Scalable manufacturing process for battery cells having stacked electrodes

Abstract

A method of manufacturing a battery cell includes providing a battery cell container. The method also includes creating a first battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode. The method additionally includes creating a second battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode. The method further includes stacking the first battery cell and the second battery cell such that the second separator of the first battery cell is adjacent to the cathode of the second battery cell. The method further includes arranging the stacked first and second battery cells in a battery cell container.

Description

Technical Field

[0001] The present disclosure relates to a scalable manufacturing process for battery cells having stacked electrodes. Background Art

[0002] Electrochemical battery cells can be broadly divided into primary and secondary batteries. Primary batteries, also known as disposable batteries, are designed to be used until they are exhausted, after which they can simply be replaced with new batteries. Secondary batteries, often called rechargeable batteries, use specific chemistries that allow them to be repeatedly charged and reused, thus offering economic, environmental, and ease-of-use benefits over disposable batteries. Electrochemical batteries can be used to power a variety of items, including toys, consumer electronics, and motor vehicles.

[0003] An electrochemical cell comprises at least one pair of anode and cathode electrodes sealed in a cell container. The anode and cathode electrodes are typically configured as wires or plates. The electrodes of an electrochemical cell are typically immersed in a liquid electrolyte or separated by a solid electrolyte membrane that conducts ions when the cell is charged or discharged. A battery cell may include one or more stacks of the electrodes in question to suit specific power, energy and packaging requirements. The corresponding anode and cathode electrodes in such a stack are typically connected by corresponding welding tabs, which are themselves connected to battery terminals mounted on the outside of the cell container.

[0004] Battery cells come in a variety of sizes and shapes - cylindrical, prismatic, and pouch cells are widely used. Multi-cell rechargeable energy storage systems (RESS) often use many battery cells arranged in an array, typically on the order of hundreds to thousands of battery cells for electric vehicles. For example, multiple battery cells may be connected in parallel to form a single layer, multiple layers may be connected in series to form a battery module, and multiple such modules may be assembled in series to form a battery pack with a desired output. Each battery cell in such an array may include multiple electrode stacks. Therefore, an efficient process for large-scale manufacturing of electrodes and electrode stacks for such battery cell arrays may be needed. Summary of the invention

[0005] A method of manufacturing a battery cell includes providing a battery cell container. The method also includes producing a first battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode. The method also includes producing a second battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode. The method also includes stacking the first battery cell and the second battery cell such that the second separator of the first battery cell is adjacent to the cathode of the second battery cell. The method also includes arranging the stacked first and second battery cells in the battery cell container.

[0006] Stacking the first battery cell and the second battery cell may include arranging one or more spring elements between the first battery cell and the second battery cell.

[0007] Stacking the first battery cell and the second battery cell may further comprise arranging a first support element in contact with the cathode of the first battery cell and a second support element in contact with the second separator of the first battery cell. Thereby, the spring element may be sandwiched by the first support element and the second support element.

[0008] Alternatively, stacking the first battery cell and the second battery cell may include arranging a foam element between the first battery cell and the second battery cell.

[0009] Producing the first and second battery cells may include extracting respective anodes and cathodes from corresponding sheets of electrode material.

[0010] Extracting the respective anode and cathode may include cutting the respective anode and cathode from the corresponding electrode material sheet using a die or a laser.

[0011] The sheets of electrode material may be constructed from respective anode and cathode materials. In such embodiments, producing the first and second battery cells may include coating the respective electrode materials onto respective substrate foils.

[0012] Each of the respective anodes and cathodes may include at least one conductive tab. In such an embodiment, applying the respective electrode material to the respective substrate foil may include: producing a respective strip of coating material for each of the anodes and cathodes, and producing at least one exposed material portion on each respective substrate foil for the corresponding conductive tab. Additionally, applying the respective electrode material on the substrate foil may include producing at least one exposed material portion on each respective substrate foil for the corresponding conductive tab.

[0013] Each cathode of the respective first and second battery cells may be defined by a corresponding outer perimeter. In such an embodiment, producing the first and second battery cells includes arranging each cathode in a row and coating the outer perimeter of each respective cathode with an electrically insulating material.

[0014] Producing the first and second battery cells may include masking each conductive tab prior to coating an outer perimeter of each respective cathode.

[0015] The battery cell container may include a battery terminal. Furthermore, the first battery cell and the second battery cell may be stacked along a stacking axis. In such an embodiment, the method may further include mechanically connecting the conductive tab of each battery cell to the battery terminal via a welding tab arranged along the stacking axis. The welding tab in question may include an expandable portion configured to absorb alternating expansion and contraction of the first and second battery cells when the battery cells are charged and discharged, respectively.

[0016] The battery cells can be cylindrical, prismatic or pouch cells with liquid or solid electrolytes.

[0017] Furthermore, the battery cells may be lithium-ion battery cells.

[0018] The present invention provides the following technical solutions:

[0019] 1. A method for manufacturing a battery cell, comprising:

[0020] Providing battery cell containers;

[0021] producing a first battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode;

[0022] producing a second battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode;

[0023] stacking the first battery cell and the second battery cell such that the second separator of the first battery cell is adjacent to the cathode of the second battery cell; and

[0024] The stacked first battery cell and the second battery cell are arranged in a battery cell container.

[0025] 2. The method for producing a battery cell according to claim 1, wherein stacking the first battery cell and the second battery cell comprises arranging at least one spring element between the first battery cell and the second battery cell.

[0026] 3. A method for manufacturing a battery cell according to Option 2, wherein stacking the first battery cell and the second battery cell further includes arranging a first support element in contact with the cathode of the first battery cell and a second support element in contact with the second diaphragm of the first battery cell, so that at least one spring element is sandwiched between the first support element and the second support element.

[0027] 4. The method for manufacturing a battery cell according to claim 1, wherein producing the first battery cell and the second battery cell comprises extracting respective anodes and cathodes from corresponding electrode material sheets.

[0028] 5. A method for manufacturing a battery cell according to Option 4, wherein extracting the respective anodes and cathodes comprises one of the following: die-cutting the respective anodes and cathodes from the corresponding electrode material sheets, and laser cutting the respective anodes and cathodes from the corresponding electrode material sheets.

[0029] 6. The method according to claim 4, wherein the electrode material sheet is composed of respective anode materials and cathode materials, and wherein producing the first battery cell and the second battery cell comprises coating the respective electrode materials onto corresponding substrate foils.

[0030] 7. A method for manufacturing a battery cell according to Option 6, wherein each of the respective anodes and cathodes includes at least one conductive tab, and wherein coating the respective electrode materials onto the respective substrate foils includes: producing respective coating material strips for each of the anodes and cathodes, and producing at least one exposed material portion for the respective conductive tab on each respective substrate foil.

[0031] 8. A method for manufacturing a battery cell according to Option 7, wherein each cathode of the respective first battery cell and the second battery cell is defined by a corresponding outer periphery, and wherein producing the first battery cell and the second battery cell includes: arranging each cathode in a row and coating the outer periphery of each respective cathode with an electrically insulating material.

[0032] 9. The method of manufacturing a battery cell according to claim 8, wherein producing the first battery cell and the second battery cell includes masking each conductive tab prior to coating the outer periphery of each respective cathode.

[0033] 10. The method for manufacturing a battery cell according to claim 1, wherein the battery cell is one of a cylindrical battery cell, a square battery cell and a pouch battery cell.

[0034] 11. A method for manufacturing a lithium-ion cylindrical battery cell, comprising:

[0035] Providing battery cell containers;

[0036] A first battery cell is produced, which has a respective lithium metal anode, a cathode, a first separator arranged therebetween, and a second separator arranged adjacent to the respective anode:

[0037] producing a second battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode;

[0038] wherein producing the first and second battery cells comprises cutting the respective anodes and cathodes from the respective electrode material sheets by one of a die and a laser, thereby extracting the respective anodes and cathodes from the respective electrode material sheets;

[0039] stacking the first battery cell and the second battery cell such that the second separator of the first battery cell is adjacent to the cathode of the second battery cell; and

[0040] The stacked first battery cell and the second battery cell are arranged in a battery cell container.

[0041] 12. The method for manufacturing a lithium-ion cylindrical battery cell according to claim 11, wherein stacking the first battery cell and the second battery cell comprises: arranging at least one spring element between the first battery cell and the second battery cell.

[0042] 13. A method for manufacturing a lithium-ion cylindrical battery cell according to Option 12, wherein stacking the first battery cell and the second battery cell further includes arranging a first support element in contact with the cathode of the first battery cell and a second support element in contact with the second diaphragm of the first battery cell, so that at least one spring element is sandwiched between the first support element and the second support element.

[0043] 14. A method for manufacturing a lithium-ion cylindrical battery cell according to Option 11, wherein the electrode material sheet is composed of respective anode materials and cathode materials, and wherein producing the first battery cell and the second battery cell includes coating the respective electrode materials onto corresponding substrate foils.

[0044] 15. A method for manufacturing a lithium-ion cylindrical battery cell according to Option 14, wherein each of the respective anodes and cathodes includes at least one conductive tab, and wherein coating the respective electrode materials onto the corresponding substrate foils includes: producing respective coating material strips for each of the anodes and cathodes, and producing at least one exposed material portion for the corresponding conductive tab on each respective substrate foil.

[0045] 16. A method for manufacturing a lithium-ion cylindrical battery cell according to Option 15, wherein each cathode of a respective first battery cell and a second battery cell is defined by a corresponding outer periphery, and wherein producing the first battery cell and the second battery cell includes arranging each cathode in a row and coating the outer periphery of each respective cathode with an electrically insulating material.

[0046] 17. The method of manufacturing a lithium-ion cylindrical battery cell according to claim 16, wherein producing the first battery cell and the second battery cell includes masking each conductive tab prior to coating the outer periphery of each respective cathode.

[0047] 18. A method for manufacturing a lithium ion battery cell, the method comprising:

[0048] Providing battery cell containers;

[0049] Producing a first battery cell having a respective lithium metal anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode;

[0050] producing a second battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode;

[0051] Stacking a first battery cell and a second battery cell such that a second separator of the first battery cell is adjacent to a cathode of the second battery cell, comprising:

[0052] at least one spring element is arranged between the first battery cell and the second battery cell; and

[0053] Arranging a first support element in contact with the cathode of the first battery cell and a second support element in contact with the second separator of the first battery cell such that at least one spring element is sandwiched between the first support element and the second support element; and

[0054] The stacked first battery cell and the second battery cell are arranged in a battery cell container.

[0055] 19. A method for manufacturing a battery cell according to Option 18, wherein producing the first battery cell and the second battery cell includes extracting the respective anodes and cathodes by cutting the respective anodes and cathodes from corresponding electrode material sheets by one of a mold and a laser.

[0056] 20. The method according to claim 19, wherein the electrode material sheet is composed of respective anode materials and cathode materials, and wherein producing the first battery cell and the second battery cell comprises coating the respective electrode materials onto corresponding substrate foils.

[0057] The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the embodiments and the best mode for carrying out the described disclosure when taken in conjunction with the accompanying drawings and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Figure 1are schematic perspective illustrations of three exemplary embodiments of battery cells, each with a corresponding cell container.

[0059] Figure 2 yes Figure 1 A schematic interior view of a cylindrical battery cell is shown, illustrating a plurality of electrode stacks arranged inside respective battery cell containers and conductive tabs having expandable portions arranged between the electrode stacks in accordance with the present disclosure.

[0060] Figure 3 According to this disclosure Figure 2 A schematic close-up partial cross-sectional view of a cylindrical battery cell and electrode stack is shown, illustrating the arrangement of the anode and cathode therein.

[0061] Figure 4 According to this disclosure Figure 3 A schematic close-up top view of a pair of anodes and cathodes is shown.

[0062] Figure 5 According to this disclosure Figure 1 The schematic interior view of a prismatic battery cell is shown, showing a plurality of electrode stacks arranged inside a respective battery cell container, the electrode stacks having electrically conductive tabs with expandable portions arranged between the electrode stacks.

[0063] Fig. 6A yes Figure 1 A schematic perspective view of an embodiment of a prismatic battery cell is shown, illustrating a plurality of vertically arranged electrode stacks arranged within respective cell containers and conductive tabs having expandable portions arranged between the electrode stacks in accordance with the present disclosure.

[0064] Figure 6B According to this disclosure Figure 1 A schematic perspective view of an embodiment of a prismatic battery cell is shown, showing a plurality of electrode stacks arranged horizontally within respective cell containers and conductive tabs having expandable portions arranged between the electrode stacks.

[0065] Figure 7 According to this disclosure Figure 1 A schematic interior view of one embodiment of a pouch battery cell is shown, illustrating a plurality of electrode stacks disposed within respective cell containers and a conductive tab having an expandable portion disposed between the electrode stacks.

[0066] Figure 8 It is shown that according to the present disclosure Figures 1 to 7 Flow chart of a method for manufacturing a battery cell of the structure shown.

[0067] Fig. 9 Shown by Figure 8A representative battery cell constructed using the method shown.

[0068] Fig.10 Shown according to Figure 8 The method shown is for Fig. 9 The arrangement and stacking of the anode, cathode and separator of a battery cell are shown.

[0069] Fig.11 Sheets of electrode material are shown for the respective anode and cathode.

[0070] Fig.12 Shown according to Figure 8 The method shown is from Fig.11 The corresponding electrode material sheets shown are extracted from the respective anode and cathode.

[0071] Fig.13 Shown according to Figure 8 The method shown in coats the outer periphery of each respective cathode with an electrically insulating material. DETAILED DESCRIPTION

[0072] Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," "left," "right," and the like are used descriptively with respect to the drawings and are not intended to limit the scope of the present disclosure as defined by the appended claims. Furthermore, the present teachings may be described herein in terms of functional and / or logical block components and / or various processing steps. It should be recognized that such block components may include a plurality of hardware, software, and / or firmware components configured to perform the specified functions.

[0073] Referring to the accompanying drawings, three exemplary embodiments of a battery cell 10 are depicted. Specifically, Figure 1 A cylindrical battery cell 10A, a prismatic battery cell 10B, and a pouch battery cell 10C are depicted. In general, battery cells generate electrical energy through an electrochemical reaction that generates heat. Battery cells 10, such as battery cells 10A, 10B, 10C, are configured as secondary (i.e., rechargeable) energy storage units. Battery cells 10 may, for example, be configured as lithium-ion (Li-ion) or lithium metal battery cells. Battery cells, such as Figure 1 The battery cells 10A, 10B, 10C shown in the drawings can be used to operate toys, consumer electronics, and motor vehicles. Multiple cylindrical or prismatic battery cells can be combined together in a battery module or battery pack to enhance performance in a particular application.

[0074] The cylindrical battery cell 10A generally operates like the rectangular prismatic battery cell 10B and the pouch battery cell 10C, and the three battery cell types include functionally similar internal components. Figure 2As schematically shown in cross-section in FIG. 1 , the assembled cylindrical battery cell 10A includes a plurality of electrode stacks, shown as a first stack 12 - 1 and a second stack 12 - 1 . Figure 3 As shown, each electrode stack 12-1, 12-2 includes at least one pair of alternating anode 14 (e.g., lithium metal electrodes) and cathode 16 (e.g., lithium nickel manganese cobalt oxide (NMC) electrodes) elements. Figure 3 As shown, each electrode stack 12-1, 12-2 includes a separator 18 located between each anode and cathode. Each separator 18 includes or contains a liquid electrolyte configured to conduct ions when the battery cell 10 is discharged or charged. The separator 18 with the electrolyte is arranged to contact the anode 14 and cathode 16 elements in each anode and cathode element pair and is located between the anode 14 and cathode 16 elements, so that each anode and cathode is immersed in the electrolyte or surrounded by the electrolyte. The battery cell 10 can use a liquid electrolyte or a solid electrolyte membrane to separate adjacent anodes 14 and cathodes 16. Although substantially circular electrodes 14, 16 with one flat side are shown, it is not excluded that the electrodes have any desired shape, such as elliptical, rectangular, trapezoidal, etc.

[0075] A single pair of alternating anode 14 and cathode 16 elements together with two separators (a first separator 18-1 arranged between the anode and cathode in question and a second separator 18-2 arranged near the anode) is defined herein as a "monocell". A monocell is a single independent sub-battery cell that can be used as a building block for constructing the first and second electrode stacks 12-1, 12-2 (and more) that are subsequently assembled into the battery cell 10. Therefore, the number of monocells in each electrode stack and the total number of stacks can define the desired size, capacity and output of the resulting battery cell. Thus, the electrode stacks 12-1, 12-2 are assembled from one or more monocells. The first such monocell is identified in the accompanying drawings by the reference numeral 19-1, while the second monocell is identified by the reference numeral 19-2.

[0076] Continue to refer Figure 1 , each embodiment of the battery cell 10 also includes a cell housing or container 20. Specifically, the container 20 of the cylindrical battery cell 10A and the square battery cell 10B can be constructed of a rigid material, typically aluminum or steel. On the other hand, the container 20 of the soft-pack battery cell 10C can be constructed of a flexible or bendable material, such as an aluminum laminate film made of aluminum foil sandwiched between polymer layers. The cell container 20 is typically sealed, for example, by crimping, adhesive, or welding, to maintain volatile and reactive substances within the respective battery cells 10 during the charge / discharge cycle, and to prevent moisture that is harmful to the performance of the battery from entering the battery cell. The container 20 is typically arranged along the longitudinal axis Y of the battery, and defines an inner chamber 22 configured to accommodate the first electrode stack 12-1 and the second electrode stack 12-2.

[0077] like Figure 1 As shown, the container 20 includes an externally mounted first or negative battery terminal 24 and an externally mounted second or positive battery terminal 26 for establishing an electrical connection between the battery cell in question and an external load. For example, as can be seen with respect to the cylindrical battery cell 10A, the negative battery terminal 24 and the positive battery terminal 26 may be arranged at opposite sides or ends of the container 20 (e.g., one terminal is at the top of the corresponding container and the other terminal is at the bottom when the battery cell is arranged upright in the module). Alternatively, as can be seen with respect to the square battery cell 10B and the soft pack battery cell 10C, the negative battery terminal 24 and the positive battery terminal 26 may be arranged adjacent to each other on the same side or opposite sides of the container 20. Thus, the battery cell 10 may have top, top and bottom, or side mounted battery terminals 24, 26. The container 20 may also include a vent 27.

[0078] like Figure 3 As shown, the battery cell 10 also includes a first electrically conductive welding tab 28 disposed within the interior chamber 22. The first welding tab 28 is mechanically connected (typically welded) to the first battery terminal 24 and fixedly connected to each anode element 14 in the first and second electrode stacks 12-1, 12-2. The battery cell 10 further includes a second electrically conductive welding tab 30 disposed within the interior chamber 22. The second welding tab 30 is mechanically connected (similarly, typically welded) to the second battery terminal 26 and fixedly connected to each cathode element 16 in the first and second electrode stacks 12-1, 12-2. Figure 4 As shown, each anode element 14 may have a corresponding negative electrode tab 14-1, and each cathode element 16 may have a corresponding positive electrode tab 16-1. Figure 3 As shown, the negative tab 14-1 and the positive tab 16-1 may be folded and welded to the respective first and second welding tabs 28, 30. Thus, each anode 14 is in continuous electrical contact with the negative terminal 24, and each cathode 16 is in continuous electrical contact with the positive terminal 26.

[0079] Continue to refer Figure 3 , the first welding tab 28 includes a first expandable portion 28-1 disposed between the first and second electrode stacks 12-1, 12-2. Similarly, the second welding tab 30 includes a second expandable portion 30-1 disposed between the first electrode stack 12-1 and the second electrode stack 12-2. Each of the first expandable portion 28-1 and the second expandable portion 30-1 is configured to absorb alternating expansion and contraction of the first electrode stack 12-1 and the second electrode stack 12-2 when the battery cell 10 is charged and discharged, respectively. The expansion and contraction of the first electrode stack 12-1 and the second electrode stack 12-2 occurs primarily due to changes in the volume of the anode element 14. As Figure 3 , Figure 5 , Fig. 6A , Figure 6B and Figure 7 As shown, each of the expandable portions 28-1, 30-1 may be configured as an accordion or bellows portion of the respective weld tab 28, 30 configured to selectively extend and compress to accommodate expansion and contraction of the first and second electrode stacks 12-1, 12-2.

[0080] Each of the first welding tab 28 and the second welding tab 30 and each of the first expandable portion 28-1 and the second expandable portion 30-1 can be arranged parallel to the longitudinal battery axis Y, for example, when the electrode stacks 12-1, 12-2 are positioned along the axis Y (e.g., Figure 2 Alternatively, each of the first expandable portion 28-1 and the second expandable portion 30-1 may be arranged perpendicular to the longitudinal battery axis Y, for example, when the electrode stacks 12-1, 12-2 are positioned in a plane orthogonal to the axis Y (as shown in FIG. Fig. 6A and 6B In the square battery cell 10B and the soft-pack battery cell 10C). Figure 7 A specific embodiment of a pouch cell 10C is shown in FIG. 1 , showing the arrangement of conductive tabs 28 , 30 between the electrode stacks relative to the side mounted negative and positive terminals 24 , 26 and relative to the longitudinal cell axis Y.

[0081] like Figure 2 and Figure 6B As shown, one or more spring elements 32 may be arranged between the first electrode stack 12-1 and the second electrode stack 12-2. The spring elements 32 are intended to accommodate the expansion of the first electrode stack 12-1 and the second electrode stack 12-2 inside the battery cell container 20. In addition, the battery cell 10 may include a first support plate 34 disposed adjacent to the first electrode stack 12-1 and a second support plate 36 disposed adjacent to the second electrode stack 12-2. The spring element 32 may be arranged between the first support plate 34 and the second support plate 36. Alternatively or additionally, the battery cell 10 may include a foam element 38 (such as Figure 5 and 6A ). The larger first expandable portion 28-1 and the second expandable portion 30-1 can be used to accommodate the expansion and contraction of the spring or foam elements 32, 38. Figure 3 and Figure 5 As shown, the first and second expandable portions 28-1, 30-1 may be configured to provide greater elongation adjacent the spring or foam elements 32, 38 than the area between the stacks 12-1, 12-2 without such intervening factors.

[0082] Continue to refer Figure 2 The battery cell container 20 has an inner surface 20-1 facing the inner chamber 22. The first conductive welding tab 28 and the second conductive welding tab 30 may be disposed in a region 22A of the inner chamber 22 between the first and second electrode stacks 12-1, 12-2 and the inner surface 20-1. The battery cell 10 may further include a separation bracket 40. Figure 2 As shown, a separator bracket 40 is disposed in region 22A and is configured to prevent cell shorting by maintaining separation and preventing accidental contact between first welding tab 28 and second welding tab 30. Separator bracket 40 may be constructed of an electrically insulating material, such as a heat and chemical resistant polymer or coated metal.

[0083] Figure 8 A method 100 for manufacturing a battery cell 10 is depicted in FIG. 1 and disclosed in detail below. The method 100 can be used as a scalable batch process for constructing a large number of battery cells having a plurality of stacked electrodes 14, 16, as described above with respect to Figure 1-7 Therefore, this method can be used to manufacture Figure 2 , 3 , 5, 6A, 6B and 7. The method 100 begins in frame 102 by providing or constructing a battery cell container 20. After frame 102, the method proceeds to frame 104. In frame 104, the method includes producing a first battery cell 19-1 having a respective anode 14, a cathode 16, a first separator 18-1 disposed therebetween, and a second separator 18-2 (such as a separator 18-2 disposed adjacent to the corresponding anode 14) Fig. 9 As shown in block 104, the method may further include first extracting the respective anode 14 and cathode 16 from the corresponding electrode material sheets, the anode sheet 50 and the cathode sheet 52, as shown in block 104. Fig.12 Extracting the respective anode and cathode 14, 16 may specifically include laser cutting (e.g. Fig.11 as shown) or die-cut (as Fig.12 The production of the first battery cell 19-1 can be achieved by means of an alignment guide 54, as shown. Fig.10 shown.

[0084] The electrode material sheets 50, 52 may be prepared or constructed from respective anode and cathode materials, for example by coating respective anode and cathode material slurries onto respective substrate foils, anode (copper) foil 56-1 and cathode (aluminum) foil 56-2 (eg, Fig.111 , 16-1). According to the method, the electrode material sheets 50, 52 thus constructed may include respective coated and dried material strips 58-1 for the anode 14 and coated and dried material strips 58-2 for the cathode 16. In addition, in frame 104, the method may include producing at least one respective exposed material portion 60-1, 60-2 for the respective conductive negative and positive tabs 14-1, 16-1 on the respective substrate foils 56-1, 56-2 (of the electrode material sheets 50, 52). The method proceeds from frame 104 to frame 106.

[0085] In block 106, the method includes producing a second battery cell 19-2 having respective anodes 14, cathodes 16, a first separator 18-1 disposed therebetween, and a second separator 18-2 disposed adjacent to the respective anodes 14 (eg, Fig.10 As shown in FIG. 1 , similar to producing the first battery cell 19 - 1 , producing the second battery cell 19 - 2 can be accomplished with the aid of the alignment guide 54 . Fig.12 As can be seen, each cathode 16 of the respective first battery cell 19-1 and the second battery cell 19-2 is defined by a corresponding outer periphery P. Producing the first battery cell 19-1 and the second battery cell 19-2 in the respective frames 104 and 106 may include closely arranging or stacking each cathode 16 in a row 62 and coating the outer periphery P of each respective cathode with an electrically insulating material 64 (e.g., Fig.13 ). For example, the outer periphery P may be sprayed or solution coated with a ceramic material having a polymer binder. The positive tab 14-1 of the cathode 16 in question may be masked to prevent it from being coated. After frame 106, the method proceeds to frame 108.

[0086] In block 108, the method includes arranging the first and second battery cells 19-1, 19-2 adjacent to each other (e.g., as shown in FIG. 1 ) for the cylindrical, prismatic, and pouch battery cells 10A, 10B, 10C. Fig.10 In addition, in frame 108, the method includes stacking the first battery cell 19-1 and the second battery cell 19-2 so that the second separator 18-2 of the first battery cell is adjacent to the cathode 16 of the second battery cell (such as Figure 3 ). In other words, the second separator 18-2 provides a functional interface between the first single cell 19-1 and the second single cell 19-2 in the resulting battery cell 10. Although the method specifically describes stacking the first and second battery cells 19-1, 19-2, in box 108, the method can include stacking as many single cells as needed to produce a particular battery cell 10.

[0087] In frame 108, the method may further include arranging one or more spring elements 32 (e.g., between the stacked first and second battery cells 19-1, 19-2) Figure 2 ). In addition, in frame 108, the method may include arranging the first support element 34 to contact the cathode 16 of the first battery cell 19-1, and arranging the second support element 36 to contact the second diaphragm 18-2 of the first battery cell 19-1. As a result, the spring element will be sandwiched by the first support element 34 and the second support element 36, and the load from the spring element will be dispersed on the surface of the adjacent single cell. Alternatively, or in addition to the spring 32, in the frame 108, the method may include arranging a foam element 38 between the first battery cell 19-1 and the second battery cell 19-2. After frame 108, the method proceeds to frame 110.

[0088] In frame 110, the method includes arranging the stacked first and second battery cells 19-1, 19-2 in the battery cell container 20 along a stacking axis 66 along the longitudinal battery axis Y or perpendicular to the longitudinal battery axis Y (in Figure 3 ). From frame 110, after arranging the stacked single cells 19-1, 19-2 in the container 20, the method may proceed to frame 112. In frame 112, the method includes mechanically connecting the negative tab 14-1 and the positive tab 16-1 of each battery single cell 19-1, 19-2 to the negative and positive battery terminals 24, 26 via welding tabs 28, 30 arranged along the stacking axis 66. The negative and positive tabs 14-1, 16-1 may be grouped and folded to fit within the battery cell container 20 before being connected to their respective welding tabs 28, 30. In frame 112, the method may also include arranging a separation bracket 40 in the area 22A between the first welding tab 28 and the second welding tab 30. As described above with respect to Figure 2-7 As described, the welding tabs 28, 30 include expandable portions 28-1, 30-1 for absorbing the alternating expansion and contraction of the first battery cell 19-1 and the second battery cell 19-2 when the battery cell 10 is charged and discharged, respectively. After frame 112, the method can end in frame 114 by packaging the manufactured battery cells for storage or assembly into a battery module or battery pack.

[0089] The detailed description and the accompanying drawings or figures are support and description of the present disclosure, but the scope of the present disclosure is limited only by the claims. Although some of the best modes and other embodiments for carrying out the claimed disclosure have been described in detail, there are various alternative designs and embodiments for practicing the disclosure defined in the appended claims. In addition, the features of the embodiments shown in the drawings or the various embodiments mentioned in this specification are not necessarily to be understood as embodiments independent of each other. Instead, each feature described in one of the examples of the embodiments can be combined with one or more other desired features from other embodiments to obtain other embodiments that are not described in words or with reference to the drawings. Therefore, such other embodiments fall within the framework of the scope of the appended claims.

Claims

1. A method for manufacturing a battery cell, comprising: Providing battery cell containers; producing a first battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode; producing a second battery cell having a respective anode, a cathode, a first separator disposed therebetween, and a second separator disposed adjacent to the respective anode; stacking the first battery cell and the second battery cell such that the second separator of the first battery cell is adjacent to the cathode of the second battery cell; and The stacked first battery cell and the second battery cell are arranged in a battery cell container.

2. The method for manufacturing a battery cell according to claim 1, wherein: Stacking the first battery cell and the second battery cell includes arranging at least one spring element between the first battery cell and the second battery cell.

3. The method for manufacturing a battery cell according to claim 2, wherein stacking the first battery cell and the second battery cell further includes arranging a first supporting element in contact with the cathode of the first battery cell and a second supporting element in contact with the second diaphragm of the first battery cell, so that at least one spring element is sandwiched between the first supporting element and the second supporting element.

4. The method of manufacturing a battery cell according to claim 1, wherein producing the first battery cell and the second battery cell comprises extracting respective anodes and cathodes from corresponding sheets of electrode materials.

5. The method for manufacturing a battery cell according to claim 4, wherein: Extracting the respective anode and cathode includes one of: die-cutting the respective anode and cathode from the respective electrode material sheet, and laser-cutting the respective anode and cathode from the respective electrode material sheet.

6. The method according to claim 4, wherein the electrode material sheet consists of respective anode material and cathode material, and wherein producing the first battery cell and the second battery cell comprises coating the respective electrode materials onto respective substrate foils.

7. The method of manufacturing a battery cell according to claim 6, wherein each of the respective anode and cathode comprises at least one conductive tab, and wherein coating the respective electrode materials onto the respective substrate foil comprises: A respective strip of coating material is produced for each of the anode and cathode, and at least one exposed material portion for a corresponding conductive tab is produced on each respective substrate foil.

8. The method for manufacturing a battery cell according to claim 7, wherein: Each cathode of the respective first and second battery cells is defined by a corresponding outer perimeter, and wherein producing the first and second battery cells comprises arranging each cathode in a row and coating the outer perimeter of each respective cathode with an electrically insulating material.

9. The method of manufacturing a battery cell according to claim 8, wherein producing the first and second battery cells includes masking each conductive tab prior to coating an outer periphery of each respective cathode.

10. The method of manufacturing a battery cell according to claim 1, wherein the battery cell is one of a cylindrical battery cell, a prismatic battery cell, and a pouch battery cell.

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