Novel double-cell packaging process
By using a parallel dual-cell structure and a multi-stage gradient constant current charging process, the problems of low packaging efficiency and poor consistency of dual cells were solved, achieving efficient and low-cost battery packaging and improving battery performance and reliability.
Patent Information
- Application Number
- CN202511104994.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-07
- Publication Date
- 2025-11-11
AI Technical Summary
Existing dual-cell packaging technology suffers from low packaging efficiency, high cost, and poor cell consistency. In particular, it is prone to polarization during the cell capacity testing process, which affects the stability and reliability of the battery.
The Pocket design, featuring a parallel dual-pit structure, enables the simultaneous packaging of two cores and the simultaneous grouping during the packaging stage. It also employs a multi-stage gradient constant current charging process, combined with rigorous testing and post-processing procedures, to ensure the consistency and performance of the battery cells.
It significantly improves packaging efficiency, reduces production costs, enhances cell consistency and overall battery performance, and extends battery life.
Smart Images
Figure CN120933424A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of novel dual-cell packaging technology, specifically a novel dual-cell packaging process. Background Technology
[0002] In the battery manufacturing industry, cell packaging is a crucial step in ensuring battery performance, safety, and lifespan. Traditional cell packaging processes mainly employ an independent packaging method for each cell, meaning that only one core is packaged at a time. This method has several drawbacks. On the one hand, packaging individual cells sequentially leads to low production efficiency, making it difficult to meet the ever-increasing market demand. On the other hand, independent packaging of each cell requires the use of more packaging materials such as aluminum-plastic film, increasing production costs.
[0003] As battery applications increasingly demand higher energy density and longer range, dual-cell and even multi-cell battery solutions are gaining popularity. However, existing dual-cell packaging technologies typically involve packaging two cells separately and then combining them. This process is not only cumbersome but also inefficient, failing to guarantee cell consistency during manufacturing and potentially leading to performance variations that affect overall battery performance and lifespan. Furthermore, conventional charging methods during cell grading can cause polarization, reducing the consistency of cell K-value combinations and further impacting battery stability and reliability. Therefore, a novel dual-cell packaging process is urgently needed that improves packaging efficiency, reduces costs, and enhances cell combination consistency. Summary of the Invention
[0004] The purpose of this invention is to provide a novel dual-cell packaging process that solves the problems mentioned in the background art.
[0005] To achieve the above objectives, the present invention provides the following technical solution: a novel dual-cell packaging process, comprising the following steps:
[0006] Step 1: Provide a pocket that can be designed as a side-by-side double-slot structure and two cores;
[0007] Step 2: Construct the Pocket as a side-by-side double-slot structure;
[0008] Step 3: During the packaging stage, the two cores are placed into the parallel double pits at the same time, and the packaging operation is carried out simultaneously. The grouping is also completed simultaneously during the packaging process.
[0009] Step 4: The dual-cell battery pack is processed using a multi-stage gradient constant current charging process.
[0010] Preferably, in step two, when fabricating the parallel double-slot structure, the size of the double slots is adapted to the size of the core, ensuring the positional stability of the core after it is placed in.
[0011] Preferably, the encapsulation operation in step three includes a hot-press encapsulation process, with the hot-press temperature in the range of 130-180℃ and the hot-press pressure in the range of 0.5-2MPa.
[0012] Preferably, the multi-stage gradient constant current charging and capacity grading process in step four has at least three charging stages with different current intensities, and each stage is performed sequentially in a preset order.
[0013] Preferably, in the at least three charging stages with different current intensities, the current intensity difference between adjacent stages is in the range of 0.1-0.5A.
[0014] Preferably, before performing step three, the two cores must undergo appearance inspection and size measurement. Only after the inspection and measurement are qualified can they be placed into the parallel double pits.
[0015] Preferably, after step three is completed, the sealed dual-cell battery is subjected to a sealing test, including an airtightness test, to ensure that there is no leakage after sealing.
[0016] Preferably, the dual-cell battery cells processed in step four are subjected to static setting, formation, shaping, secondary packaging, and edge trimming operations to ensure that the dual-cell battery cells meet the requirements for subsequent use.
[0017] This invention provides a novel dual-cell packaging process. This novel dual-cell packaging process has the following advantages:
[0018] 1. This novel dual-cell packaging process, by designing the pocket as a parallel dual-pit structure, enables the simultaneous packaging of two cells at once. Compared to the traditional method of packaging single cells sequentially, this significantly reduces packaging steps and operation time. Simultaneous grouping during the packaging stage avoids the extra time and procedures required for separate grouping in traditional processes. The capacity testing process employs a multi-stage gradient constant current charging technology, effectively shortening the capacity testing time while ensuring cell performance through the rational setting of charging stages and current intensities. The optimized collaboration of multiple processes significantly improves overall packaging production efficiency, better meeting the needs of large-scale production.
[0019] 2. This novel dual-cell packaging process, with its parallel dual-pit design, allows for the processing of two cells in a single package. Compared to single-cell independent packaging, this directly reduces the amount of packaging materials such as aluminum-plastic film used. In the pocket manufacturing process, high-precision mold injection molding combined with precise dimensional design avoids material waste and rework costs due to size mismatches. During the thermopressing process, the thermopressing temperature and pressure are precisely controlled based on the characteristics of the core material and aluminum-plastic film, ensuring packaging quality while reducing scrap rates caused by improper process parameters and lowering raw material and energy consumption. This combination of cost control measures effectively reduces the production cost of dual-cell packaging and enhances the product's market competitiveness.
[0020] 3. This novel dual-cell packaging process ensures that the two cells are in nearly identical manufacturing environments during packaging, and the pairing is completed in advance during the packaging stage, guaranteeing a high degree of consistency between the two cells during production. In the capacity grading process, the multi-stage gradient constant current charging process effectively reduces cell polarization and significantly improves the consistency of K-value pairing through staged and gradient current charging. Subsequent rigorous appearance inspection, dimensional measurement, sealing inspection, and post-processing steps such as settling and formation control and optimize cell quality from multiple stages. The comprehensive application of these technologies results in a high degree of matching of the two cells in terms of performance parameters, greatly improving battery pack efficiency and overall battery performance, extending battery life, and providing users with higher quality and more reliable battery products. Attached Figure Description
[0021] Figure 1 This is a schematic diagram of the Pocket structure of the present invention;
[0022] Figure 2 This is a schematic diagram of the dual-pit structure of the present invention. Detailed Implementation
[0023] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention will now be described with reference to the accompanying drawings.
[0024] Example 1
[0025] like Figure 1-2 As shown, the present invention provides a technical solution: a novel dual-cell packaging process, characterized by comprising the following steps:
[0026] Step 1: Provide a pocket that can be designed as a side-by-side double-slot structure and two cores;
[0027] Step 2: Construct the Pocket as a side-by-side double-slot structure;
[0028] Step 3: During the encapsulation stage, place the two cores into the parallel double slots at once and carry out the encapsulation operation simultaneously, and complete the grouping at the same time during the encapsulation process;
[0029] Step 4: The dual-cell battery pack is processed using a multi-stage gradient constant current charging process.
[0030] In step two, when fabricating the parallel double-pit structure, the dimensions of the double pits are matched with the dimensions of the core to ensure the positional stability of the core after it is placed in. Step three involves encapsulation, including a hot-pressing process with a temperature between 130-180℃ and a pressure between 0.5-2MPa. Step four involves a multi-stage gradient constant current charging and capacity testing process with at least three charging stages of different current intensities, performed sequentially according to a preset order. The current intensity difference between adjacent stages in these three stages is between 0.1-0.5A. Before step three, both cores undergo visual inspection and dimensional measurement; only after passing these tests can they be placed in the parallel double pits. After step three, the encapsulated double cores undergo a sealing test, including an airtightness test, to ensure no leakage after encapsulation. Step five involves the double cores processed in step four undergoing resting, formation, shaping, secondary encapsulation, and edge trimming to ensure they meet subsequent usage requirements.
[0031] In this embodiment, step one: preparation process, providing a Pocket that can be designed as a parallel double pit structure and two cores; wherein, the material of the Pocket can be selected according to actual needs, such as high temperature resistant and high strength engineering plastics, to ensure that it can withstand high temperature and pressure during the packaging process and does not chemically react with the battery cell; the specifications of the cores are determined according to the application scenario of the battery, such as the core specifications are different for batteries used in different fields such as smartphones, power tools, and energy storage devices;
[0032] Step 2: Pocket manufacturing process. The pocket is made into a side-by-side double slot structure. During manufacturing, it is necessary to ensure that the size of the double slots is precisely matched with the size of the roll core. A small gap is reserved for each slot based on the size of the roll core, with a 0.2mm allowance in the length, width and thickness directions, to ensure the positional stability of the roll core after it is placed in, and to avoid affecting the sealing effect due to excessive gaps.
[0033] Step 3: Packaging Process. In the packaging stage, the two cores undergo visual inspection and dimensional measurement. Using manual visual inspection or automated inspection equipment, the core surfaces are checked for defects such as scratches, damage, and wrinkles. The length, width, and thickness of the cores are measured using calipers and other measuring tools to ensure they meet production requirements. After passing inspection, the two cores are placed into parallel double-slot positions and packaged using a hot-pressing process. The hot-pressing temperature is 130℃, and the hot-pressing pressure is 0.5MPa. Based on the core materials and the characteristics of the aluminum-plastic film, the hot-pressing temperature and pressure parameters are appropriately selected, and the packaging operation is carried out simultaneously. Grouping is also completed during the packaging process. After packaging, the sealed dual cells undergo a sealing test, primarily using airtightness testing. Gas is injected into the dual cells at a certain pressure to check for gas leaks, ensuring no leakage after packaging and preventing external air and moisture from entering the cells, affecting battery performance and lifespan.
[0034] Step 4: Capacity rating process. A multi-stage gradient constant current charging process is used to process the packaged dual cells. This capacity rating process has at least three charging stages with different current intensities, and each stage is carried out in a preset order. In the at least three charging stages with different current intensities, the current intensity difference between adjacent stages is 0.1A. Through staged and gradient current charging, cell polarization is effectively reduced and the consistency of cell K-value matching is improved.
[0035] Step 5: Post-processing. After the capacity testing process, the dual cells undergo standing, formation, shaping, secondary encapsulation, and edge trimming. The standing process stabilizes the chemical composition and physical structure inside the cell. The formation process activates the active materials inside the cell, forming a stable electrode interface. The shaping process ensures that the cell's dimensions meet design requirements. The secondary encapsulation further enhances the cell's sealing and safety. Edge trimming removes excess encapsulation material, ensuring the dual cells meet subsequent usage requirements.
[0036] Example 2
[0037] Based on Example 1, the present invention provides a novel dual-cell packaging process;
[0038] In this embodiment, step one: preparation process, providing a Pocket that can be designed as a parallel double pit structure and two cores; wherein, the material of the Pocket can be selected according to actual needs, such as high temperature resistant and high strength engineering plastics, to ensure that it can withstand high temperature and pressure during the packaging process and does not chemically react with the battery cell; the specifications of the cores are determined according to the application scenario of the battery, such as the core specifications are different for batteries used in different fields such as smartphones, power tools, and energy storage devices;
[0039] Step 2: Pocket manufacturing process. The pocket is made into a side-by-side double slot structure. During manufacturing, it is necessary to ensure that the size of the double slots is precisely matched with the size of the roll core. A small gap is reserved for each slot based on the size of the roll core, with a 0.3mm allowance in the length, width and thickness directions, to ensure the positional stability of the roll core after it is placed in, and to avoid affecting the sealing effect due to excessive gaps.
[0040] Step 3: Packaging Process. In the packaging stage, the two cores undergo visual inspection and dimensional measurement. Using manual visual inspection or automated inspection equipment, the core surfaces are checked for defects such as scratches, damage, and wrinkles. The length, width, and thickness of the cores are measured using calipers and other measuring tools to ensure they meet production requirements. After passing inspection, the two cores are placed into parallel double-slot positions and packaged using a hot-pressing process. The hot-pressing temperature is 150℃, and the hot-pressing pressure is 1MPa. Based on the core material and the characteristics of the aluminum-plastic film, the hot-pressing temperature and pressure parameters are appropriately selected, and the packaging operation is carried out simultaneously. Grouping is also completed during the packaging process. After packaging, the sealed dual cells undergo a sealing test, primarily using airtightness testing. Gas is injected into the dual cells at a certain pressure to check for gas leaks, ensuring no leakage after packaging and preventing external air and moisture from entering the cells, affecting battery performance and lifespan.
[0041] Step 4: Capacity rating process. A multi-stage gradient constant current charging process is used to process the packaged dual cells. This capacity rating process has at least three charging stages with different current intensities, and each stage is carried out in a preset order. In the at least three charging stages with different current intensities, the current intensity difference between adjacent stages is 0.3A. Through staged and gradient current charging, cell polarization is effectively reduced and the consistency of cell K-value matching is improved.
[0042] Step 5: Post-processing. After the capacity testing process, the dual cells undergo standing, formation, shaping, secondary encapsulation, and edge trimming. The standing process stabilizes the chemical composition and physical structure inside the cell. The formation process activates the active materials inside the cell, forming a stable electrode interface. The shaping process ensures that the cell's dimensions meet design requirements. The secondary encapsulation further enhances the cell's sealing and safety. Edge trimming removes excess encapsulation material, ensuring the dual cells meet subsequent usage requirements.
[0043] Example 3
[0044] Based on Example 1, the present invention provides a novel dual-cell packaging process;
[0045] In this embodiment, step one: preparation process, providing a Pocket that can be designed as a parallel double pit structure and two cores; wherein, the material of the Pocket can be selected according to actual needs, such as high temperature resistant and high strength engineering plastics, to ensure that it can withstand high temperature and pressure during the packaging process and does not chemically react with the battery cell; the specifications of the cores are determined according to the application scenario of the battery, such as the core specifications are different for batteries used in different fields such as smartphones, power tools, and energy storage devices;
[0046] Step 2: Pocket manufacturing process. The pocket is made into a side-by-side double slot structure. During manufacturing, it is necessary to ensure that the size of the double slots is precisely matched with the size of the roll core. A small gap is reserved for each slot based on the size of the roll core. A 0.4mm gap is reserved in the length, width and thickness directions to ensure the positional stability of the roll core after it is placed in, and to avoid affecting the sealing effect due to excessive gaps.
[0047] Step 3: Packaging Process. In the packaging stage, the two cores undergo visual inspection and dimensional measurement. Using manual visual inspection or automated inspection equipment, the core surfaces are checked for defects such as scratches, damage, and wrinkles. The length, width, and thickness of the cores are measured using calipers or other measuring tools to ensure they meet production requirements. After passing inspection, the two cores are placed into parallel double-cell slots and packaged using a hot-pressing process. The hot-pressing temperature is 180℃, and the hot-pressing pressure is 2MPa. Based on the core material and the characteristics of the aluminum-plastic film, the hot-pressing temperature and pressure parameters are appropriately selected, and the packaging operation is carried out simultaneously. Grouping is also completed during the packaging process. After packaging, the sealed dual cells undergo a sealing test, primarily using airtightness testing. Gas is injected into the dual cells at a certain pressure to check for gas leaks, ensuring no leakage after packaging and preventing external air and moisture from entering the cells, affecting battery performance and lifespan.
[0048] Step 4: Capacity rating process. A multi-stage gradient constant current charging process is used to process the packaged dual cells. This capacity rating process has at least three charging stages with different current intensities, and each stage is carried out in a preset order. In the at least three charging stages with different current intensities, the current intensity difference between adjacent stages is within 0.5A. Through staged and gradient current charging, cell polarization is effectively reduced and the consistency of cell K-value matching is improved.
[0049] Step 5: Post-processing. After the capacity testing process, the dual cells undergo standing, formation, shaping, secondary encapsulation, and edge trimming. The standing process stabilizes the chemical composition and physical structure inside the cell. The formation process activates the active materials inside the cell, forming a stable electrode interface. The shaping process ensures that the cell's dimensions meet design requirements. The secondary encapsulation further enhances the cell's sealing and safety. Edge trimming removes excess encapsulation material, ensuring the dual cells meet subsequent usage requirements.
[0050] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A novel dual-cell packaging process, characterized in that, Includes the following steps: Step 1: Provide a pocket that can be designed as a side-by-side double-slot structure and two cores; Step 2: Construct the Pocket as a side-by-side double-slot structure; Step 3: During the packaging stage, the two cores are placed into the parallel double pits at the same time, and the packaging operation is carried out simultaneously. The grouping is also completed simultaneously during the packaging process. Step 4: The dual-cell battery pack is processed using a multi-stage gradient constant current charging process.
2. The novel dual-cell packaging process according to claim 1, characterized in that, In step two, when making the parallel double-slot structure, the size of the double slots is adapted to the size of the core to ensure the positional stability of the core after it is placed in.
3. The novel dual-cell packaging process according to claim 1, characterized in that, The encapsulation operation in step three includes a hot-press encapsulation process, with the hot-press temperature in the range of 130-180℃ and the hot-press pressure in the range of 0.5-2MPa.
4. The novel dual-cell packaging process according to claim 1, characterized in that, The multi-stage gradient constant current charging and capacity grading process in step four has at least three charging stages with different current intensities, and each stage is carried out in a preset order.
5. The novel dual-cell packaging process according to claim 4, characterized in that, In the at least three charging stages with different current intensities, the current intensity difference between adjacent stages is in the range of 0.1-0.5A.
6. The novel dual-cell packaging process according to claim 1, characterized in that, Before performing step three, the appearance and dimensions of the two cores must be inspected and measured. Only after the inspection and measurement are qualified can they be placed into the parallel double pits.
7. The novel dual-cell packaging process according to claim 1, characterized in that, After step three is completed, the sealed dual-cell battery is subjected to a sealing test, including an airtightness test, to ensure that there is no leakage after sealing.
8. The novel dual-cell packaging process according to claim 1, characterized in that, It also includes step five: after the dual cells have been processed in step four, they are subjected to static setting, formation, shaping, secondary packaging and trimming operations to make the dual cells meet the requirements for subsequent use.