Device and method for accelerating electrolyte filling process

Abstract

An apparatus and method for wetting a plurality of pore surfaces of a substrate forming a lithium ion battery with a liquid solvent and then filling the lithium ion battery with a liquid electrolyte are disclosed.

Description

TECHNICAL FIELD

[0001] The technical field is generally related to batteries, compartments of batteries, and methods of manufacturing the same. BACKGROUND

[0002] The process of manufacturing lithium-ion batteries in large scale production involves filling the cells of each battery with an electrolyte solution. A significant amount of time is required to allow the electrolyte solution to fill the narrow spaces between the battery components and to fill the pores in the inner surfaces of the battery components to obtain acceptable performance and to avoid lithium plating during operation of the battery.

[0003] It is desirable to manufacture an apparatus and method of filling a battery with an electrolyte solution (liquid electrolyte) that reduces the time to fill each battery and ensures or increases the likelihood that the pores in the inner surfaces of the battery components are filled. Furthermore, other desirable features and characteristics of the variations disclosed herein will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field. SUMMARY

[0004] The variations can include a method comprising flowing a solvent vapor over a plurality of inner surfaces of a cell, wherein at least one of the plurality of inner surfaces of the cell has a plurality of pores formed therein, each of the plurality of pores being defined by a pore surface; condensing the solvent vapor into a liquid solvent such that the liquid solvent is deposited on at least the pore surface of each of the plurality of pores; and then filling the cell with a solution comprising a solvent and a salt.

[0005] The variations can include a method wherein the liquid solvent is deposited on at least one of the plurality of inner surfaces.

[0006] The variations can include a method further comprising flowing a carrier gas over the plurality of inner surfaces of the cell along with the solvent vapor.

[0007] The variations can include a method further comprising, prior to flowing the solvent vapor over the plurality of inner surfaces of the cell, drawing a vacuum on the cell to remove gas from the cell.

[0008] The variations can include a method wherein the solvent vapor has a vapor pressure and a vapor temperature, and wherein condensing the solvent vapor into a liquid solvent comprises adjusting at least one of the vapor pressure or the vapor temperature.

[0009] The variations can include a method wherein the solvent vapor has a vapor pressure, and further comprising adjusting the vapor pressure to promote capillary condensation.

[0010] Variations can include a method further comprising heating the solvent vapor flowing over the plurality of interior surfaces of the battery cell.

[0011] Variations can include a method further comprising heating the solvent to produce the solvent vapor.

[0012] Variations can include a method wherein heating the solvent to produce the solvent vapor is performed in a bubbler.

[0013] Variations can include a method further comprising flowing a carrier gas into the bubbler and flowing the carrier gas and the solvent vapor over the plurality of interior surfaces of the battery cell.

[0014] Variations can include a method wherein the plurality of interior surfaces of the battery cell comprises at least one interior surface of a housing enclosing the battery cell, a first electrode, a second electrode, and a separator between the first electrode and the second electrode.

[0015] Variations can include a method further comprising a housing enclosing the battery cell; wherein the plurality of interior surfaces of the battery cell comprises at least one interior surface of a housing enclosing the battery cell, a first electrode, a second electrode, and a separator between the first electrode and the second electrode; heating the solvent to produce the solvent vapor; and flowing a carrier gas into the bubbler and flowing the carrier gas and the solvent vapor over the plurality of interior surfaces of the battery cell.

[0016] Variations can include a method comprising wetting a plurality of pore surfaces formed in a substrate of a lithium ion battery with a liquid solvent; and then, filling the lithium ion battery with a liquid electrolyte.

[0017] Variations can include a method wherein wetting comprises flowing a solvent vapor over the plurality of pore surfaces formed in the substrate and then condensing the solvent vapor into a liquid solvent.

[0018] Variations can include a method wherein the substrate comprises at least one of an anode, an active material on the anode, a first face of a separator, a second face of the separator, a cathode, an active material on the cathode, or a surface of a battery housing.

[0019] Variations can include a product comprising a bubbler comprising a container and a heat source, a solvent vapor conduit connected to the container and an electrolyte hopper having an open end for filling a lithium ion battery.

[0020] Variations can include a product further comprising a carrier gas conduit connected to the container, the carrier gas conduit having a discharge end positioned to flow a carrier gas into the container.

[0021] Variations can include a product further comprising a vacuum line connected to the electrolyte hopper.

[0022] Variations can include a product further comprising a fill port connected to the electrolyte hopper for filling the electrolyte hopper with liquid solvent.

[0023] Variations can include a product further comprising a vacuum pump connected to the vacuum line. BRIEF DESCRIPTION OF DRAWINGS

[0024] Variations will be described below with reference to the following drawings, in which like numbers represent like elements, and in which:

[0025] Figure 1 is a perspective schematic illustration of select components and methods of a lithium ion battery according to variations;

[0026] Figure 2 is a perspective schematic illustration of select components and methods of a lithium ion battery according to variations;

[0027] Figure 3 is a perspective view of select components of a lithium ion battery according to variations, with portions removed;

[0028] Figure 4 is a method of wetting a surface of a battery cell according to variations;

[0029] Figures 5A-5F shows devices and actions in a method according to variations;

[0030] Figure 6 shows a method according to variations;

[0031] Figure 7 shows a method according to variations;

[0032] Figure 8 is a perspective schematic illustration of a prismatic battery according to variations;

[0033] Figure 9 shows a prismatic battery and a device for wetting internal bad surfaces of the prismatic battery prior to filling the prismatic battery with electrolyte comprising solvent and salt according to variations; and

[0034] Figure 10 shows a prismatic battery and a device for wetting internal bad surfaces of the prismatic battery prior to filling the prismatic battery with electrolyte comprising solvent and salt according to variations. DETAILED DESCRIPTION

[0035] The following detailed description is merely illustrative in nature and is not intended to limit the application or the use of applications and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description.

[0036] Figure 1 and Figure 2 A product, which can be a lithium-ion battery, and a discharge and charge method are shown in accordance with a number of variations. The product 100 can be a battery cell, which can include a first electrode 102, such as a cathode, and a first active material 106 on or adjacent to the first electrode 102. For a cathode electrode, the first active material 106 can be deposited on the first electrode 102 with a composition that includes a metal oxide as an active material, as well as one or more conductive additives and one or more binders. The first active material 106 can include, but is not limited to, at least one of lithium cobalt oxide (LiCo02), lithium manganese oxide (LiMn204), lithium iron phosphate (LiFeP04or LFP), or lithium nickel manganese cobalt oxide (LiNiMnCo02or NMC). A second electrode 116, such as an anode, can be provided, and a second active material 112 can be deposited on the second electrode 116. The second active material 112 can include, but is not limited to, at least one of a carbon-based material, such as graphite, silicon, or a combination of the two, or a lithium metal carbon material. A separator 108 can be provided between the first electrode 102 and the second electrode 116 and can be constructed and arranged to allow lithium ions to move through. The product 100 can also include an electrolyte 110. The electrolyte 110 can include, but is not limited to, at least one of LiPF6, LiBF4, or LiC104in an organic solvent.

[0037] The lithium battery 100 can include a number of interior surfaces, which can include a number of pores of various sizes, including, but not limited to, at least one of millipores, micropores, or nanopores. The number of interior surfaces can include at least a surface of the anode 116 or active material 204 thereon, a first face 206 and a second face 208 of the separator 108, the cathode 102 or active material 210 thereon, a sidewall 212 or a bottom wall 214 of the housing 118. The housing 118 can also include a cover plate 120 (shown in Figure 3 ), which can have an interior surface.

[0038] Referring again to Figure 1 When the product 100 (battery) is discharging and providing current, such as to power an electric motor in a vehicle, the second electrode 116 (anode) or second active material 112 releases lithium ions 114 to the first electrode 102 (cathode) or first active material 106, generating a flow of electrons 104 from the second electrode 116 (anode) to the first electrode 102 (cathode). Referring again to Figure 2When the product 100 (battery) is inserted into a current source, the opposite occurs such that lithium ions 114 are released by the first electrode 102 (cathode) or first active material 106 and received by the second electrode 116 (anode) of the second active material 112.

[0039] Figure 3 A product 100, which can be a battery and can include a plurality of battery cells 200, is shown, which can include a first electrode 102 (cathode) and a second electrode 116 (anode) and a separator 108 therebetween. The plurality of battery cells 200 can be enclosed in a housing 118, which can be made of a material including a metal such as, but not limited to, aluminum or steel. A cover plate 120 can be provided as part of the housing 118 or as a separate piece. A first terminal 122 can extend through the cover plate 120 and can be electrically isolated from the cover plate 120 by a first electrically insulating material 124. A second terminal 126 can extend through the cover plate 120 and can be electrically isolated from the cover plate 120 by a second electrically insulating material 128. An electrolyte injection port 131 can be provided in the cover plate 120.

[0040] Figure 3 A plurality of variations are shown in the middle, which can include an electrode stack 142, which can include a plurality of battery cells 200, wherein the first electrode 102 can include a first electrode tab 140, which can be a cathode tab, and wherein the second electrode 116 can include a second electrode tab 144, which can be an anode tab.

[0041] Figure 4 A plurality of variations are shown in the middle, which can include a substrate 218 having an inner surface 220 including a plurality of pores 222, 224, which can include at least one of millipores, micropores, or nanopores. Each pore can be defined by a pore surface. A solvent vapor source 228 can be provided, which includes a solvent vapor conduit 230 connected to the port 130 of the housing 118 to flow solvent vapor over the inner surface 220 of the substrate 218 and into the plurality of pores 222, 224. The solvent vapor can be condensed into a liquid solvent deposited on the pore surface defining each of the plurality of pores 222, 224. The liquid solvent in the pores 222, 224 can have various thicknesses such as, but not limited to, 1-20 molecules, 2-10 molecules, 2-6 molecules, 2-4 molecules, or any range therebetween. The housing 118 can include a portion 225 defining a headspace chamber 226 to receive solvent vapor to improve flow of the solvent vapor into the plurality of battery cells 200 in the housing 118. In a plurality of variations, the solvent vapor can include at least one or more of the same solvents used in an electrolyte solution including a solvent and a salt as described below.

[0042] Figures 5A-5F A number of variations are shown in FIG. 1, which can include a device 300, which can include a bubbler 302, which can include a container 304 and a heat source 306. The heat source 306 can be an electric coil or a combustible fuel, such as but not limited to natural gas or propane. The container 304 can be constructed and arranged to hold a liquid solvent 308 therein. A carrier gas conduit 310 can be connected to a carrier gas source 309 and can have a discharge end 311 that extends into the container 304 such that the discharge end 312 is immersed in the liquid solvent 308. The carrier gas source 309 can be a carrier gas tank. The carrier gas can be any of a variety of gases, including but not limited to argon or nitrogen. A solvent vapor conduit 312 can be connected to the container 304 and can have an inlet 313 that is located above the liquid solvent 308 in the container 304. The solvent vapor conduit 312 can be connected to an electrolyte hopper 314 and can have an open end 315 for dispensing solvent vapor and / or carrier gas into the battery cell 200. At least one valve 319 can be provided to control the flow of solvent vapor and / or carrier gas into the electrolyte hopper 314. An electrolyte hopper valve 320 can be provided near the opening 315 of the electrolyte hopper 314 to selectively charge the battery cell 200 with material. A fill port 316 can be provided in the electrolyte hopper 314 to fill the electrolyte hopper 314 with liquid electrolyte. A fill port valve 317 can be provided in the fill port 316.

[0043] The device 300 can be used to perform a number of actions in the method shown in FIG. 1. Figures 5A-5F For example, in FIG. 1, a vacuum pump 321 can be used to pull a vacuum on the battery cell 200 to remove any air or gas from the battery cell 200. Then, as shown in FIG. 1, carrier gas and solvent vapor can be charged into the electrolyte hopper 314 and the battery cell 200 to flow over the interior surfaces of the battery cell 200. At least one of the pressure or temperature can be adjusted to cause the solvent vapor to condense on the interior surfaces of the battery cell 200 and into the plurality of pores 222, 224 (shown in FIG. 2) in the separator 220. In a number of variations, the pressure of the solvent vapor is adjusted to cause capillary condensation of the solvent vapor. The solvent vapor is caused to condense so as to wet the interior surfaces with liquid solvent, which reduces the time required to fill the battery cell 200 with electrolyte including solvent and salt, as will be described below. Then, as shown in FIG. 1, a vacuum is pulled on the battery cell 200. Then, as shown in FIG. 1, the electrolyte hopper 314 can be charged with liquid electrolyte 322 including solvent and electrolyte. Then, as shown in FIG. 1, the battery cell 200 can be filled with the liquid electrolyte 322 from the electrolyte hopper 314. Figure 5A Figure 5B Figure 4 Figure 5C Figure 5D Figure 5E ​​​​​As shown, the electrolyte hopper valve 320 can be opened to fill the battery cell 200 with liquid electrolyte 322. Then, as... Figure 5F As shown, a vacuum can be drawn on the battery cell 200 to remove any air or carrier gas.

[0044] Figure 6 A method is shown that may include flowing solvent vapor across a plurality of inner surfaces of a battery cell, wherein at least one of the plurality of inner surfaces of the battery cell has a plurality of pores formed therein, each of the plurality of pores being defined by a pore surface 350. The solvent vapor is condensed into a liquid solvent such that the liquid solvent is deposited at least on the pore surface 352 of each of the plurality of pores. The battery cell 354 is then filled with a solution comprising a solvent and a salt.

[0045] Figure 7 A method is shown that may include wetting a plurality of pore surfaces 356 formed in a substrate of a lithium-ion battery with a liquid solvent, and then filling the lithium-ion battery 358 with a liquid electrolyte.

[0046] Figure 8 This is a perspective schematic diagram of a prismatic cell 400 based on several variations. The prismatic cell 400 includes... Figures 1-2 The same internal component described may include an inner surface 220 having a plurality of holes 222, 224 defined by a bore surface. The prismatic battery 400 may include a housing 418, which may be made of metal and may be non-flexible.

[0047] The device 300 described herein and the steps for wetting the surface of the hole with a solvent and then filling the battery or battery cell with an electrolyte including the solvent and salt can be used for various batteries and battery cells, including but not limited to pouch cells, prismatic cells and cylindrical cells. Figure 9 As previously shown regarding Figures 5A-5F The described device 300, and the device that can be performed with respect to the prismatic battery 400 as described herein, are made by... Figures 5A-5F The steps are shown.

[0048] Figure 10 The cylindrical battery 500 is shown, and as previously mentioned... Figures 5A-5F The described device 300, and the device that can perform with respect to the cylindrical battery 500 as described herein, are made by... Figures 5A-5F The steps are shown. The cylindrical battery 500 may include a housing 518, which may be made of metal and may be non-flexible.

[0049] Clause 1. A method comprising: flowing a solvent vapor over a plurality of interior surfaces of a battery cell, wherein at least one of the plurality of interior surfaces of the battery cell has a plurality of pores formed therein, each of the plurality of pores being defined by a pore surface; condensing the solvent vapor into a liquid solvent such that the liquid solvent is deposited on at least the pore surface of each of the plurality of pores; and then filling the battery cell with an electrolyte comprising a solvent and a salt.

[0050] Clause 2. The method of clause 1, wherein the liquid solvent is deposited on at least one of the plurality of interior surfaces.

[0051] Clause 3. The method of clause 1, further comprising flowing a carrier gas over the plurality of interior surfaces of the battery cell with the solvent vapor.

[0052] Clause 4. The method of clause 1, further comprising, prior to flowing the solvent vapor over the plurality of interior surfaces of the battery cell, pulling a vacuum on the battery cell to remove gas from the battery cell.

[0053] Clause 5. The method of clause 1, wherein the solvent vapor has a vapor pressure and a vapor temperature, and wherein condensing the solvent vapor into a liquid solvent comprises adjusting at least one of the vapor pressure or the vapor temperature.

[0054] Clause 6. The method of clause 1, wherein the solvent vapor has a vapor pressure, and further comprising adjusting the vapor pressure to promote capillary condensation.

[0055] Clause 7. The method of clause 1, further comprising heating the solvent vapor flowing over the plurality of interior surfaces of the battery cell.

[0056] Clause 8. The method of clause 1, further comprising heating the solvent to produce the solvent vapor.

[0057] Clause 9. The method of clause 8, wherein heating the solvent to produce the solvent vapor is performed in a bubbler.

[0058] Clause 10. The method of clause 9, further comprising flowing a carrier gas into the bubbler and flowing the carrier gas and the solvent vapor over the plurality of interior surfaces of the battery cell.

[0059] Clause 11. The method of clause 1, wherein the plurality of interior surfaces of the battery cell comprises at least one interior surface of a housing that encloses the battery cell, a first electrode, a second electrode, and a separator between the first electrode and the second electrode.

[0060] Clause 12. The method of clause 1, further comprising a housing surrounding the battery cell; wherein the plurality of interior surfaces of the battery cell comprises at least one interior surface of the housing surrounding the battery cell, the first electrode, the second electrode, and the separator between the first electrode and the second electrode; heating the solvent to produce solvent vapor; and flowing a carrier gas into the bubbler and flowing the carrier gas and the solvent vapor over the plurality of interior surfaces of the battery cell.

[0061] Clause 13. A method, comprising: wetting a plurality of pore surfaces formed in a substrate of a lithium ion battery with a liquid solvent; and then, filling the lithium ion battery with a liquid electrolyte.

[0062] Clause 14. The method of clause 13, wherein wetting comprises flowing solvent vapor over the plurality of pore surfaces formed in the substrate and then condensing the solvent vapor into the liquid solvent.

[0063] Clause 15. The method of clause 14, wherein the substrate comprises at least one of an anode, an active material on the anode, a first face of a separator, a second face of the separator, a cathode, an active material on the cathode, or a surface of a battery housing.

[0064] Clause 16. A product, comprising: a bubbler comprising a container and a heat source, a solvent vapor conduit connected to the container and an electrolyte hopper having an open end for filling a lithium ion battery.

[0065] Clause 17. The product of clause 16, further comprising a carrier gas conduit connected to the container, the carrier gas conduit having a discharge end positioned to flow a carrier gas into the container.

[0066] Clause 18. The product of clause 17, further comprising a vacuum conduit connected to the electrolyte hopper.

[0067] Clause 19. The product of clause 18, further comprising a fill port connected to the electrolyte hopper for filling the liquid solvent into the electrolyte hopper.

[0068] Clause 20. The product of clause 18, further comprising a vacuum pump connected to the vacuum conduit.

[0069] While illustrative variations have been presented in the foregoing detailed description of exemplary variations, it should be appreciated that a wide range of variations exist. It should also be appreciated that one or more variations are merely examples and are not intended to limit the scope, applicability, or configuration of the disclosure in any way. Rather, the foregoing detailed description will provide a convenient road map for implementing one or more variations for the benefit of persons skilled in the art. It should be appreciated that various changes can be made to the functions and arrangements of elements without departing from the scope of the disclosure as set forth in the appended claims and the legal equivalents thereof.

Claims

1. A method comprising: Solvent vapor is allowed to flow on a plurality of inner surfaces of a battery cell, wherein at least one of the plurality of inner surfaces of the battery cell has a plurality of pores formed therein, each of the plurality of pores being defined by a pore surface; The solvent vapor is condensed into a liquid solvent, such that the liquid solvent is deposited at least on the surface of the pores of each of the plurality of pores; and The battery cell is then filled with an electrolyte that includes a solvent and a salt.

2. The method according to claim 1, wherein, The liquid solvent is deposited on at least one of the plurality of inner surfaces.

3. The method of claim 1, further comprising causing a carrier gas to flow together with the solvent vapor on the plurality of inner surfaces of the battery cell.

4. The method of claim 1, further comprising evacuating the battery cell to remove gas from the battery cell before allowing the solvent vapor to flow over the plurality of inner surfaces of the battery cell.

5. The method according to claim 1, wherein, The solvent vapor has a vapor pressure and a vapor temperature, and wherein condensing the solvent vapor into the liquid solvent includes adjusting at least one of the vapor pressure or the vapor temperature.

6. The method according to claim 1, wherein, The solvent vapor has a vapor pressure, and further includes adjusting the vapor pressure to promote capillary condensation.

7. The method of claim 1, further comprising heating the solvent vapor flowing on the plurality of inner surfaces of the battery cell.

8. The method of claim 1, further comprising heating the solvent to generate the solvent vapor.

9. The method of claim 1, further comprising a housing surrounding the battery cell; wherein, The plurality of inner surfaces of the battery cell include at least one inner surface of a housing surrounding the battery cell, a first electrode, a second electrode, and a separator between the first electrode and the second electrode; heating the solvent to generate the solvent vapor; And to allow the carrier gas to flow into the bubbler, and to allow the carrier gas and the solvent vapor to flow on the plurality of inner surfaces of the battery cell.

10. A product comprising: A bubbler comprising a container and a heat source is connected to a solvent vapor conduit of the container and an electrolyte hopper having an open end for filling a lithium-ion battery.

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