of the battery stack, an incompletely secured fold may allow the electrodes to slide or become misaligned. This misalignment may be exacerbated when the battery stack is transported. Misalignment of the battery electrodes may have an adverse effect on battery efficiency. Therefore, it is desirable to provide a system for securing the battery foil between the folds of the battery stack. Summary of the invention

[0004] A battery stack according to a non-limiting example includes an electrically insulating material formed into a series of folds that create a plurality of foil support surfaces. A battery foil is disposed between adjacent folds in the series of folds. An amount of ultraviolet (UV) activated adhesive is disposed between adjacent foil support surfaces in the plurality of foil support surfaces. The amount of UV activated adhesive bonds adjacent foil support surfaces in the plurality of foil support surfaces to each other to form a consolidated battery pack.

[0005] In addition to one or more features described herein, each of the plurality of foil support surfaces includes a first dimension defining a first axis and a second dimension defining a second axis, the first dimension being smaller than the second dimension.

[0006] In addition to one or more features described herein, the amount of UV activated adhesive is applied to each of the plurality of foil support surfaces along the first axis.

[0007] In addition to one or more features described herein, each of the plurality of foil support surfaces includes a first end and a second end opposite the first end, the second end being spaced apart from the first end by the second dimension, the quantity of UV activated adhesive being applied to each of the plurality of foil support surfaces along the first axis at each of the first end and the second end.

[0008] In addition to one or more features described herein, each of the plurality of foil support surfaces includes a fold edge extending along the second axis, and a pre-fold edge extending along the second axis and spaced apart from the fold edge by the first dimension.

[0009] In addition to one or more features described herein, the amount of UV activated adhesive is applied to the folded edge along the second axis.

[0010] In addition to one or more features described herein, an amount of UV activated adhesive is applied to the pre-folded edge.

[0011] In addition to one or more features described herein, each of the plurality of foil support surfaces includes a foil support area defined by the first dimension and the second dimension, the amount of UV activated adhesive covering the foil support area.

[0012] In addition to one or more features described herein, the amount of UV activated adhesive substantially completely covers the foil support area.

[0013] According to a non-limiting example, a system for stacking and joining battery cells includes: a stacking station including a stacking surface, a first battery foil supply station arranged on a first side of the stacking station, a second battery foil supply station arranged at a second side of the stacking station, and a folding arm supporting an electrically insulating sheet feeding system and a folding guide. The folding arm is operable to form a series of folds in the electrically insulating sheet, thereby generating a plurality of foil support surfaces. A battery foil assembly system is operable to position a battery foil from each of the first battery foil supply station and the second battery foil supply station on a selected foil support surface of the plurality of foil support surfaces, wherein the selected foil support surface of the plurality of foil support surfaces includes a certain amount of ultraviolet (UV) activated adhesive.

[0014] In addition to one or more features described herein, a UV light source is disposed adjacent to the stacking stage.

[0015] In addition to one or more features described herein, the UV light source is fixedly mounted relative to the stacking table.

[0016] In addition to one or more features described herein, a UV light source is mounted to the folding arm.

[0017] In addition to one or more features described herein, the folded arms create a battery stack wherein each of the plurality of foil support surfaces includes a first dimension defining a first axis and a second dimension defining a second axis, the first dimension being smaller than the second dimension.

[0018] In addition to one or more features described herein, the amount of UV activated adhesive is applied to each of the plurality of foil support surfaces along the first axis.

[0019] In addition to one or more features described herein, the folded arm forms each of the plurality of foil support surfaces to include a first end and a second end opposite the first end, the second end being spaced apart from the first end by a second dimension, and a quantity of UV activated adhesive is applied to each of the plurality of foil support surfaces along a first axis at each of the first end and the second end.

[0020] In addition to one or more features described herein, the folding arm forms each of the plurality of foil support surfaces to include a fold edge extending along the second axis, and a pre-fold edge extending along the second axis and spaced apart from the fold edge by a first dimension.

[0021] In addition to one or more features described herein, the amount of UV activated adhesive is applied to the folded edge along the second axis.

[0022] In addition to one or more features described herein, an amount of UV activated adhesive is applied to the pre-folded edge.

[0023] In addition to one or more features described herein, the folded arm forms each of the plurality of foil support surfaces to include a foil support area defined by a first size and a second size, with an amount of UV activated adhesive covering the foil support area.

[0024] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages and details appear, by way of example only, from the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 depicts a system for Z-stacking and joining battery cells according to a non-limiting example;

[0027] Figure 2 is a plan view of a battery cell stack bonded with an ultraviolet (UV) activated adhesive according to a non-limiting example;

[0028] Figure 3 is a plan view of a battery foil support surface including an amount of UV activated adhesive according to a non-limiting example;

[0029] Figure 4 is a plan view of a battery foil support surface including an amount of UV activated adhesive according to another non-limiting example;

[0030] Figure 5 Depicted is a non-limiting example of a UV light source. Figure 1 The Z-shaped folding arm of the system;

[0031] Figure 6 Depicted is a UV light source according to another non-limiting example. Figure 1 The Z-folding arm of the system; and

[0032] Figure 7 According to a non-limiting example, in a UV light box by Figure 1 The battery stack formed by the system. DETAILED DESCRIPTION

[0033] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0034] According to a non-limiting example, a system for Z-stacking and joining battery cells is provided in Figure 1 The system 10 is generally indicated at 10. The system 10 includes a stacking station 12 and a battery foil assembly system 13, the battery foil assembly system 13 including a first battery foil supply station 14 arranged on one side of the stacking station 12 and a second battery foil supply station 16 arranged on the opposite side of the stacking station 12. The system 10 includes a Z-folding arm 18 with an electrically insulating material feeding system 20. The Z-folding arm 18 places a certain amount of electrically insulating material 22 onto the stacking station 12 to form a battery foil assembly system 13. Figure 2 The battery stack 24 is shown. The Z-folded arm 18 includes an ultraviolet (UV) light shield 26 including a first shield member 28 and a second shield member 30 that shield a certain amount of the electrically insulating material 22 from UV light, as will be described in more detail herein.

[0035] exist Figure 2In the non-limiting example shown, the Z-shaped folding arm 18 includes a tip 32 having a pair of guide rollers 34 that move the electrically insulating material back and forth on the stacking table 12 to form the battery stack 24. The guide rollers 34 move a volume of the electrically insulating material 22 through a selectively displaceable folding guide 36 to create a series of folds 38. In the non-limiting example, each of the series of folds 38 is Z-shaped, thereby forming a foil support surface 42, and the battery foil assembly system 13 positions the battery foil 44 on the foil support surface 42. The plurality of battery foils 44 and the plurality of battery support surfaces 42 form a consolidated battery stack 46, as shown in FIG. Figure 7 At this point, it should be understood that the series of folds may take other geometric shapes.

[0036] Now refer to Figure 3 , continue to refer to Figure 2 , one of a plurality of foil support surfaces 42 is described in a non-limiting example. The foil support surface 42 includes a first dimension D1 defining a first axis and a second dimension D2 defining a second axis substantially perpendicular to the first axis. In the non-limiting example, the first dimension D1 is smaller than the second dimension D2. The foil support surface 42 includes a folding edge 56 extending along the second axis and a pre-folding edge 58 extending along the second axis. At this point, it should be understood that the term "folding edge" describes an edge that has been folded on the folding guide 36, and the term "pre-folding edge" describes an edge that has not yet been folded. As shown in FIG. Figure 3 As shown, a dimension D2 is defined between the first end 59 and the second end 60 of the foil support surface 42 .

[0037] In a non-limiting example, a curing system, shown in the form of a UV lamp 61, is fixedly mounted relative to the stacking station 12 along the first axis. A certain amount of UV activated adhesive 64 is applied to the foil support surface 42. In a non-limiting example, the amount of UV activated adhesive 64 is applied on the first axis at the first end 59 and the second end 60. Once applied, the Z-folded arm 18 is displaced to position a new layer of electrically insulating material 22 over the battery foil 44, thereby creating a new foil support surface 42. At this time, the UV lamp 61 can be illuminated to activate the amount of UV activated adhesive 64 applied to the foil support surface 42. In this way, the battery stack 24 includes multiple adhesive layers that are more stable and less prone to displacement when stored or transported.

[0038] Now refer to Figure 4 And continue to refer to Figure 2, wherein like reference numerals denote corresponding parts in the corresponding views when describing alternative applications of UV activated adhesive 64 according to non-limiting examples. In the non-limiting example shown, a quantity of UV activated adhesive 64 is applied to the pre-folded edge 58 along the second axis. Of course, additional UV activated adhesive 64 may also be applied to the folded edge 56 along the second axis. The UV lamp 61 is fixedly mounted relative to the stacking station 12 along the second axis. In a manner similar to that discussed herein, the UV lamp 61 is selectively activated to cure the quantity of UV activated adhesive 64 so as to join the series of folds 38 to produce a consolidated battery stack 46 ( Figure 7 ).

[0039] Now refer to Figure 5 , wherein like reference numerals denote corresponding parts in the respective views when describing a Z-fold arm 70 according to another non-limiting example. The Z-fold arm 70 includes a first UV lamp 72 and a second UV lamp 74 mounted to the end 32 at the guide roller 34. In the non-limiting example shown, the foil support surface 42 includes a foil support area 76 defined by a first dimension D1 and a second dimension D2. The foil support area 76 is coated with a certain amount of UV activated adhesive 64. At this point, it is apparent that the number and location of the UV lamps mounted at the end 32 can vary and can depend on the location, geometry, and amount of UV activated adhesive 64 employed.

[0040] In a non-limiting example, according to a non-limiting example, as the Z-shaped fold arm 70 traverses the series of folds 38 to apply a new layer of electrically insulating material 22 and form a new foil support surface 42, a UV lamp 74 is irradiated to cure a certain amount of UV-activated adhesive 64 so as to connect the series of folds 38 to produce a consolidated battery stack 46.

[0041] exist Figure 6 , the UV light 72 is shown in the form of a UV light roller 84, which not only activates a certain amount of UV activated adhesive 64, but also applies moving pressure to the series of folds 38 to produce a more cohesive bond. In a non-limiting example, as Figure 7 As shown, the consolidated battery stack 46 is formed by a selected number of series of folds 38 joined together with the battery foil 44. After formation, the consolidated battery stack 46 can be placed in a UV light box 100, where the amount of UV activated adhesive 64 is further cured by a plurality of UV light sources 102, such as Figure 7 shown.

[0042] Although shown and described in conjunction with a battery stack formed with a Z-fold, the non-limiting examples described herein may be used in various other battery pack manufacturing processes that may employ stacking of components, rolling of components, etc. For example, the UV activated adhesive may be incorporated into a monolithic stacking process, a winding process, and other processes for embedding electrodes between electrically insulating sheet materials used to manufacture a battery stack. In addition, although shown as being applied to a separator, the UV activated adhesive may be applied to an electrode or both a separator and an electrode. The amount of adhesive applied, the shape of the adhesive applied, and the adhesive application location may vary.

[0043] The term "one" does not indicate a limitation of quantity, but rather indicates the presence of at least one of the referenced items. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0044] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0045] Unless otherwise indicated herein, all test standards are the most current standards in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standards appear.

[0046] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0047] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery stack, comprising: an electrically insulating material formed into a series of folds that create a plurality of foil support surfaces; a battery foil disposed between adjacent folds in the series of folds; as well as An amount of ultraviolet activated adhesive, i.e., an amount of UV activated adhesive, is disposed between adjacent ones of the plurality of foil support surfaces, the amount of UV activated adhesive bonding the adjacent ones of the plurality of foil support surfaces to each other to form a consolidated battery stack. 2 . The battery stack of claim 1 , wherein each of the plurality of foil support surfaces includes a first dimension defining a first axis and a second dimension defining a second axis, the first dimension being smaller than the second dimension. 3 . The battery stack of claim 2 , wherein the amount of UV activated adhesive is applied to each of the plurality of foil support surfaces along the first axis.

4. The battery stack of claim 3 , wherein each of the plurality of foil support surfaces comprises a first end and a second end opposite the first end, the second end being spaced apart from the first end by the second dimension, the amount of UV activated adhesive being applied to each of the plurality of foil support surfaces along the first axis at each of the first end and the second end. 5 . The battery stack of claim 2 , wherein each of the plurality of foil support surfaces includes a folded edge extending along the second axis, and a pre-folded edge extending along the second axis and spaced apart from the folded edge by the first dimension.

6. The battery stack of claim 5, wherein the amount of UV activated adhesive is applied to the folded edge along the second axis.

7. The battery stack of claim 6, wherein the amount of UV activated adhesive is applied to the pre-folded edge.

8. The battery stack of claim 2, wherein each of the plurality of foil support surfaces includes a foil support area defined by the first dimension and the second dimension, the amount of UV activated adhesive covering the foil support area.

9. The cell stack of claim 8, wherein the amount of UV activated adhesive substantially completely covers the foil support area.

10. A system for stacking and connecting battery cells, comprising: a stacking station, the stacking station comprising a stacking surface; a first battery foil supply station arranged at a first side of the stacking station; a second battery foil supply station, the second battery foil supply station being arranged on a second side of the stacking station; as well as a folding arm supporting the electrically insulating sheet feed system and the folding guide, the folding arm being operable to form a series of folds in the electrically insulating sheet to create a plurality of foil support surfaces; as well as a battery foil assembly system operable to position the battery foil from each of the first battery foil supply station and the second battery foil supply station on a selected foil support surface of the plurality of foil support surfaces, Wherein the selected one of the plurality of foil support surfaces comprises an amount of ultraviolet activated adhesive.

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