Electrode assembly for cylindrical battery cell

Abstract

An electrode assembly for a cylindrical battery cell (e.g., a roll core battery cell) includes a plurality of electrode tabs, one or more separator tabs separating the plurality of electrode tabs, and a rubbed region at a first end of the roll core assembly and formed at a first portion of an uncoated region at the first end of the electrode tabs. The kneading region includes a chamfered edge at the first end of the winding core assembly.

Description

TECHNICAL FIELD

[0001] The present application relates generally to battery cells, and more particularly to a battery cell tucker apparatus for manufacturing jelly-roll battery cells. BACKGROUND

[0002] Batteries or battery cells are critical in providing power to many everyday dependent electrical devices. Cylindrical batteries having a jelly-roll arrangement are commonly used to power electrical devices. These battery types are commonly referred to as “jelly-roll” batteries. The jelly-rolled cylindrical batteries typically include an anode and a cathode rolled together into a cylindrical shape with small gaps between the concentric layers of the roll, and the anode and cathode are placed in a battery casing with electrical terminals disposed at both ends of the casing. In tabless jelly-roll battery cells, a conductive tab (typically formed from an uncoated portion of the electrode foil) extends along the length of the cathode and / or anode. The conductive tab of each concentric layer of the roll can be tucked (or otherwise formed) together with the other conductive tabs of each concentric layer of the jelly-roll at a tuck region such that they can form a connection point to be effectively electrically connected to the electrical terminals of the battery casing. A tucker is commonly used to tuck the concentric layers of the jelly-roll battery cell together. Examples of tuckers can be found in Chinese Patent Publication Nos. CN 107394248 and CN 209843873, the contents of which are incorporated herein by reference. SUMMARY

[0003] In one aspect, an electrode assembly for a cylindrical battery cell is described. The electrode assembly includes a plurality of electrode tabs, a tuck region located at a first end of the jelly-roll assembly and formed at a first portion of an uncoated region at a first end of the electrode tabs, one or more separator tabs that separate the electrode tabs, and a chamfered edge located at the first end of the jelly-roll assembly.

[0004] In yet another aspect, a tucker assembly configured to tuck a portion of an electrode assembly of a cylindrical battery cell, the tucker assembly including a plate, a mounting pin configured to engage a distal end of the battery cell, and a plurality of tuck heads located on the plate, wherein each of the plurality of tuck heads is positioned circumferentially about the battery cell, wherein the electrode assembly includes a chamfered edge located at a distal end of the electrode assembly, and wherein movement of the plate simultaneously moves the plurality of tuck heads relative to the battery cell such that the plurality of tuck heads move into and out of engagement with the chamfered edge of the battery cell.

[0005] Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in their application to the details of construction and the arrangements of components set forth in the following description or illustrated in the following drawings. Embodiments are capable of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled,” and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

[0006] In addition, it should be understood that embodiments can include hardware, software, and electronic components or modules that, for purposes of discussion, can be illustrated and described as if the majority of the components were implemented solely in hardware. However, those skilled in the art will appreciate that one or more components of an embodiment can be implemented in software, for example, stored on non-transitory computer-readable medium, executed by one or more processing units of, for example, a microprocessor and / or application specific integrated circuits (“ASICs”). Those skilled in the art will recognize that, in at least one embodiment, an electronic aspect of the disclosure can be implemented by one or more computer programs executed by one or more processing units. Accordingly, it should be noted that the described embodiments can be implemented in a number of different hardware and software configurations, including a number of different processors and memory arrangements. For example, the “server,” “computing device,” “controller,” “processor,” and the like described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input / output interfaces, and various connection devices (e.g., system bus) connecting the components.

[0007] Relative terms, such as “about,” “approximately,” “substantially” and the like, used in connection with a quantity or a condition, are understood to encompass the absolute values and to have the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances in the materials, manufacturing, assembly, usage tolerances, etc.). These terms should also be considered as disclosing a range that is defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.” Relative terms can refer to a percentage of the indicated value (e.g., 1%, 5%, 10% or more).

[0008] It should be understood that, although certain embodiments are illustrated as including certain hardware and software, these are merely examples. The functions described herein as being performed by one or more components can be performed by more, fewer, or different components. For example, although depicted as being performed by a single electronic processor, functions performed by a component can be distributed across multiple electronic processors. Furthermore, certain functions performed by one or more components can be merged into a single component or separated into multiple components. Whether described as being performed by hardware or software, certain components can be configured to perform functions that are not explicitly described herein. Similarly, a component described as performing only certain functions can also be configured to perform additional functions that are not explicitly described herein. For example, devices or structures described as being "configured" to perform certain operations can also be so configured to perform additional operations that are not explicitly stated.

[0009] Other aspects of embodiments will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0010] Figure 1 A rolling assembly of a battery cell rolling machine that interfaces with an electrode assembly of a battery cell during rolling is shown in accordance with one embodiment.

[0011] Figure 2 A perspective view of an electrode assembly in accordance with some embodiments is shown. Figure 1

[0012] Figure 3 A perspective view of a rolling assembly in accordance with some embodiments is shown. Figure 1

[0013] Figure 4 A perspective view of a rolling head of a rolling assembly in accordance with some embodiments is shown. Figure 1

[0014] Figure 5A An enlarged perspective view of a portion of a rolling head in accordance with some embodiments is shown. Figure 4

[0015] Figure 5B An enlarged cross-sectional view of a portion of a rolling head in accordance with some embodiments is shown. Figure 4

[0016] Figure 5C Partial enlarged cross-sectional views of a rolling assembly in accordance with some embodiments are shown. Figure 5A Figure 5B

[0017] Figure 6A ​​​​​​​Illustrations are shown according to some embodiments Figure 1 A partially magnified cross-sectional view of the leveling assembly and electrode assembly during the leveling process.

[0018] Figure 6B Illustrations are shown according to some embodiments Figure 1 A magnified cross-sectional view of the leveling assembly and electrode assembly after the leveling process.

[0019] Figure 7 Illustrations are shown according to some embodiments Figure 1 An enlarged cross-sectional view of the electrode assembly after the flattening process.

[0020] Figures 8A to 8E It shows the relationship with Figure 1 A partially magnified cross-sectional view of an alternative core used in conjunction with a flattening component. Detailed Implementation

[0021] Figure 1 A portion of a battery cell flattening machine 10 according to one embodiment is shown. The battery cell flattening machine 10 is operable to flatten coiled battery cells (…) at specific "flattening areas". Figure 2 The conductive strips of the concentric layers of the electrode assembly 14 are flattened or formed together. Thus, the battery cell flattener 10 forms a substantially flat connection surface and / or plane on the electrode assembly 14, which is effectively electrically connected to the electrical terminals of the battery housing of the electrode assembly 14. Conductive sheets (e.g., uncoated portions of electrode foil) may be uncoated portions of the corresponding anode and cathode sheets of the electrode assembly, as described in more detail below.

[0022] refer to Figure 2 The electrode assembly 14 is formed by winding an anode sheet, a cathode sheet, and at least one separator sheet together. In some embodiments, an insulator sheet 18 may be disposed on the exterior of the electrode assembly 14. For example, the insulator sheet 18 may be formed from a separator sheet wound together with the anode sheet, cathode sheet, and separator sheet in the electrode assembly 14. In other embodiments, the insulator sheet 18 may be omitted. Uncoated portions 22 or foils of the electrode sheets (e.g., anode sheets and / or cathode sheets) are disposed at a first end 30 of the electrode assembly 14. A flattening process may be performed on the uncoated portions 22 to form a flattened region 26. In some examples, a second flattened region is disposed at a second end of the electrode assembly 14 and is formed similarly to the flattened region 26. The flattened region 26 allows the uncoated portions 22 of the electrode assembly 14 to be directly coupled to a welding plate at the first end 30 of the electrode assembly 14. The welding plate can then provide an electrical connection between the battery terminals and the electrodes of the electrode assembly 14.

[0023] The electrode assembly 14 can have a nominal voltage between about 1 V and about 5 V and a nominal capacity between about 1 Ah and about 5 Ah or more (e.g., up to about 9 Ah). The electrode assembly 14 can have any rechargeable chemical composition type, such as lithium (“Li”), lithium-ion (“Li-ion”), other lithium-based chemical compositions, nickel-cadmium (“NiCd”), nickel-metal hydride (“NiMH”), etc.

[0024] Referring to Figure 2 , Figure 6B and Figure 7 The first end 30 (e.g., the tuck flat region 26) of the electrode assembly 14 includes a chamfered edge 34 along the outer edge 28 of the electrode assembly 14. The chamfered edge 34 is formed during the tucking process described herein. In one embodiment, the chamfered edge 34 is formed via a tucking operation using a specialized tucking head having one or more tapered portions, as described in more detail below. The tucking head can have a modified fold line (e.g., the juncture between the conical portion of the tucking head and the collar) for forming the chamfered edge 34. The tucking operation is applied to the uncoated portion of the electrode sheet (e.g., an anode sheet or a cathode sheet) at the first end 30 of the electrode assembly 14. The chamfered edge 34 can be formed to reduce or avoid formation of a burr or a nub (e.g., a portion of the uncoated electrode portion that gathers or accumulates during the tucking operation) formed during the tucking operation. The burr can require additional rework to remove during manufacturing, thereby reducing manufacturing efficiency. The burr can also have a size sufficient to cause a potential short circuit between the uncoated portion of the electrode sheet and another component of the jelly-roll battery cell, such as a housing or can (not shown).

[0025] In one embodiment, the chamfered edge 34 is comprised of a first portion 38, a second portion 42 connected to the first portion 38, and an edge 46 connecting the first portion 38 and the second portion 42. As shown in Figure 7As shown, the first portion 38 can be oriented at a first angle Al relative to the outer edge 28 of the electrode assembly 14 and at a second angle A2 relative to the edge 46. In one embodiment, the first angle Al can be approximately 230°; however, values greater than 230° or less than 230° are also contemplated depending on the needs of a given application. The second angle A2 can be approximately 125°; however, values greater than 125° or less than 125° are also contemplated depending on the needs of a given application. The second portion 42 can be oriented at a third angle A3 relative to the edge 46 and at a fourth angle A4 relative to the first end 30. The third angle A3 can be approximately 215°; however, values greater than 215° or less than 215° are also contemplated depending on the needs of a given application. The fourth angle A4 can have an angle of 230°; however, values greater than 230° or less than 230° are also contemplated. The above angles and distances are for exemplary purposes and it is contemplated that other distance and / or angle values can be used depending on the needs of a given application.

[0026] In the illustrated embodiment, the first portion 38 and the second portion 42 are generally tapered relative to the outer edge 28 and the first end 30 of the electrode assembly 14. More specifically, in the illustrated embodiment, both the first portion 38 and the second portion 42 are tapered in a direction toward the first end 30 of the electrode assembly 14. However, in alternative embodiments, the first portion 38 and the second portion 42 can be tapered in opposite directions or include alternative configurations (e.g., curved configurations, etc.). Further, in the illustrated embodiment, the length of the second portion 42 is greater than the length of the first portion 38. In one example, the length of the second portion 42 can be approximately twice the length of the first portion 38. However, in other examples, the length of the second portion 42 can be greater than or less than twice the length of the first portion 38. In other embodiments, the first portion 38 and the second portion 42 can include alternative lengths or can be configured as a single portion. For example, Figure 8A An alternative configuration of the electrode assembly 14 is shown, illustrated as electrode assembly 14a. More specifically, the electrode assembly 14a includes a chamfered edge 34a having a single tapered portion 38a. The tapered portion 38a can be oriented at an angle A5 relative to the outer edge 28a. The value of the angle A5 can be 200°. However, values greater than 200° or less than 200° are also contemplated depending on the needs of a given application.

[0027] Figures 8B to 8D Alternative configurations of the above-described electrode assembly 14 are shown and illustrated as electrode assemblies 14b-14d, respectively, in Figures 8B to 8D Figures 8B to 8D ​In the electrode assemblies 14b, 14c, and 14d, the chamfered edges 34b, 34c, and 34d include first tapered portions 38b, 38c, and 38d positioned relative to each other at various angles, and second tapered portions 42b, 42c, and 42d. For example, in Figure 8B In this configuration, the first tapered portion 38b is oriented at a first angle A6 relative to the outer edge 28b, and the second tapered portion 42b may be oriented at a second angle A7 relative to the first portion 38b, but without an intermediate edge (e.g., edge 46) located therebetween. The value of the first angle A6 may be 190°; however, values ​​greater than or less than 190° are also conceivable depending on the needs of a given application. The value of the second angle A7 may be 205°; however, values ​​greater than or less than 205° are also conceivable depending on the needs of a given application.

[0028] In another example, such as Figure 8C As shown, the first tapered portion 38c is oriented substantially parallel to the second tapered portion 42c, and the edge 46c extends between the first tapered portion 38c and the second tapered portion 42c. The first tapered portion 38c may be oriented at a first angle A8 relative to the outer edge 28c. The first tapered portion 38c may also be oriented at a second angle A9 relative to the edge portion 46c. The second tapered portion 42c may be oriented at a third angle A10 relative to the edge portion 46c. As described above, the first tapered portion 38c and the second tapered portion 42c may be substantially parallel, such that the first angle A8 and the third angle A10 are equal. In one embodiment, the values ​​of the first angle A8 and the second angle A10 may be 225°; however, values ​​greater than or less than 225° are also contemplated depending on the needs of a given application. The value of the second angle A9 may be 135°; however, values ​​greater than or less than 135° are also contemplated depending on the needs of a given application. Figure 8C As shown, the length of the first conical portion 38c can be substantially equal to the length of the second conical portion 42c.

[0029] exist Figure 8D In the illustrated embodiment, the first tapered portion 38d is oriented at a first angle A11 relative to the outer edge 28d and at a second angle A12 relative to the edge portion 46d. The second tapered portion 42d may be oriented at a third angle A13 relative to the edge portion 46d. The value of the first angle A11 may be 225°; however, values ​​greater than or less than 225° are also contemplated. The value of the second angle A12 may be 135°; however, values ​​greater than or less than 135° are also contemplated. The value of the third angle A13 may be 205°; however, values ​​greater than or less than 205° are also contemplated. Figure 8DAs shown, the length of the first portion 38d of the chamfered edge 34d is less than the length of the second tapered portion 42d.

[0030] Turning now to Figure 8E which illustrates an alternative configuration of the electrode assembly, shown as electrode assembly 14e. Specifically, the chamfered edge 34e of the electrode assembly 14e includes a first tapered portion 38e, a second tapered portion 42e, and a third tapered portion 44e. The first tapered portion 38e can be oriented at a first angle A14 relative to the outer edge 28e. The second tapered portion 42e can be oriented at a second angle A15 relative to the first tapered portion 38e, and the third tapered portion 44e can be oriented at a third angle A16. The value of the first angle A14 can be 200°; however, values greater than 200° or less than 200° are also contemplated. The value of the second angle A15 can be 195°; however, values greater than 195° or less than 195° are also contemplated. The value of the third angle A16 can be 200°; however, values greater than 200° or less than 200° are also contemplated.

[0031] The above-described embodiments provide various configurations of the electrode assembly. These alternative embodiments can be implemented based on one or more characteristics of a given electrode, such as thickness, material type, battery cell size, etc.

[0032] The above-described alternative embodiments are exemplary, and it should be understood that the electrode assembly can have various tapered portions formed thereon, thereby having various numbers of tapered portions and various orientations of the tapered portions. As described above, the above-described various chamfered portion embodiments are formed on the electrode assembly during a tucking process by a machine, such as the battery cell tucker 10, as described in more detail below.

[0033] Referring to Figure 1 and Figure 3 the battery cell tucker 10 includes a mounting support platform and a battery cell tucking or forming assembly 50. The tucking assembly 50 includes a base plate 54, a rotating plate 58, a center pin 62, and a plurality of tucking head assemblies 66. The base plate 54 is generally cylindrical and includes a first face 54a and a second face 54b opposite the first face 54a. The first face 54a includes a series of rectangular grooves 70. The grooves 70 extend from a distal edge of the base plate 54 toward a center point of the base plate 54 and are shaped and sized to be able to receive a portion of one of the tucking head assemblies 66.

[0034] With continued reference to Figure 1 and Figure 3The base plate 54 includes a central aperture 74 and a series of secondary apertures 78. The central aperture 74 extends through the base plate 54 along a central longitudinal axis 82. The central aperture 74 is generally circular in shape and sized to receive a portion of the center pin 62. In some examples, the center pin 32 can be referred to as a mounting pin. The secondary apertures 78 are positioned adjacent to the central aperture 74. More specifically, the base plate 54 includes three secondary apertures 78 such that each of the secondary apertures 78 is equally spaced relative to the central longitudinal axis 82. In some examples, the secondary apertures 78 are configured to ensure that the one or more crimping head assemblies 66 are in place.

[0035] Referring to Figure 1 and Figure 3 The rotating plate 58 is generally cylindrical in shape and includes a first face 58a and a second face 58b opposite the first face 58a. The rotating plate 58 has a diameter equal to the diameter of the base plate 54 and a thickness less than the thickness of the base plate 54. The rotating plate 58 is coupled to the base plate 54 and rotatable relative to the base plate 54. More specifically, the base plate 54 and the rotating plate 58 are concentrically aligned such that the rotating plate 58 can rotate about the central longitudinal axis 82. The rotating plate 58 includes a central aperture 86 and various curved apertures 90. The central aperture 86 is generally circular in shape and sized to receive the center pin 62.

[0036] Referring to Figure 1 and Figure 3 The center pin or mounting pin 62 extends through the base plate 54 and the rotating plate 58 and is configured to support and protrude into the electrode assembly 14. The center pin 62 is shaped and sized such that all or a portion of the center pin 62 protrudes through the central aperture 74 of the base plate 54 and the central aperture 86 of the rotating plate 58. More specifically, the center pin 62 can have a diameter corresponding to the diameter of the central aperture 74 of the base plate 54, thereby forming a tight fit between the center pin 62 and the rotating plate 58.

[0037] The distal end 94 of the center pin 62 is generally conical in shape. Specifically, the distal end 94 is generally pointed and configured to support and protrude into an uncoated portion of an electrode tab of the electrode assembly 14. An extension 98 is integrally formed with the distal end 94 of the center pin 62. The extension 98 can be configured to extend into the electrode assembly 14 to provide support for the electrode assembly 14 during a crimping operation. Thus, the extension 98 can be secured to the center pin 62 by positioning the distal end 94 of the center pin 62 within an aperture of the extension 98. The extension 98 can be inserted into a central hole of the electrode assembly 14 and used as additional support for the electrode assembly 14, which enables the electrode assembly 14 to be positioned centrally.

[0038] With continued reference Figure 1 and Figure 3 The flattening head assembly 66 can include a housing 102 and a flattening head 106. The housing 102 is generally rectangular and includes a main body 114 and flanges 118 on opposite sides of the main body 114. The main body 114 includes a circular through-hole shaped and sized to receive the flattening head 106.

[0039] The flanges 118 are generally rectangular and are integrally formed with the sidewalls of the main body 114. The upper surface of each of the flanges 118 includes an elongated slot 122. The elongated slot 122 extends through the flange 118 and is shaped and sized to receive a pin or fastener.

[0040] Referring to Figure 4 , Figure 5A and Figure 5B The flattening head 106 is generally cylindrical and includes a main body 126, a flattening portion 130a adjacent a first end 126a of the main body 126, and a mounting portion 130b adjacent a second end 126b of the main body 126 opposite the first end 126a. The flattening portion 130a is configured to engage the electrode assembly 14 and more particularly the uncoated portions of the anode and / or cathode of the electrode assembly 14. The flattening portion 130a includes a conical portion 134 and a first tapered portion 138. The first tapered portion 138 or tapered edge extends circumferentially between a base of the conical portion 134 and a collar 142 of the flattening head 106. The first tapered portion 138 includes a first end 138a integrally formed with a distal end of the conical portion 134 and an opposite second end 138b. The first tapered portion 138 tapers in a direction from the second end 126b of the main body 126 to the first end 126a of the main body 126, thereby forming an obtuse angle between the first tapered portion 138 and the conical portion 134.

[0041] The second end 126b of the main body 126 is generally cylindrical and is positioned within the circular through-hole of the housing 102. More particularly, the second end 126b of the main body 126 is secured to the housing 102 via a bearing and end cap. Referring to Figure 4 The flattening head 106 includes two diametrically opposed flat portions 146. The flattening head 106 is driven in rotation by a rotary mechanism (not shown) to perform the flattening of the electrode assembly 14.

[0042] Referring to Figure 4 , Figure 5A and Figure 5B The collar or wheel portion 142 is located on the flattening head 106 adjacent the first end 126a of the main body 126 of the flattening head 106. In the illustrated embodiment, the collar 142 is integrally formed with the main body 126 of the flattening head 106. However, in alternative embodiments, the collar 142 can be removably coupled with the flattening head 106. As shown, the collar 142 includes a first flat portion 146a and a second flat portion 146b.Figures 5A to 5B As shown, the collar 142 includes a first cylindrical portion 150 and a second cylindrical portion 154 integrally formed with the first cylindrical portion 150. The first cylindrical portion 150 is positioned adjacent to the first end 126a of the body 126 of the paddle 106, and the second cylindrical portion 154 is positioned below the first cylindrical portion 150 between the first cylindrical portion 150 and the second end 126b of the body 126 of the paddle 106. In the illustrated embodiment, the diameter of the second cylindrical portion 154 is greater than the diameter of the first cylindrical portion 150. However, in alternative embodiments, the diameter of the first cylindrical portion 150 can be equal to or greater than the diameter of the second cylindrical portion 154.

[0043] Referring to Figure 5A , the first cylindrical portion 150 of the collar 142 circumferentially surrounds a portion of the paddle 106. Accordingly, a gap is formed between the upper surface 158 of the first cylindrical portion 150 and the distal end of the first tapered portion 138 of the paddle portion 130a. As shown in the illustrated embodiment, the outer edge 162 of the first cylindrical portion 150 of the collar 142 is generally rounded. However, in alternative embodiments, the outer edge 162 can include alternative configurations.

[0044] The upper surface 158 of the first cylindrical portion 150 is generally flat and includes a tapered, cylindrical edge or portion 166 extending toward the first tapered portion 138 of the paddle portion 130a. The second tapered portion 166 includes a first end 166a integrally formed with the edge of the upper surface 158 of the first cylindrical portion 150 and an opposite second end 166b. The second tapered portion 166 tapers in a direction from the first end 126a of the body 126 of the paddle 106 to the second end 126b of the body 126, thereby forming an obtuse angle between the second tapered portion 166 and the upper surface 158 of the collar 142.

[0045] Referring to Figures 5A to 5C , a cylindrical edge 170 is formed at the junction between the second end 138b of the first tapered portion 138 of the paddle 106 and the second end 166b of the second tapered portion 166 of the collar 142. The cylindrical edge 170 protrudes from the junction and extends cylindrically around the circumference of the paddle portion 130a. Referring to Figure 5B , the cylindrical edge 170 includes a triangular cross-section. However, in alternative embodiments, the edge 170 can include alternative shapes and sizes. Turning now to Figure 5Cwhich is a 2D cross-sectional view of a portion of the tucker head 106, the first tapered portion 138 is at a first angle A17 relative to the cylindrical edge 170, and the second tapered portion 166 is at a second angle A18 relative to the cylindrical edge 170. In one embodiment, the first angle A17 can have a value of 170°; however, values greater than 170° or less than 170° are also contemplated depending on the needs of a given application. The second angle A18 can have a value of 155°; however, values greater than 155° or less than 155° are also contemplated depending on the needs of a given application. The first tapered portion 138 can be oriented at a third angle A19 relative to the edge of the conical portion 134. In one embodiment, the third angle A19 can have a value of 130°; however, values greater than 130° or less than 130° are also contemplated depending on the needs of a given application. In one embodiment, the first tapered portion 138, the second tapered portion 166, and the cylindrical edge 170 are configured to form corresponding tapered and edge portions on the beveled portion of the electrode sheet as described above with respect to at least Figure 7 and Figures 8A to 8E Accordingly, the positioning of the first tapered portion 138, the second tapered portion 166, and the cylindrical edge can be modified as needed to form the beveled portion of the electrode assembly as described above. As described above, these modifications can be made based on various characteristics of the electrode assembly and / or battery cell assembly, such as electrode assembly thickness, uncoated portion length, electrode assembly material type, battery cell size, or other appropriate parameters, to improve the tucking operation and reduce burrs or other deformations formed during the tucking operation.

[0046] In some embodiments, the first tapered portion 138 of the tucking portion 130a, the second tapered portion 166 of the collar 142, and the cylindrical edge 170 can be removed. More specifically, in such cases, the distal end of the conical portion 134 is directly connected with the collar 142 of the tucker head 106. Further, in some embodiments, the first tapered portion 138 and the cylindrical edge 170 of the tucking portion 130a can be removed such that only the second tapered portion 166 of the collar 142 extends between the conical portion 134 and the collar 142. Further, in some embodiments, the second tapered portion 166 of the collar and the cylindrical edge 170 can be removed such that only the first tapered portion 138 of the tucking portion 130a extends between the conical portion 134 and the collar 142.

[0047] To position each of the flattening head assemblies 50 at an optimal position relative to the electrode assembly 14, the electrode assembly 14 is first positioned on the center pin 62. Specifically, the distal end 94 or extension 98 of the center pin 62 is inserted or pressed into the center hole of the electrode assembly 14. To adjust the position of the flattening heads 106, a user can manually adjust one of the rotating plates 58 or the housings 102. In some examples, the position of the flattening heads 106 can be automatically adjusted, for example, by one or more automated controller devices. The distal ends of the plurality of flattening heads 106 are arranged in the same imaginary plane so as to form a planar flattening surface on the electrode assembly 14. Movement of one of the housings 102 will cause the other housings 102 to move synchronously. In one embodiment, a user rotates the rotating plate 58 relative to the base plate 54. Rotation of the rotating plate 58 causes each of the flattening head assemblies 66 to translate relative to the electrode assembly 14. More specifically, when the rotating plate 58 is rotated in a clockwise direction relative to the central longitudinal axis 82, the flattening head assemblies 66 translate toward the electrode assembly 14, while when the rotating plate 58 is rotated in a counterclockwise direction relative to the central longitudinal axis 82, the flattening head assemblies 66 translate in a direction away from the electrode assembly 14.

[0048] When the flattening head assemblies 66 translate toward the electrode assembly 14, a portion of the first end 30 of the uncoated portion of the electrode assembly 14 abuts or interfaces with one or more of the flattening heads 106. That is, a portion of the first end of the electrode assembly 14 interfaces with the upper surface 158 of the collar 142 and the flattening portion 130a of the flattening head 106. Referring to Figures 6A to 6B , the first end 30 of the electrode assembly 14 interfaces with the conical portion 134 of the flattening head 106 and the edges of the first end 30 of the electrode assembly 14 interface with the first tapered portion 138 of the flattening head 106 and the second tapered portion 166 and cylindrical edge 170 of the collar 142 to form the chamfered edge 34. More specifically, the first tapered portion 138 of the flattening head 106 interfaces with the first end 30 of the electrode assembly and forms the second portion 42 and the cylindrical edge 170 and second tapered portion 166 interface with the first end 30 to form the first portion 38 of the chamfered edge.

[0049] Referring to Figures 6A to 6BWhen the flattening head 106 and the electrode assembly 14 interface, such as during a flattening operation, the chamfered edge 34 advantageously allows for an increased contact angle with the flattening head 106. Further, the formation of the chamfered edge 34 of the electrode assembly 14 advantageously reduces burr formation on the electrode assembly. More specifically, the first tapered portion 138, the second tapered portion 166, and the cylindrical edge 170 of the flattening head 106 allow for a greater surface area of the electrode assembly 14 to contact a greater surface of the flattening head 106 as compared to conventional jellyroll flattening head configurations. The increased contact angle prevents the outer edge (e.g., aluminum foil) on the electrode assembly 14 from contacting or rubbing against the conical portion 134 or the collar 142 of the flattening head 106, which can cause burr formation as the sharp angle between the collar 142 and the flattening head 106 causes the uncoated portions to bunch together. More specifically, the first tapered portion 138 of the flattening portion 130a, the second tapered portion 166 of the collar 142, and the cylindrical edge 170 allow for an increased contact angle A20 between the electrode assembly 14 and the upper surface 158 of the collar 142 of the flattening head 106. Typically, without the first tapered portion 138 of the flattening portion 130a, the second tapered portion 166 of the collar 142, and the cylindrical edge 170, the contact angle A20 between the electrode assembly 14 and the upper surface 158 of the collar 142 is 37°. However, in the illustrated embodiment, the first tapered portion 138 of the flattening portion 130a, the second tapered portion 166 of the collar 142, and the cylindrical edge 170 allow for an increased angle, so the contact angle A20 is approximately 45°. This increased contact angle A20 reduces burr formation at the outer edge 28 of the first end 30 of the electrode assembly 14 due to contact with the flattening head 106.

[0050] Accordingly, the embodiments described herein provide, among other things, a battery cell flattening machine for battery cells. Various features and advantages will be set forth in the claims.

Claims

1. An electrode assembly for a cylindrical battery cell, the electrode assembly comprising: Multiple electrode plates; One or more separators, the one or more separators separating the plurality of electrode sheets; as well as A flattened area is located at a first end of the electrode assembly and is formed in a first portion of an uncoated area at the first end of one of the plurality of electrode sheets, wherein the flattened area includes a chamfered edge at the first end of the electrode assembly and a flat connecting surface.

2. The electrode assembly according to claim 1, wherein, The chamfered edge includes a first tapered portion, a second tapered portion, and an edge located between the first tapered portion and the second tapered portion.

3. The electrode assembly according to claim 2, wherein, The edge is parallel to the longitudinal axis of the electrode assembly.

4. The electrode assembly according to claim 2, wherein, The length of the second conical portion is greater than the length of the first conical portion.

5. The electrode assembly according to claim 2, wherein, The first conical portion is oriented at an angle parallel to the second conical portion.

6. The electrode assembly according to claim 1, wherein, The chamfered edge includes a first portion, a second portion, and a third portion, wherein the first portion, the second portion, and the third portion are tapered.

7. The electrode assembly according to claim 6, wherein, The second portion is tapered relative to the first portion toward the first end of the electrode assembly, and the third portion is tapered relative to the second portion in the direction toward the first end of the electrode assembly.

8. The electrode assembly according to claim 1, wherein, The chamfered edge includes a first tapered portion and a second tapered portion, wherein the second tapered portion is tapered relative to the first tapered portion toward the first end of the electrode assembly.

9. The electrode assembly according to claim 8, wherein, The length of the second conical portion is greater than the length of the first conical portion.

10. The electrode assembly according to claim 8, wherein, The first tapered portion is oriented at a first angle relative to the outer edge of the electrode assembly, wherein the first angle is greater than 180 degrees and less than 210 degrees.

11. The electrode assembly according to claim 10, wherein, The second conical portion is oriented at a second angle relative to the first conical portion, wherein the second angle is greater than 180 degrees and less than 210 degrees.

12. An electrode assembly for a cylindrical battery cell, the electrode assembly comprising: Multiple electrode plates; One or more separators, the one or more separators separating the plurality of electrode sheets; as well as A flattened area, located at a first end of the electrode assembly, and formed in a first portion of an uncoated area at the first end of one of the plurality of electrode sheets, wherein the flattened area includes a chamfered edge located at the first end of the electrode assembly. The chamfered edge includes a first portion, a second portion, and an edge located between the first portion and the second portion.

13. The electrode assembly according to claim 12, wherein, The first part and the second part are conical.

14. The electrode assembly according to claim 13, wherein, The length of the second part is greater than the length of the first part.

15. The electrode assembly according to claim 12, wherein, The first portion and the second portion are tapered toward the first end of the electrode assembly.

16. The electrode assembly of claim 12, wherein, The plurality of electrode plates includes at least one anode plate and one cathode plate.

17. The electrode assembly according to claim 12, wherein, The second portion is tapered relative to the first portion toward the first end of the electrode assembly.

18. The electrode assembly according to claim 17, wherein, The first portion is oriented at a first angle relative to the outer edge of the electrode assembly, wherein the first angle is greater than 180 degrees and less than 210 degrees.

19. The electrode assembly according to claim 18, wherein, The second portion is oriented relative to the first portion at a second angle, wherein the second angle is greater than 180 degrees and less than 210 degrees.

20. The electrode assembly of claim 12, wherein, The chamfered edge includes a third portion, wherein the third portion is tapered.

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