Method for manufacturing an electrochemical battery cell

Abstract

A method (1000) for manufacturing a battery cell (200), comprising: introducing (1100) an electrode assembly (220) into a battery housing (210); arranging (1200) an upper cap assembly (230) on the battery housing (210) to form the battery cell (200) having at least one first filling hole (232) and a second filling hole (234); introducing (1300) a first part (242) of a liquid solution into the battery cell (200) through the first filling hole (232), the liquid solution comprising an organic solvent, a crosslinkable polymer, and a crosslinking agent; converting (1400) the first part (242) of the liquid solution into a first conductive layer (242A) arranged between the electrode assembly (220) and the battery housing (210); introducing (1500) a second part (244) of the liquid solution into the battery cell (200) via the second filling hole (234);Converting (1600) the second part (244) of the liquid solution into a second conductive layer (244A) arranged between the electrode assembly (220) and the battery casing (210); and filling (1700) the battery cell (200) with a liquid electrolyte (250) via an electrolyte filling hole (236).

Description

The invention relates to a method of making a battery cell, particularly an electrochemical battery cell, including, but not limited to, prismatic battery cells and cylindrical battery cells having metallic housings or "cans" that contain heat dissipation paths for effective and uniform heat dissipation over the life of the battery cell.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 on opposite sides of a porous polymer separator and form an electrode stack. The electrode stack can be part of an electrode arrangement and can contain a protective sheath. The electrode stack or assembly is disposed in a hollow rectangular metallic battery housing or "can" and impregnated or "wetted" with an electrolyte solution suitable for conducting lithium ions.In most cylindrical battery cells, a jelly roll design (JR) is used. Generally, in the JR type, an insulating base is placed, followed by the anode layer, the separator layer, and the cathode layer to form an electrode stack. The electrode stack is then rolled up into a cylinder and inserted into a hollow metallic cylindrical housing or battery housing and impregnated or "wetted" with an electrolyte solution suitable for conducting lithium ions.DC power sources, such as lithium ion batteries, may be used to store and deliver electrical energy that may be used by a circuit or electric machine to perform operations, for example, for communication, display, or propulsion. Heat may be generated when converting electrical energy into chemical potential energy, i.e., charging the battery, and when converting chemical potential energy into electrical energy, i.e., discharging the battery.Lithium-ion battery cells, for example, but not limited to, 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 include multiple lithium ion battery cells. Accordingly, each lithium ion battery module or battery pack may generate an even greater amount of heat than a single lithium ion battery cell.The individual lithium ion battery cells, including but not limited to prismatic battery cells and cylindrical battery cells, may have a cavity between a sidewall of a metallic battery housing and an electrode assembly contained within the metallic battery housing. The cavity may contain air that may reduce thermal power within the single battery cell.Current cooling or heat dissipation strategies for lithium ion battery modules or battery packs may include cooling plates disposed within a lithium ion battery module or battery pack, for example, but not limited to, between the lithium ion battery cells as a unit and the battery module or battery pack and / or between the individual lithium ion battery cells within the battery module or battery pack. These cooling or heat dissipation strategies are located outside the lithium-ion battery cell unit, inside the battery module or the battery pack, and / or outside the single lithium-ion battery cell itself.DE 10 2007 012 693 A1 describes a battery which can be filled with liquid electrolyte and an electrolyte dispenser for filling a battery. A battery has an active battery area. The active battery region is arranged in an interior space which is provided by a carrier and an encapsulation. Between the carrier and / or the encapsulation and the active battery region, an intermediate space is arranged which is filled with electrically non-conductive material and has at least one hole for filling the inner space with liquid electrolyte. The space is filled with at least one material, the material having void inclusions, the hole being arranged to be disposed exclusively within the space, and the material having the void inclusions connecting the at least one hole to the battery active area. Furthermore, the hole can be closed.DE 10 2004 054 807 A1 describes a stabilization of bending of a feed line which is accommodated in a space formed by an outer housing. Leads of a battery element are connected to a circuit board housed in an upper cover. A holder is mechanically attached to the top cover made of a resin molding material and manufactured by, for example, injection molding. The edge surfaces of ribs formed on the holder serve as planes that receive the circuit board in the upper cover. The top cover and holder attached together are rotated 90° and moved to the opening in the edge face of the cell while bending over the leads which are bent over along the runs of the two side walls and the underside of the holder and are accommodated in a space formed by the outer casing. The peripheral surface of the top cover is heat bonded to the inner surface of the outer casing.US 2004 / 0 155 065 A1 describes a fuel reservoir for a liquid fuel cell, which is particularly useful for portable electronic devices, comprising a container defining a volume for receiving a liquid fuel; a wick structure which is positioned within the volume and into which at least a part of the liquid fuel wicks and from which the liquid fuel can subsequently be metered, for example by pumping; a holder for holding the wick structure in a desired orientation within the container; and an outlet for the liquid fuel which is connected to the wick structure.DE 10 2022 126 815 A1 describes an electrochemical system with a thermal barrier layer. The thermal barrier layer includes a polymer network having an inorganic portion and an organic portion, such as silicone or a polysiloxane polymer network. The polymer network may further include filler components dispersed therein, such as milled fibers of oxidized polyacrylonitrile, aerogel, hollow glass microspheres, and mica.In view of the above, it is therefore the object of the invention to develop a method for producing a battery cell with improved thermal performance within the battery cell.By way of introduction, an unclaimed battery cell is described to describe the battery produced by the claimed method. A battery cell includes a heat dissipation path provided by a conductive layer within the battery cell disposed between an electrode assembly and a battery housing. The conductive layer may be more effective than current cooling or heat dissipation strategies used, for example, but not exclusively, in rechargeable energy storage system (RESS) battery cells without compromising the existing thermal breakdown characteristics.According to one example, an electrochemical battery cell includes an electrode assembly, a battery housing, and a top cap assembly. The battery housing has a first side wall and a second side wall.According to one example, the electrode assembly is disposed within the battery housing. The upper cap assembly is assembled with the battery housing to form a battery cell having a first fill hole and a second fill hole.According to one example, a first portion of the liquid solution is introduced into the battery cell via the first fill hole. The first portion of the liquid solution is transformed into a first conductive layer disposed between a first side wall of the battery housing and the electrode assembly.According to one example, a second part of the liquid solution is introduced into the battery cell via the second filling hole. The second portion of the liquid solution is converted into a second conductive layer disposed between a second side wall of the battery case and the electrode assembly.According to one example, the liquid solution contains an organic solvent, a crosslinkable polymer and a crosslinking agent.According to one example, a vacuum filling is used to enable introduction of the liquid electrolyte into the battery cell.According to an example, the first part and the second part of the liquid solution are respectively converted into the first conductive layer and the second conductive layer 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 is contained in the reaction product.According to one example, reacting the crosslinkable polymer and the crosslinking agent of both the first portion and the second portion of the liquid solution includes applying heat to the liquid solution.According to an example, the first portion of the liquid solution located in the battery cell is converted into the first conductive layer by applying heat at least to the first sidewall of the battery housing when the battery cell is in a first position.According to an example, the second portion of the liquid solution located in the battery cell is converted into the second conductive layer by applying heat at least to the second sidewall of the battery housing when the battery cell is in a second position.According to an example, the first conductive layer is in contact with the first sidewall of the battery housing and a first side portion of the electrode assembly. The second conductive layer is in contact with the second side wall of the battery case and a second side portion of the electrode assembly.According to one example, the first fill hole and / or the second fill hole are disposed in the upper cap assembly.According to one example, the first fill hole and / or the second fill hole are arranged in the battery housing.According to one example, the battery is preheated before the first or the second part of the liquid solution is introduced into the battery cell.According to one example, vacuum filling is used to facilitate placement of the liquid electrolyte within the battery cell.According to one example, the liquid solution contains a mixed alkyl phosphate solution.The object is achieved by a method according to the invention for producing a battery cell. The method comprises: disposing an electrode assembly in a battery case; disposing a top cap assembly on the battery case to form the battery cell with at least a first fill hole and a second fill hole; disposing a first portion of a liquid solution in the battery cell through 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 case; disposing a second portion of the liquid solution into 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.According to an embodiment, 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 such that the organic solvent is contained in the reaction product.According to one embodiment, reacting the crosslinkable polymer and the crosslinking agent of both the first and second portions of the liquid solution comprises applying heat to the liquid solution.According to an embodiment, the battery cell is in a first position when the first portion of the liquid solution is converted into the first conductive layer. Further, the battery cell is rotated to a second position prior to converting the second portion of the liquid solution to the second conductive layer.According to an embodiment, the angle between the first position and the second position is 180 degrees.According to an embodiment, 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 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.According to an embodiment, the first conductive layer is in contact with the first side wall of the battery housing and a first side portion of the electrode assembly, and the second conductive layer is in contact with the second side wall of the battery housing and a second side portion of the electrode assembly.According to an embodiment, the first fill hole and / or the second fill hole is arranged in the upper cap assembly.According to one embodiment, the first filling hole and / or the second filling hole is arranged in the battery housing.According to one embodiment, the method comprises preheating the battery container before introducing the first part of the liquid solution and / or the second part of the liquid solution into the battery cell.According to one embodiment, filling the battery cell with the liquid electrolyte comprises vacuum filling.According to one embodiment, the battery is preheated before the first and / or the second part of the liquid solution is introduced into the battery cell.According to an unclaimed example, another method is described. This method of manufacturing a battery cell comprises: disposing an electrode assembly within a battery case; disposing an upper cap assembly on the battery case to form a battery cell having two fill holes; disposing a liquid solution within the battery cell via at least one of the two fill holes, the liquid solution containing an organic solvent, a crosslinkable polymer, and a crosslinking agent; converting the liquid solution into at least one conductive layer disposed between at least one side part of the electrode assembly and the battery case, wherein converting the liquid solution into the at least one conductive layer includes reacting the crosslinkable polymer and the crosslinking agent of the liquid solution to form a reaction product, the organic solvent being contained in the reaction product; filling the battery cell with a liquid electrolyte using vacuum filling.According to one example, introducing the liquid solution into the battery cell comprises introducing a first part of the liquid solution into the battery cell via one of the two filling holes and introducing a second part of the liquid solution into the battery cell via the other of the two filling holes.According to one example, the battery cell is rotated from a first position to a second position before the second portion of the liquid solution is introduced into the battery cell.According to one example, the battery cell is stored in the first position for a predefined period of time before being rotated to the second position.According to an example, the at least one conductive layer comprises two conductive layers. The first portion of the liquid solution will be converted to one of the two conductive layers when the battery cell is in the first position, and the second portion of the liquid solution will be converted to another one of the two conductive layers when the battery cell is in the second position.According to one example, one of the two conductive layers is arranged between the battery housing and one side part of the electrode arrangement, and another of the two conductive layers is arranged between the battery housing and another side part of the electrode arrangement.According to one example, one of the two conductive layers is in contact with the battery housing and one side part of the electrode arrangement, and another of the two conductive layers is in contact with the battery housing and another side part of the electrode arrangement.According to one example, reacting the crosslinkable polymer and the crosslinking agent of the liquid solution to form the reaction product comprises applying heat to the battery housing.According to one example, the method comprises preheating the battery housing before introducing the liquid solution into the battery cell.A heat dissipation path may be provided by a conductive layer inside the battery cell, which is arranged between an electrode arrangement and a battery housing. The conductive layer may 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 the existing thermal breakdown characteristics.The above features and advantages, as well as other features and attendant advantages of this specification, will be readily apparent from the following detailed description of illustrative examples and modes for carrying out the present specification when considered in connection with the accompanying drawings and the appended claims. Moreover, this specification expressly includes combinations and sub-combinations of the elements and features set forth above and below.FIG. 1 is a schematic illustration of a cross-section of an example battery cell in an upright position, without liquid solution. FIG. 2A is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present description rotated to position 1 prior to converting the liquid solution. FIG. 2B is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present description rotated at position 1 after converting the liquid solution to a conductive layer. FIG. 3A is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present description rotated to position 2 prior to converting the liquid solution. FIG. 3B is a schematic illustration of a cross section of an example battery cell constructed in accordance with the present description rotated at position 2 after converting the liquid solution to a conductive layer. FIG. 4 is a schematic illustration of a cross-section of an example battery cell constructed in accordance with the present description 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 description. FIG. 5B is a flowchart describing a method of manufacturing a battery cell according to the present description.The accompanying drawings are not necessarily to scale, presenting a somewhat simplified representation of various preferred features of the present specification as described herein, including, for example, certain dimensions, orientations, locations, and shapes. Details associated with such features will be determined in part by the particular intended application and use environment.Referring now to the drawings, wherein like numerals designate like parts throughout the several views, a battery cell including a liquid solution converted to a conductive layer and methods of making a battery cell including a liquid solution converted to a conductive layer are shown and described herein.As generally shown in FIG. 1, an electrochemical battery cell 100 is shown in an upright position. The battery cell 100 generally includes a battery housing 110, an electrode assembly 120, and an upper cap assembly 130. The battery housing 110 includes a first side wall 112, a second side wall 114, and a bottom 116.The battery case 110 is made of a metallic material, for example, but not limited to, aluminum.The electrode assembly 120 includes electrode tabs 122 and 124 that extend through the top cap assembly 130, respectively, to the terminals 122A and 124A. The electrode tab 122 extends upward from a first side portion 120A of the electrode assembly 120. The electrode tab 124 extends upward from a second side portion 120B of the electrode assembly 120.The upper cap assembly 130 includes a first fill hole 132, a second fill hole 134, and an electrolyte fill hole 136.The electrode assembly 120 is located inside the battery container 110.Air gaps 115A and 115B are respectively formed 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 housing 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 housing 110.The upper cap assembly 130 is mounted to the battery case 110 to form the battery cell 100.With continued reference to FIG. 1, a battery cell 100 is shown in a first position P 1 as shown in FIGS. 2A and 2B.In the first position P 1, a battery cell 100 is rotated 90 degrees counterclockwise from the upright position shown in FIG. 1 such that the first sidewall 112 of the battery cell 100 is horizontal.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.The first portion 142 of the liquid solution is converted into a first conductive layer 142A disposed between a first sidewall 112 of the battery container 110 and a first side portion 120A of the electrode assembly 120, as shown in FIG. 2B.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.As shown in FIGS. 3A and 3B, a battery cell 100 is seen in a second position P 2, with continued reference to FIG. 1.In the second position P 2, the battery cell 100 is rotated 180 degrees clockwise from the first position P 1 shown in FIGS. 2A and 2B or 90 degrees clockwise from the upright position shown in FIG. 1 such that the second side wall 114 is horizontal.A second portion 144 of the liquid solution is introduced into the battery cell 100 through the second fill hole 134 located in the top cap assembly 130, as shown in FIG. 3A.The second portion 144 of the liquid solution is converted into a second conductive layer 144A disposed between a second sidewall 114 of the battery container 110 and the second side portion 120B of the electrode assembly 120, as shown in FIG. 3B.The second conductive layer 144A is in contact with an inner surface 114A of the second sidewall 114 of the battery housing 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 housing 110 and the second side portion 120B of the electrode assembly 120.The liquid solution contains an organic solvent, a crosslinkable polymer and a crosslinking agent, a non-limiting example of which may comprise 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 crosslinkable oligomer (or monomer) and a crosslinking agent activated by a temperature increase.The first liquid solution portion 142 and the second liquid solution portion 144 illustrated in FIGS. 2A and 3A are respectively converted into the first conductive layer 142A and the second conductive layer 144A illustrated in FIGS. 2B and 3B by reacting the crosslinkable polymer and the crosslinking agent of the first liquid solution portion 142 and the second liquid solution portion 144 to form a reaction product so that the organic solvent is contained in the reaction product.The first portion 142 of the liquid solution is converted to the first conductive layer 142A by heating at least the first sidewall 112 of the battery container 110.The shape of the first conductive layer 142A is defined by the inner surface 112A of the first sidewall 112 of the battery housing 110 and an outer surface 126 of the electrode assembly 120.A dimension of the first conductive layer 142A is defined by a predetermined amount of liquid solution contained in the first portion 142.The second portion 144 of the liquid solution is converted to the second conductive layer 144A by heating at least the second sidewall 114 of the battery housing 110.The shape of the second conductive layer 144A is determined by the inner surface 114A of the second sidewall 114 of the battery housing 110 and the outer surface 126 of the electrode assembly 120.A dimension of the second conductive layer 144A is defined by a predetermined amount of liquid solution contained in the second portion 144.Each of the first conductive layer 142A and the second conductive layer 144A illustrated in FIGS. 2B and 3B includes a gel that does not freely flow at a shear force of zero after completion of the crosslinking process.Since each of the first conductive layer 142A and the second conductive layer 144A illustrated in FIGS. 2B and 3B fills the air gaps 115A, 115B illustrated in FIG. 1 with, for example, an alkyl phosphate in a gel form, thermal performance is improved by increasing thermal conductivity between the electrode assembly 120 and the battery case 110.While the first fill hole 132 and the second fill hole 134 are shown as being disposed in the top cap assembly 130, it should be appreciated that at least one or both of the first fill holes 132 and the second fill holes 134 may be disposed in the battery housing 110.According to an aspect of the present description, the battery housing 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.As shown in FIG. 4, an electrochemical battery cell 200 according to the present description is shown in an upright position. The battery cell 200 generally includes a battery housing 210, an electrode assembly 220, and an upper cap assembly 230. The battery housing 210 includes a first side wall 212, a second side wall 214, and a bottom 216.The battery housing 210 is made of a metallic material, for example, but not limited to, aluminum.The electrode assembly 220 includes electrode tabs 222 and 224 that extend through the top cap assembly 230 to the terminals 222A and 224A, respectively. The electrode tab 222 extends upward from a first side portion 220A of the electrode assembly 220. The electrode tab 224 extends upward from a second side portion 220B of the electrode assembly 220.The upper cap assembly 230 includes a first fill hole 232, a second fill hole 234, and an electrolyte fill hole 236.The electrode assembly 220 is disposed within the battery container 210.A first conductive layer 242A is disposed between the first sidewall 212 of the battery housing 210 and the first side portion 220A of the electrode assembly 220 and fills the air gap 115A (FIG. 1 ).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 portion 220A of the electrode assembly 220.A second conductive layer 244A is disposed on the second sidewall 214 of the battery housing 210 and the second side portion 220B of the electrode assembly 220 and fills the air gap 115B (FIG. 1 ).The second conductive layer 244A is disposed between an inner surface 214A of the second sidewall 214 of the battery case 210 and the second side portion 220B of the electrode assembly 220.The upper 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.A liquid electrolyte 250 is located in the battery cell 200.As shown in FIG. 5A, a method 1000 for manufacturing a battery cell 200 comprises: inserting 1100 an electrode assembly 220 within a battery housing 210; arranging 1200 an upper cap assembly 230 on the battery housing 210 to form a battery cell 200 having at least a first fill hole 232 and a second fill hole 234; inserting 1300 a first portion 242 of a liquid solution within the battery cell 200 via the first fill hole 232, the liquid solution including an organic solvent, a crosslinkable polymer and a crosslinking 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 housing 210; inserting 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 housing 210; and filling 1700 the battery cell 200 with a liquid electrolyte 250 within the battery cell 200 via an electrolyte filling hole 236.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 contained in the reaction product.The battery cell 200 is in a first position P 1 when the first portion 242 of the liquid solution is converted to the first conductive layer 242A at 1400. The battery cell 200 is rotated 180 degrees to a second position P 2 before converting the second portion 244 of the liquid solution into the second conductive layer 244A at 1600.According to an aspect of the present description, converting 1400 the first portion 242 of the liquid solution into the first conductive layer 242A may include applying heat 1390 to at least one first sidewall 212 of the battery housing 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 one second sidewall 214 of the battery housing 210.The first conductive layer 242A is in contact with the first sidewall 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 sidewall 214 of the battery case 210 and a second side portion 220B of the electrode assembly 220.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.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.In an example according to the present description, the first fill hole 232 and / or the second fill hole 234 may be disposed in the upper cap assembly 230.In another example according to the present description, the first fill hole 232 and / or the second fill hole 234 may be disposed in the battery case 210.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.According to an aspect of the present description, filling 1700 the battery cell 200 with a liquid electrolyte 250 comprises a vacuum filling.As shown in FIG. 5B, a method 2000 for manufacturing a battery cell 200 may include: inserting 2100 an electrode assembly 220 within a battery housing 210; disposing 2200 an upper cap assembly 230 on the battery housing 210 to form a battery cell 200 having two fill holes 232, 234; inserting 2300 first and second portions 242, 244 of a liquid solution within the battery cell 200 via at least one of the two fill holes 232, 234, the first and second portions 242, 244 of the liquid solution including an organic solvent, a crosslinkable polymer, and a crosslinking agent; converting 2400 the first and second portions 242, 244 of the liquid solution 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 housing 210; and filling 2500 the battery cell 200 with a liquid electrolyte 250 using vacuum filling 2600.Converting 2400 the first and second portions 242, 244 of the liquid solution into the at least one conductive layer 242A, 244A comprises reacting 2450 the crosslinkable polymer and the crosslinking agent of the first and second portions 242, 244 of the liquid solution to form a reaction product, wherein the organic solvent is contained in the reaction product.Introducing 2300 the liquid solution 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 fill holes 232, 234, and introducing a second portion 244 of the liquid solution into the battery cell 200 via the other of the two fill holes 232, 234.The method 2000 further comprises rotating 2330 the battery cell 200 from a first position P 1 to a second position P 2 before introducing the second portion 244 of the liquid solution into the battery cell 200 at 2340.The method 2000 may include storing 2320 the battery cell 200 in the first position P 1 for a predefined amount of time before rotating 2330 the battery cell 200 to the second position P 2.According to an aspect of the present description, at least one conductive layer may include two conductive layers 242A and 244A. The first portion 242 of the liquid solution is converted to one of the two conductive layers 242A, 244A when the battery cell 200 is in the first position P 1, and the second portion 244 of the liquid solution is converted to another one of the two conductive layers 242A, 244A when the battery cell 200 is in the second position P 2.One of the two conductive layers 242A, 244A is disposed between the battery case 210 and one side part 220A, 220B of the electrode assembly 220, and another of the two conductive layers 242A, 244A is disposed between the battery case 210 and another side part 220A, 220B of the electrode assembly 220.One of the two conductive layers 242A, 244A is in contact with the battery case 210 and one side part 220A, 220B of the electrode assembly 220, and another of the two conductive layers 242A, 244A is in contact with the battery case 210 and another side part 220A, 220B of the electrode assembly 220.According to an aspect of the present description, reacting 2450 the crosslinkable polymer and the crosslinking agent of the first and second portions 242, 244 of the liquid solution to form the reaction product comprises applying 2455 heat to the battery housing 210.The incorporation of at least one conductive layer between an electrode assembly and a battery housing of a battery cell creates a heat dissipation path within the battery cell that is more effective than an air gap between the electrode assembly and the battery housing and / or other cooling strategies currently used for heat dissipation without compromising the existing thermal runaway characteristics.These and other advantages of the present description will be appreciated by those skilled in the art in view of the foregoing description.

Claims

A method (1000) of manufacturing a battery cell (200), comprising: inserting (1100) an electrode assembly (220) in a battery case (210); disposing (1200) an upper cap assembly (230) on the battery case (210) to form the battery cell (200) with at least a first fill hole (232) and a second fill hole (234); inserting (1300) a first portion (242) of a liquid solution into the battery cell (200) via the first fill hole (232), wherein the liquid solution includes an organic solvent, a crosslinkable polymer, and a crosslinking 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 into 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) via an electrolyte fill hole (236).The method (1000) of manufacturing a battery cell (200) of claim 1, wherein converting (1400, 1600) the first part (242) and / or the second part (244) of the liquid solution into the respective first and / or second conductive layer (242A, 244A) comprises reacting (1450, 1650) the crosslinkable polymer and the crosslinking agent of the first part (242) and / or the second part (244) of the liquid solution to form a reaction product, wherein the organic solvent is contained in the reaction product.The method (1000) of manufacturing a battery cell (200) of claim 1, wherein the battery cell (200) is in a first position (P1) when the first portion (242) of the liquid solution is converted to the first conductive layer (242A), and further comprising: rotating the battery cell (200) to a second position (P2) prior to converting (1600) the second portion (244) of the liquid solution to the second conductive layer (244A).The method (1000) of manufacturing a battery cell (200) of claim 1, wherein converting (1400) the first portion (242) of the liquid solution into the first conductive layer (242A) comprises applying heat (1390) to at least one first sidewall (212) of the battery housing (210); and wherein converting (1600) the second portion (244) of the liquid solution into the second conductive layer (244A) comprises applying heat (1590) to at least one second sidewall (214) of the battery housing (210).The method (1000) of manufacturing a battery cell (200) of claim 1, wherein the first conductive layer (242A) is in contact with the first sidewall (212) of the battery case (210) and a first side portion (220A) of the electrode assembly (220); and wherein the second conductive layer (244A) is in contact with the second sidewall (214) of the battery case (210) and a second side portion (220B) of the electrode assembly (220).The method (1000) of manufacturing a battery cell (200) of claim 1, wherein the first fill hole (232) and / or the second fill hole (234) is disposed in the top cap assembly (230).The method (1000) of manufacturing a battery cell (200) according to claim 1, wherein the first filling hole (232) and / or the second filling hole (234) is disposed in the battery case (210).The method (1000) of manufacturing a battery cell (200) of claim 1, further comprising preheating the battery case (210) prior to introducing the first liquid solution portion (242) and / or the second liquid solution portion (244) into the battery cell (200).The method (1000) of manufacturing a battery cell (200) according to claim 1, wherein filling (1700) the battery cell (200) with the liquid electrolyte (250) comprises vacuum filling.

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