An electrochemical battery cell with a conductive layer and a method for manufacturing it

Abstract

A method for manufacturing a battery cell comprises: placing an electrode assembly in a battery casing; arranging a top cap assembly on the battery casing to form a battery cell with at least one first filling hole and one second filling hole; introducing a first portion of a liquid solution into the battery cell through the first filling hole, the liquid solution comprising an organic solvent, a crosslinkable polymer, and a crosslinking agent; converting the first portion of the liquid solution into a first conductive layer arranged between the electrode assembly and the battery casing; introducing a second portion of the liquid solution into the battery cell through the second filling hole; converting the second portion of the liquid solution into a second conductive layer arranged between the electrode assembly and the battery casing;and filling the battery cell with a liquid electrolyte through an electrolyte filling hole.

Description

[0001] The concepts described here generally relate to electrochemical battery cells, including but not limited to prismatic battery cells and cylindrical battery cells with metallic casings or “cans” that contain heat dissipation pathways for effective and uniform heat dissipation over the lifetime of the battery cell.

[0002] A lithium-ion battery is an electrochemical device in which lithium ions are transferred between a negative electrode (or anode) and a positive electrode (or cathode). In most prismatic battery cells, the negative and positive electrodes are located on opposite sides of a porous polymer separator, forming an electrode stack. The electrode stack may be part of an electrode assembly and may include a protective covering. The electrode stack or electrode assembly is housed in a hollow, rectangular, metallic battery case or "can" and is impregnated, or "wetted," with an electrolyte solution suitable for conducting lithium ions.

[0003] Most cylindrical battery cells use a jelly-roll (JR) design. Generally, the JR construction involves applying an insulating base layer, followed by the anode layer, the separator layer, and the cathode layer to form an electrode stack. The electrode stack is then rolled into a cylinder and inserted into a hollow, metallic, cylindrical casing or battery can, and impregnated, or "wetted," with an electrolyte solution suitable for conducting lithium ions.

[0004] DC power sources, such as lithium-ion batteries, can be used to store and release electrical energy, which can be used by an electrical circuit or machine to perform work, such as communication, display, or propulsion. Heat can be generated during the conversion of electrical energy into chemical potential energy (i.e., charging the battery) and during the conversion of chemical potential energy into electrical energy (i.e., discharging the battery).

[0005] Lithium-ion battery cells, for example, but not exclusively, lithium-ion battery cells used in a rechargeable energy storage system (RESS), are typically packaged in battery modules or battery packs. Each lithium-ion battery module or battery pack may contain multiple lithium-ion battery cells. Accordingly, each lithium-ion battery module or battery pack can generate an even greater amount of heat than a single lithium-ion battery cell.

[0006] Individual lithium-ion battery cells, including but not limited to prismatic battery cells and cylindrical battery cells, may include a cavity between a sidewall of a metallic battery casing and an electrode assembly contained within the metallic battery casing. The cavity may contain air, which may reduce thermal performance within the individual battery cell.

[0007] Current cooling or heat dissipation strategies for lithium-ion battery modules or packs may include cooling plates disposed within a lithium-ion battery module or pack, for example, but not exclusively, between the lithium-ion battery cells as a unit and the battery module or pack, and / or between the individual lithium-ion battery cells within the battery module or pack. These cooling or heat dissipation strategies are located outside the lithium-ion battery cell unit, within the battery module or pack, and / or outside the individual lithium-ion battery cell itself. Description

[0008] In light of the above, it makes sense to develop a battery cell with improved thermal performance within the battery cell. A heat dissipation path can be provided by a conductive layer within the battery cell, positioned between an electrode assembly and a battery casing. The conductive layer can be more effective than current cooling or heat dissipation strategies used, for example, but not exclusively, in battery cells for rechargeable energy storage systems (RESS), without compromising existing thermal breakdown characteristics.

[0009] An electrochemical battery cell may include an electrode assembly, a battery case, and a top cap assembly. The battery case may have a first sidewall and a second sidewall.

[0010] The electrode assembly can be disposed within the battery case. The top cap assembly can be assembled with the battery case to form a battery cell having a first fill hole and a second fill hole.

[0011] A first portion of the liquid solution can be introduced into the battery cell through the first fill hole. The first portion of the liquid solution can be converted into a first conductive layer disposed between a first sidewall of the battery housing and the electrode assembly.

[0012] A second portion of the liquid solution can be introduced into the battery cell through the second fill hole. The second portion of the liquid solution can be converted into a second conductive layer disposed between a second sidewall of the battery case and the electrode assembly.

[0013] The liquid solution may contain an organic solvent, a crosslinkable polymer and a crosslinking agent.

[0014] To enable the liquid electrolyte to be introduced into the battery cell, vacuum filling can be used.

[0015] The first part and the second part of the liquid solution can be converted into the first conductive layer and the second conductive layer, respectively, by reacting the crosslinkable polymer and the crosslinking agent of the first part and the second part of the liquid solution to form a reaction product, so that the organic solvent can be contained in the reaction product.

[0016] Reacting the crosslinkable polymer and the crosslinking agent of both the first part and the second part of the liquid solution may involve applying heat to the liquid solution.

[0017] The first portion of the liquid solution located in the battery cell can be converted into the first conductive layer by applying heat to at least the first sidewall of the battery case when the battery cell is in a first position.

[0018] The second portion of the liquid solution located in the battery cell can be converted into the second conductive layer by applying heat to at least the second sidewall of the battery case when the battery cell is in a second position.

[0019] The first conductive layer may be in contact with the first sidewall of the battery case and a first side portion of the electrode assembly. The second conductive layer may be in contact with the second sidewall of the battery case and a second side portion of the electrode assembly.

[0020] According to one aspect of the present disclosure, the first fill hole and / or the second fill hole may be disposed in the upper cap assembly.

[0021] According to another aspect of the present disclosure, the first filling hole and / or the second filling hole may be arranged in the battery case.

[0022] The battery can be preheated before the first or second portion of the liquid solution is introduced into the battery cell.

[0023] According to another aspect of the present disclosure, vacuum filling may be used to facilitate the placement of the liquid electrolyte in the battery cell.

[0024] The liquid solution may contain a mixed alkyl phosphate solution.

[0025] A method of manufacturing a battery cell according to one aspect of the present disclosure may include: inserting an electrode assembly into a battery case; disposing a top cap assembly on the battery case to form a battery cell having at least a first fill hole and a second fill hole; introducing a first portion of a liquid solution into the battery cell through the first fill hole, the liquid solution containing an organic solvent, a cross-linkable polymer, and a cross-linking agent; converting the first portion of the liquid solution into a first conductive layer disposed between the electrode assembly and the battery case; introducing a second portion of the liquid solution within the battery cell via the second fill hole; converting the second portion of the liquid solution into a second conductive layer disposed between the electrode assembly and the battery case.and filling the battery cell with a liquid electrolyte via an electrolyte fill hole.;

[0026] Converting the first or second portion of the liquid solution into a first or second conductive layer may comprise reacting the crosslinkable polymer and the crosslinking agent of the first or second portion of the liquid solution to form a reaction product such that the organic solvent is included in the reaction product.

[0027] Reacting the crosslinkable polymer and the crosslinking agent of both the first and second portions of the liquid solution may involve applying heat to the liquid solution.

[0028] The battery cell may be in a first position when the first portion of the liquid solution is converted into the first conductive layer. The battery cell may be rotated to a second position before the second portion of the liquid solution is converted into the second conductive layer. The angle between the first position and the second position may be 180 degrees.

[0029] Converting the first portion of the liquid solution into the first conductive layer may comprise applying heat to at least a first sidewall of the battery container, while converting the second portion of the liquid solution into the second conductive layer may comprise applying heat to at least a second sidewall of the battery container.

[0030] The first conductive layer may be in contact with the first side wall of the battery case and a first side portion of the electrode assembly, while the second conductive layer may be in contact with the second side wall of the battery case and a second side portion of the electrode assembly.

[0031] According to one aspect of the present disclosure, at least one of the first fill holes and second fill holes may be disposed in the upper cap assembly.

[0032] According to another aspect of the present disclosure, the first filling hole and / or the second filling hole may be arranged in the battery case.

[0033] The battery can be preheated before the first and / or second part of the liquid solution is introduced into the battery cell.

[0034] According to another aspect of the present disclosure, filling the battery cell with the electrolyte comprises vacuum filling.

[0035] A method of manufacturing a battery cell according to one aspect of the present disclosure may include: inserting an electrode assembly within a battery casing; disposing a top cap assembly on the battery casing to form a battery cell with two fill holes; introducing a liquid solution within the battery cell via at least one of the two fill holes, the liquid solution containing an organic solvent, a cross-linkable polymer, and a cross-linking agent; converting the liquid solution into at least one conductive layer disposed between at least one side portion of the electrode assembly and the battery casing, wherein converting the liquid solution into the at least one conductive layer includes reacting the cross-linkable polymer and the cross-linking agent of the liquid solution to form a reaction product, the organic solvent being included in the reaction product;Filling the battery cell with a liquid electrolyte using vacuum filling.;

[0036] Introducing the liquid solution into the battery cell may comprise introducing a first portion of the liquid solution into the battery cell via one of the two filling holes and introducing a second portion of the liquid solution into the battery cell via the other of the two filling holes.

[0037] The method may include rotating the battery cell from a first position to a second position before introducing the second portion of the liquid solution into the battery cell.

[0038] The method may include storing the battery cell in the first position for a predefined period of time before rotating it to the second position.

[0039] According to one aspect of the present disclosure, the at least one conductive layer may comprise two conductive layers. The first portion of the liquid solution may be converted into one of the two conductive layers when the battery cell is in the first position, and the second portion of the liquid solution may be converted into another of the two conductive layers when the battery cell is in the second position.

[0040] One of the two conductive layers may be disposed between the battery casing and one side portion of the electrode assembly, and another of the two conductive layers may be disposed between the battery casing and another side portion of the electrode assembly.

[0041] One of the two conductive layers may be in contact with the battery casing and a side portion of the electrode assembly, and another of the two conductive layers may be in contact with the battery casing and another side portion of the electrode assembly.

[0042] According to one aspect of the present disclosure, reacting the crosslinkable polymer and the crosslinking agent of the liquid solution to form the reaction product comprises applying heat to the battery casing.

[0043] According to another aspect of the present disclosure, the method may include preheating the battery casing prior to introducing the liquid solution into the battery cell.

[0044] Therefore, a conductive layer inside the battery cell, positioned between an electrode assembly and a battery casing, can provide a heat dissipation path. The conductive layer can be more effective than current cooling or heat dissipation strategies used, for example, but not exclusively, in battery cells in a rechargeable energy storage system (RESS), without compromising existing thermal breakdown characteristics.

[0045] The above features and advantages, as well as other features and associated advantages of this disclosure, will become readily apparent from the following detailed description of illustrative examples and modes for carrying out the present disclosure, when considered in conjunction with the accompanying drawings and the appended claims. Furthermore, this disclosure expressly includes combinations and subcombinations of the elements and features presented above and below. Brief description of the drawings

[0046] The accompanying drawings, which are incorporated in this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure. Fig. Figure 1 is a schematic representation of a cross-section of an example battery cell in an upright position, without liquid solution. Fig. 2A is a schematic representation of a cross-section of an example battery cell constructed in accordance with the present disclosure, rotated in position 1, prior to converting the liquid solution. Fig. 2B is a schematic representation of a cross-section of an example battery cell constructed in accordance with the present disclosure, rotated in position 1, after converting the liquid solution into a conductive layer. Fig. 3A is a schematic representation of a cross-section of an example battery cell constructed in accordance with the present disclosure, rotated to position 2, prior to converting the liquid solution. Fig. 3B is a schematic representation of a cross-section of an example battery cell constructed in accordance with the present disclosure, rotated in position 2, after converting the liquid solution into a conductive layer. Fig. 4 is a schematic representation of a cross-section of an example battery cell constructed in accordance with the present disclosure in an upright position, including conductive layers and liquid electrolyte solution. Fig. 5A is a flowchart describing a method of manufacturing a battery cell according to the present disclosure. Fig. 5B is a flowchart describing a method of manufacturing a battery cell according to the present disclosure.

[0047] The accompanying drawings are not necessarily to scale and present a somewhat simplified representation of various preferred features of the present disclosure as disclosed herein, including, for example, specific dimensions, orientations, positions, and shapes. Details associated with such features will be determined in part by the particular intended application and environment of use. Detailed description

[0048] The present disclosure may be embodied in many different forms. Representative examples of the disclosure are illustrated in the drawings and are described in detail herein as non-limiting examples of the disclosed principles. To this end, elements and limitations described in the "Summary," "Introduction," "Summary," and "Detailed Description" sections, but not expressly set forth in the claims, should not be incorporated into the claims, individually or collectively, by implication, inference, or otherwise.

[0049] For the purposes of this description, the use of the singular includes the plural and vice versa, unless expressly excluded; the terms "and" and "or" apply both subjunctive and disjunctive; and the words "including," "containing," "comprising," "having," and the like mean "including without limitation." Furthermore, words of approximation such as "approximately," "almost," "substantially," "generally," "about," etc., may be used herein to mean "at, near, or almost at," or "within 0-5% of," or "within acceptable manufacturing tolerances," or logical combinations thereof.

[0050] Referring now to the drawings, wherein like numerals designate like parts throughout the several views, there is shown and described a battery cell including a liquid solution converted into a conductive layer and methods of making a battery cell including a liquid solution converted into a conductive layer.

[0051] As in Fig. 1, an electrochemical battery cell 100 is shown in an upright position. The battery cell 100 generally includes a battery case 110, an electrode assembly 120, and a top cap assembly 130. The battery case 110 includes a first sidewall 112, a second sidewall 114, and a bottom 116.

[0052] The battery housing 110 is made of a metallic material, for example, but not only, aluminum.

[0053] Electrode assembly 120 includes electrode tabs 122 and 124, which extend through top cap assembly 130 to terminals 122A and 124A, respectively. Electrode tab 122 extends upwardly from a first side portion 120A of electrode assembly 120. Electrode tab 124 extends upwardly from a second side portion 120B of electrode assembly 120.

[0054] The upper cap assembly 130 includes a first fill hole 132, a second fill hole 134, and an electrolyte fill hole 136.

[0055] The electrode assembly 120 is located inside the battery container 110.

[0056] Air gaps 115A and 115B are formed, respectively, between the first side portion 120A of the electrode assembly 120 and an inner surface 112A of the first side wall 112 of the battery case 110 and the second side portion 120B of the electrode assembly 120 and an inner surface 114A of the second side wall 114 of the battery case 110.

[0057] The top cap assembly 130 is mounted to the battery case 110 to form the battery cell 100.

[0058] As in the Fig. 2A and Fig. 2B, with further reference to Fig. 1 shows a battery cell 100 in a first position P1.

[0059] In the first position P1, a battery cell 100 is rotated 90 degrees counterclockwise from the position shown in Fig. 1 so that the first side wall 112 of the battery cell 100 is horizontal.

[0060] A first portion 142 of a liquid solution is introduced into the battery cell 100 through the first fill hole 132 in the upper cap assembly 130, as shown in Fig. 2A.

[0061] The first portion 142 of the liquid solution is converted into a first conductive layer 142A disposed between a first side wall 112 of the battery container 110 and a first side portion 120A of the electrode assembly 120, as shown in Fig. 2B.

[0062] The first conductive layer 142A is in contact with an inner surface 112A of the first sidewall 112 of the battery case 110 and the first side portion 120A of the electrode assembly 120 and fills the air gap 115A between the inner surface 112A of the first sidewall 112 of the battery case 110 and the first side portion 120A of the electrode assembly 120.

[0063] As in the Fig. 3A and Fig. 3B, a battery cell 100 can be seen in a second position P2, with Fig. 1 is referred to.

[0064] In the second position P2, the battery cell 100 is rotated 180 degrees clockwise from the position shown in the Fig. 2A and Fig. 2B or 90 degrees clockwise from the first position P1 shown in Fig. 1 so that the second side wall 114 is horizontal.

[0065] A second portion 144 of the liquid solution is introduced into the battery cell 100 through the second fill hole 134 located in the upper cap assembly 130, as shown in Fig. 3A.

[0066] The second portion 144 of the liquid solution is converted into a second conductive layer 144A disposed between a second side wall 114 of the battery container 110 and the second side portion 120B of the electrode assembly 120, as shown in Fig. 3B.

[0067] The second conductive layer 144A is in contact with an inner surface 114A of the second sidewall 114 of the battery case 110 and the second side portion 120B of the electrode assembly 120 and fills the air gap 115B between the inner surface 114A of the second sidewall 114 of the battery case 110 and the second side portion 120B of the electrode assembly 120.

[0068] The liquid solution contains an organic solvent, a cross-linkable polymer, and a cross-linking agent, a non-limiting example of which may include an alkyl phosphate solution mixed with a carbonate- or ester-based organic solvent such that the content of the mixed alkyl phosphate solution is between 5 wt% and 100 wt%, a cross-linkable oligomer (or monomer), and a cross-linking agent that is activated by an increase in temperature.

[0069] The first part 142 and the second part 144 of the liquid solution which is in the Fig. 2A and Fig. 3A are respectively divided into the first conductive layer 142A and the second conductive layer 144A shown in the Fig. 2B and Fig. 3B, by reacting the crosslinkable polymer and the crosslinking agent of the first portion 142 and the second portion 144 of the liquid solution to form a reaction product such that the organic solvent is included in the reaction product.

[0070] The first portion 142 of the liquid solution is converted into the first conductive layer 142A by heating at least the first sidewall 112 of the battery container 110.

[0071] The shape of the first conductive layer 142A is defined by the inner surface 112A of the first sidewall 112 of the battery case 110 and an outer surface 126 of the electrode assembly 120.

[0072] A dimension of the first conductive layer 142A is defined by a predetermined amount of liquid solution contained in the first part 142.

[0073] The second portion 144 of the liquid solution is converted into the second conductive layer 144A by heating at least the second sidewall 114 of the battery case 110.

[0074] The shape of the second conductive layer 144A is determined by the inner surface 114A of the second sidewall 114 of the battery case 110 and the outer surface 126 of the electrode assembly 120.

[0075] A dimension of the second conductive layer 144A is defined by a predetermined amount of liquid solution contained in the second part 144.

[0076] Each of the first conductive layer 142A and the second conductive layer 144A formed in the Fig. 2B and Fig. 3B, contains a gel that does not flow freely at zero shear force after completion of the cross-linking process.

[0077] Since each of the first conductive layer 142A and the second conductive layer 144A formed in the Fig. 2B and Fig. 3B, which are shown in Fig. By filling the air gaps 115A, 115B shown in Figure 1 with, for example, an alkyl phosphate in gel form, the thermal performance is improved by increasing the thermal conductivity between the electrode assembly 120 and the battery case 110.

[0078] While the first fill hole 132 and the second fill hole 134 are illustrated as being located in the top cap assembly 130, it should be understood that at least one or both of the first fill holes 132 and the second fill holes 134 may be located in the battery case 110.

[0079] According to one aspect of the present disclosure, the battery casing 110 may be preheated before the first portion 142 and / or the second portion 144 of the liquid solution is introduced into the battery cell 100.

[0080] As in Fig. 5A, an electrochemical battery cell 200 according to the present disclosure is shown in an upright position. The battery cell 200 generally includes a battery case 210, an electrode assembly 220, and a top cap assembly 230. The battery case 210 includes a first sidewall 212, a second sidewall 214, and a bottom 216.

[0081] The battery housing 210 is made of a metallic material, for example, but not exclusively, aluminum.

[0082] Electrode assembly 220 includes electrode tabs 222 and 224, which extend through top cap assembly 230 to terminals 222A and 224A, respectively. Electrode tab 222 extends upwardly from a first side portion 220A of electrode assembly 220. Electrode tab 224 extends upwardly from a second side portion 220B of electrode assembly 220.

[0083] The upper cap assembly 230 includes a first fill hole 232, a second fill hole 234, and an electrolyte fill hole 236.

[0084] The electrode assembly 220 is arranged within the battery container 210.

[0085] A first conductive layer 242A is disposed between the first side wall 212 of the battery case 210 and the first side part 220A of the electrode assembly 220 and fills the air gap 115A ( Fig. 1).

[0086] The first conductive layer 242A is in contact with an inner surface 212A of the first side wall 212 of the battery case 210 and the first side part 220A of the electrode assembly 220.

[0087] A second conductive layer 244A is disposed on the second side wall 214 of the battery case 210 and the second side part 220B of the electrode assembly 220 and fills the air gap 115B ( Fig. 1).

[0088] The second conductive layer 244A is disposed between an inner surface 214A of the second side wall 214 of the battery case 210 and the second side portion 220B of the electrode assembly 220.

[0089] The top cap assembly 230, including the first fill hole 232 and the second fill hole 234, is mounted to the battery case 210 to form the battery cell 200.

[0090] The battery cell 200 contains a liquid electrolyte 250.

[0091] As in Fig. 5A, a method 1000 for manufacturing a battery cell 200 includes: inserting 1100 an electrode assembly 220 within a battery case 210; disposing 1200 a top cap assembly 230 on the battery case 210 to form a battery cell 200 having at least a first fill hole 232 and a second fill hole 234; introducing 1300 a first portion 242 of a liquid solution within the battery cell 200 via the first fill hole 232, the liquid solution containing an organic solvent, a cross-linkable polymer, and a cross-linking agent; converting 1400 the first portion 242 of the liquid solution into a first conductive layer 242A disposed between the electrode assembly 220 and the battery case 210; Introducing 1500 a second portion 244 of the liquid solution within the battery cell 200 via the second fill hole 234;Converting 1600 the second portion 244 of the liquid solution into a second conductive layer 244A disposed between the electrode assembly 220 and the battery case 210; and filling 1700 the battery cell 200 with a liquid electrolyte 250 within the battery cell 200 via an electrolyte fill hole 236.

[0092] Converting 1400, 1600 at least one of the first portion 242 and / or the second portion 244 of the liquid solution into at least one of the first conductive layer 242A and / or the second conductive layer 244A may comprise reacting 1450, 1650 the crosslinkable polymer and the crosslinking agent of at least one of the first portion 242 and / or the second portion 244 of the liquid solution to form a reaction product such that the organic solvent is included in the reaction product.

[0093] The battery cell 100 is in a first position P1 when the first portion 242 of the liquid solution 1400 is converted into the first conductive layer 242A. The battery cell 200 is rotated 180 degrees to a second position P2 before the second portion 244 of the liquid solution is converted into the second conductive layer 244A 1600.

[0094] According to one aspect of the present disclosure, converting 1400 the first portion 142 of the liquid solution into the first conductive layer 242A includes applying heat 1390 to at least a first sidewall 212 of the battery case 210, while converting the second portion 244 of the liquid solution into the second conductive layer 244A may include applying heat 1590 to at least a second sidewall 214 of the battery case 210.

[0095] The first conductive layer 242A is in contact with the first side wall 212 of the battery case 210 and a first side portion 220A of the electrode assembly 220, while the second conductive layer 244A is in contact with the second side wall 214 of the battery case 210 and a second side portion 220B of the electrode assembly 220.

[0096] Converting 1400 the first portion 242 of the liquid solution into a first conductive layer 242A may include storing 1410 the battery cell 200 at a predetermined temperature for a predetermined period of time.

[0097] Converting 1600 the second portion 244 of the liquid solution into a second conductive layer 244A may include storing 1610 the battery cell 200 at a predetermined temperature for a predetermined period of time.

[0098] In one example according to the present disclosure, the first fill hole 232 and / or the second fill hole 234 may be disposed in the upper cap assembly 230.

[0099] In another example according to the present disclosure, the first fill hole 232 and / or the second fill hole 234 may be disposed in the battery case 210.

[0100] The battery housing 210 may be preheated before the first portion 242 and / or the second portion 244 of the liquid solution is introduced into the battery cell 200.

[0101] According to one aspect of the present disclosure, filling the battery cell 200 with a liquid electrolyte 250 includes vacuum filling (1700).

[0102] As in Fig.5B, a method 2000 for manufacturing a battery cell 200 may include: inserting 2100 an electrode assembly 220 within a battery casing 210; disposing 2200 a top cap assembly 230 on the battery casing 210 to form a battery cell 200 having two fill holes 232, 234; introducing 2300 a liquid solution 242, 244 within the battery cell 200 via at least one of the two fill holes 232, 234, wherein the liquid solution 242, 244 includes an organic solvent, a cross-linkable polymer, and a cross-linking agent; Converting 2400 the liquid solution 242, 244 into at least one conductive layer 242A, 244A disposed between at least one side portion 220A, 220B of the electrode assembly 220 and the battery case 210; and filling 200 the battery cell 200 with a liquid electrolyte 250 using vacuum filling.

[0103] Converting 2400 the liquid solution 242, 244 into the at least one conductive layer 242A, 244A comprises reacting 2450 the crosslinkable polymer and the crosslinking agent of the liquid solution 242, 244 to form a reaction product, wherein the organic solvent is included in the reaction product.

[0104] The introduction of 2300 of the liquid solution 240 into the battery cell 200 comprises introducing a first portion 242 of the liquid solution into the battery cell 200 via one of the two filling holes 232, 234 and introducing a second portion 244 of the liquid solution into the battery cell 200 via the other of the two filling holes 232, 234.

[0105] The method 2000 further includes rotating 2330 the battery cell 200 from a first position P1 to a second position P2 before 2340 the second portion 244 of the liquid solution is introduced into the battery cell 200.

[0106] The method 2000 may include storing 2320 the battery cell 200 in the first position P1 for a predefined period of time before rotating 2330 the battery cell 200 to the second position P2.

[0107] According to one aspect of the present disclosure, at least one conductive layer 242A, 244A may comprise two conductive layers 242A and 244A. The first portion 242 of the liquid solution is converted into one of the two conductive layers 242A, 244A when the battery cell 200 is in the first position P1, and the second portion 244 of the liquid solution is converted into another of the two conductive layers 242A, 244A when the battery cell 200 is in the second position P2.

[0108] One of the two conductive layers 242A, 244A is arranged between the battery housing 210 and a side part 220A, 220B of the electrode assembly 220, and another of the two conductive layers 242A, 244A is arranged between the battery housing 210 and another side part 220A, 220B of the electrode assembly 220.

[0109] One of the two conductive layers 242A, 244A is in contact with the battery housing 210 and a side part 220A, 220B of the electrode assembly 220, and another of the two conductive layers 242A, 244A is in contact with the battery housing 210 and another side part 220A, 220B of the electrode assembly 220.

[0110] According to one aspect of the present disclosure, reacting 2450 the crosslinkable polymer and the crosslinking agent of the liquid solution 242, 244 to form the reaction product includes applying heat 2455 to the battery case 210.

[0111] By incorporating at least one conductive layer between an electrode assembly and a battery casing of a battery cell, a heat dissipation path within the battery cell is created that is more effective than an air gap between the electrode assembly and the battery casing and / or other cooling strategies currently used for heat dissipation, without compromising the existing thermal runaway properties.

[0112] These and other advantages of the present disclosure will be recognized by those skilled in the art in view of the foregoing disclosure.

[0113] The detailed description and the drawings or figures are supportive and descriptive of the present teachings, but the scope of the present teachings is defined solely by the claims. While some of the best modes and other embodiments for carrying out the present teachings have been described in detail, various alternative designs and embodiments for carrying out the present teachings are defined in the appended claims.

Claims

[1] A method of manufacturing a battery cell, comprising: Inserting an electrode assembly into a battery housing; disposing a top cap assembly on the battery case to form the battery cell having at least a first fill hole and a second fill hole; Introducing a first portion of a liquid solution into the battery cell via the first fill hole, the liquid solution containing an organic solvent, a crosslinkable polymer, and a crosslinking agent; Converting the first portion of the liquid solution into a first conductive layer disposed between the electrode assembly and the battery casing; Introducing a second portion of the liquid solution into the battery cell via the second filling hole; Converting the second portion of the liquid solution into a second conductive layer disposed between the electrode assembly and the battery casing; and Filling the battery cell with a liquid electrolyte via an electrolyte filling hole. [2] A method for producing a battery cell according to claim 1, wherein converting the first part and / or the second part of the liquid solution into the respective first and / or second conductive layer comprises reacting the crosslinkable polymer and the crosslinking agent of the first part and / or the second part of the liquid solution to form a reaction product, wherein the organic solvent is contained in the reaction product. [3] A method of manufacturing a battery cell according to claim 1, wherein the battery cell is in a first position when converting the first portion of the liquid solution into the first conductive layer, and further comprising: rotating the battery cell to a second position prior to converting the second portion of the liquid solution into the second conductive layer. [4] A method of manufacturing a battery cell according to claim 1, wherein converting the first portion of the liquid solution into the first conductive layer comprises applying heat to at least a first sidewall of the battery container, and wherein converting the second portion of the liquid solution into the second conductive layer comprises applying heat to at least a second sidewall of the battery container. [5] A method of manufacturing a battery cell according to claim 1, wherein the first conductive layer is in contact with a first side wall of the battery case and a first side part of the electrode assembly; and wherein the second conductive layer is in contact with a second side wall of the battery case and a second side part of the electrode assembly. [6] A method of manufacturing a battery cell according to claim 1, wherein the first filling hole and / or the second filling hole is arranged in the upper cap assembly. [7] A method for manufacturing a battery cell according to claim 1, wherein the first filling hole and / or the second filling hole is arranged in the battery case. [8] A method of manufacturing a battery cell according to claim 1, further comprising preheating the battery container prior to introducing the first portion of the liquid solution and / or the second portion of the liquid solution into the battery cell. [9] A method of manufacturing a battery cell according to claim 1, wherein filling the battery cell with the liquid electrolyte comprises vacuum filling.

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