Method for manufacturing a lead-containing plate having at least one projection for a battery

Abstract

A method for manufacturing a lead-containing plate for a battery having at least one protrusion comprises the following steps: a) Providing a lead-containing workpiece, b) Providing a tool comprising a lower tool and an upper tool, wherein the lower tool and / or the upper tool has at least one recess, c) Positioning the workpiece between the lower tool and the upper tool, d) Arranging a deformable intermediate plate between the workpiece and the upper tool or the lower tool, e) Arranging a first rib and at least one second rib between the intermediate plate and the upper tool or the lower tool on a side of the intermediate plate facing away from the workpiece, f) Performing a relative movement along a first direction between the upper tool and the lower tool, in which a distance between the upper tool and the lower tool is reduced in order to exert pressure on the workpiece via the intermediate plate, the first bar and the at least one second bar, thereby causing a flow movement of the material of the workpiece in a second direction perpendicular to the first direction, wherein in step e) the first strip and the at least one second strip along the second direction are arranged spaced apart from each other, and Steps e) and f) are repeated several times to ensure that at least some of the workpiece material flows into the at least one recess to form the at least one projection.

Description

[0001] The present invention relates to a method for producing a lead-containing plate for a battery, said plate having at least one projection. Furthermore, the present invention relates to a method for producing a bipolar plate for the battery using the lead-containing plate having the at least one projection, a method for producing the battery, and the battery.

[0002] The present invention particularly relates to a method for producing a lead-containing plate or foil having at least one projection for a battery, in particular a bipolar lead battery, in which the height of the at least one projection is approximately two to five times greater than the thickness of the lead-containing plate between the projections.

[0003] Bipolar lead batteries are generally known, for example, from US 8,357,469 B2 and US 9,634,319 B2.

[0004] In one in-house known method for manufacturing a plate with projections, a workpiece is formed by means of a press tool having recesses such that a portion of the workpiece flows into the recesses to form the projections.

[0005] In order to form solid protrusions with a height approximately two to five times greater than the thickness of the plate between the protrusions, a comparatively large initial material thickness of the workpiece must be used. This leads to a correspondingly large compression stroke and workpiece volume to be displaced.

[0006] If the workpiece is subjected to compressive stress by the press tool and the workpiece's yield point is exceeded, the workpiece begins to plastically flow. A workpiece under pressure, preferably in the form of a cuboid, will flow along its length and width directions under rigid, plate-like parts of the press tool while its height decreases. Accordingly, the surface area under pressure increases, as does the force required to maintain plastic flow. Due to the increasing surface area, more and more material is in contact with a part of the press tool that acts largely over its entire surface.This leads to an increase in the frictional force to be overcome, which counteracts the increase in surface area, resulting in a sharp increase in the forming force required, necessitating presses capable of applying higher pressure, as well as press tools, particularly their press plates, with increased mechanical stability. The high contact stresses result in elastic embedding of the formed workpiece in the tool, which can lead to difficulties in maintaining thickness tolerances and / or the formation of massive protrusions on the finished workpiece.

[0007] It is an object of the present invention to provide an improved method for producing a lead-containing plate or foil for a battery, said plate or foil having at least one projection. Further objects of the present invention are to provide an improved method for producing a bipolar plate for the battery, an improved method for producing the battery, and an improved battery.

[0008] These objects are achieved by the features of the independent patent claims. Further preferred embodiments of the invention are the subject of the dependent patent claims.

[0009] A method for producing a lead-containing plate or foil for a battery having at least one projection comprises, according to a preferred embodiment, the following steps: a) Providing a workpiece containing lead, b) providing a tool having a lower tool and an upper tool, wherein the lower tool and / or the upper tool has at least one recess, c) arranging the workpiece between the lower tool and the upper tool, d) arranging a deformable intermediate plate, in one embodiment a flat deformable intermediate plate, between the workpiece and the upper tool or the lower tool, e) arranging a first strip and at least one second strip between the intermediate plate and the upper tool or the lower tool on a side of the intermediate plate facing away from the workpiece, f) performing a relative movement along a first direction between the upper tool and the lower tool, in which a distance between the upper tool and the lower tool is reduced in order to exert pressure on the workpiece via the intermediate plate, the first bar and the at least one second bar and thereby cause a flow movement of the material of the workpiece in a second direction which is perpendicular to the first direction, wherein in step e) the first strip and the at least one second strip are arranged spaced apart from each other along the second direction, and steps e) and f) are repeated several times to cause at least a portion of the material of the workpiece to flow into the at least one recess to form the at least one projection.

[0010] A “lead-containing plate having at least one projection” is to be understood in particular as a lead-containing material with a geometric shape which has two main surfaces facing away from one another and side surfaces which connect the two main surfaces, wherein the main surfaces are preferably planar or flat or substantially planar or flat, and the at least one projection extends from one of the main surfaces in a direction away from this main surface, preferably perpendicular to this main surface. In this case, in particular, the area of ​​the main surfaces is larger than that of the side surfaces. Furthermore, in this case, in particular, a thickness of the lead-containing plate having the at least one projection, which is determined by a distance between the two main surfaces, measured along a direction perpendicular to at least one of the two main surfaces, is considerably smaller than a length and / or width of the lead-containing plate having the at least one projection.Preferably, the thickness of the lead-containing plate having the at least one projection is substantially constant.

[0011] A "workpiece" is understood to mean, in particular, a semi-finished product, a blank, or the like, which is preferably produced by providing and subsequently processing a starting material such that the "workpiece" provided in step a) and arranged between the lower tool and the upper tool in step c) has a predetermined shape. When step f) is carried out at least once, the "workpiece" is processed by the interaction of regions of the upper or lower tool against which the first or second bar rests, the first or second bar, the intermediate plate, and regions of the other part selected from the upper and lower tool against which the "workpiece" rests, such that at least part of the workpiece or part of the material of the workpiece is formed.

[0012] In a preferred embodiment, a first or second strip is understood to be an elongated object made of a material with a geometric shape, which has two main surfaces facing away from one another and side surfaces which connect the two main surfaces, wherein preferably at least in a final execution of steps e) and f) the main surface facing the intermediate plate is flat or substantially flat or planar.

[0013] A “deformable intermediate plate” is understood to mean an object made of a material with a geometric shape, which has two main surfaces facing away from each other and side surfaces which connect the two main surfaces, wherein the “deformable intermediate plate” is in particular elastically deformable and the material of the “deformable intermediate plate” has a significantly higher strength and at the same time lower rigidity than the first or second strip.

[0014] By using the first strip, the at least one second strip, and the intermediate plate, in a preferred embodiment, the surface of the workpiece subjected to direct pressure and the workpiece volume involved in the forming process can be deliberately kept small. In this way, the required pressure applied by the tool, in particular the press tool, can be kept small and compliance with tight thickness tolerances can be ensured.

[0015] In this case, an essential component for achieving that the at least one projection can be formed in a solid form is the intermediate plate, which transmits the force of the first bar or center bar, which is preferably arranged in a center of the workpiece, relative to the second direction, and the at least one second bar or side bar, preferably two second bars, to the material to be deformed.

[0016] On the one hand, the intermediate plate prevents the material of the workpiece from rising or falling between any gaps that may exist between different components of the upper tool or lower tool.

[0017] On the other hand, the elastic compliance of the intermediate plate is important. The positive influence on the flatness of the manufactured lead-containing plate results from the initially compliant behavior of the intermediate plate, which places the already thin material of the workpiece under a state of tensile stress after the first stroke or after the first partial execution of step f). As the upper tool is lowered further or the height of the lower tool increases during the relative movement, the center, stiffened by the first bar or center bar, engages.

[0018] Due to the tensile stress state, the displaced material of the workpiece develops a strong tendency to flow outward along the second direction. Backflow into the center is prevented by the coordinated effect of the displacement by the first bar or center bar and the counterpressure exerted by the at least one second bar or side bar, which is necessary for the complete filling of the at least one recess.

[0019] Here, the formation of a solid projection is achieved by successively filling the at least one recess by means of a sideways flow of the workpiece material along the second direction. The workpiece material displaced in the center by the first bar or center bar is placed under pressure by the at least one second bar or side bar. This pressure prevents the workpiece material from flowing freely over the at least one recess. The lateral pressure promotes the flow of the workpiece material into the at least one recess. Also helpful here is the early buildup of accumulations of the workpiece material (hills) between the first bar and the at least one second bar. The height of these accumulations of the workpiece material exceeds the thickness of the initial material of the workpiece.These accumulations of workpiece material are formed beneath the elastically bent intermediate plate. The material volume in the mounds is influenced by the position of at least one second bar or side bar and the lateral boundary formed by the first bar or center bar. The thickness of the intermediate plate is also a significant parameter, as its elastic bending curve is directly dependent on its flexural rigidity.

[0020] The lead-containing workpiece provided in step a) can be a pure lead material with 100% or almost 100% lead content. However, the lead-containing workpiece provided can also be a lead alloy that contains an additional material in addition to lead. The additional material can preferably reduce the formation of a passivation layer or its thickness, which typically occurs with pure lead material, and / or increase the strength of the workpiece and / or reduce corrosion of the workpiece. For this purpose, the additional material can preferably contain calcium and / or zinc and / or silver and / or tin and / or another suitable metal.Preferably, the lead-containing workpiece is a lead-tin alloy, for example with a tin content of 0.8% to 1.5%, preferably 1.4% tin content, which in one embodiment may additionally contain calcium, for example with a calcium content of 0.05% to 0.1%, preferably 0.08% calcium content, and / or other metals such as silver or antimony.

[0021] The provided lead-containing workpiece is preferably a coherent material, such as a lead-containing plate. The provided lead-containing workpiece, designed as a lead-containing plate, is preferably cuboid-shaped or rectangular and / or, in some embodiments, can have dimensions of approximately 0.5-1.1 mm x 70-150 mm x 70-500 mm, in one embodiment 0.9 mm x 70-75 mm x 175-180 mm. According to one embodiment, the workpiece designed as a lead-containing plate is or is produced by casting and / or rolling and, if appropriate, post-annealing.

[0022] In a preferred embodiment, steps e) and f) are carried out at least 5 times, preferably at least 10 times, particularly preferably at least 18 times.

[0023] The method according to the invention is preferably used to produce a lead-containing plate for a battery, said plate having at least one projection and preferably being cuboidal or rectangular. The dimensions of the lead-containing plate having at least one projection and produced by the method according to the invention can, in some embodiments, be approximately 0.05-0.35 mm x 130-500 mm x 130-500 mm. The height of the at least one projection of the lead-containing plate having at least one projection and produced by the method according to the invention can, in some embodiments, be in a range from 0.4 mm to 1.5 mm, preferably in a range from 1.0 mm to 1.2 mm, and particularly preferably 1.1 mm. In this case, a plurality of recesses can be provided or formed, for example in a plurality of rows and columns, for example six recesses, in particular in two rows and three columns.which in some embodiments are hollow cylindrical with a diameter in a range of about 7-25 mm, preferably with a diameter of about 8-10 mm, in order to form a plurality of corresponding projections, in particular six corresponding projections.

[0024] According to a preferred embodiment, in at least one repetition of step e), a first strip is arranged with a width which, measured along the second direction, is greater than a width of a first strip arranged in a previous implementation of step e).

[0025] According to a preferred embodiment, in at least one repetition of step e), at least one of the at least one second strip is arranged at a different position with respect to the second direction, in particular further away from the first strip, than in a previous implementation of step e).

[0026] According to a preferred embodiment, in step c) the workpiece is arranged such that it does not overlap with the at least one recess along the first direction.

[0027] Preferably, in step e), a first strip and two second strips are arranged such that the first strip is arranged between the two second strips, and the two second strips are arranged such that in the directly following step f), the flow movement of the material of the workpiece in the second direction is at least limited by a deformation of the intermediate plate caused by the two second strips.

[0028] In this case, preferably in step e), the first strip and the two second strips can be arranged parallel to one another, and the first strip can be arranged in the middle between the two second strips, wherein a distance between the two second strips, measured along the second direction, is greater in at least one repetition of step e) than in a previous implementation of step e).

[0029] Preferably, in step e), the two second strips are arranged symmetrically with respect to the first strip.

[0030] According to a preferred embodiment, a position of the first strip and / or the at least one second strip in the second direction is fixed by means of a holding device or the first strip and / or the at least one second strip is fastened to the intermediate plate.

[0031] According to a preferred embodiment, the intermediate plate is deformed when step f) is carried out at least once, wherein after step f) is carried out, a thickness of the material of the workpiece at a position arranged between the first strip and at least one of the at least one second strip is greater than at a position at which the first strip overlaps the workpiece along the first direction and / or is greater than at a position at which the at least one second strip overlaps the workpiece along the first direction.

[0032] Preferably, in step b), a tool is provided with a device which is configured to limit a flow movement of the material of the workpiece during step f) in a third direction which runs perpendicular to the first direction and perpendicular to the second direction, in a preferred embodiment to limit it on both sides, in order to obtain a lead-containing plate having at least one projection and having a predetermined length for a battery. Preferably, this device is further configured to limit the flow movement of the material of the workpiece during step f) in the second direction, in a preferred embodiment to limit it on both sides. In this case, a length of the first or second strip along the third direction can be selected such that it corresponds to the limitation of the flow movement of the material of the workpiece in the third direction brought about by the device.Furthermore, a length and a width of the intermediate plate can be selected such that they correspond to the limitation of the flow movement of the material of the workpiece in the second or third direction caused by the device.

[0033] In a particularly preferred embodiment, step a) comprises extruding a lead-containing material to obtain a lead-containing workpiece formed as a lead-containing extrudate, wherein in step c) the lead-containing extrudate is arranged between the lower tool and the upper tool.

[0034] Through extrusion, a lead-containing extrudate can be produced or provided as a workpiece that is softer or has greater extensibility than a corresponding lead-containing plate produced by casting and / or rolling. As a result, the workpiece produced by extrusion in the form of a lead-containing extrudate can advantageously be dispensed with after-annealing, as is necessary for the lead-containing plate produced by casting and / or rolling in order to obtain the material properties with regard to deformability required for subsequent steps of the process. In addition, the workpiece produced by extrusion and in the form of a lead-containing extrudate advantageously has smaller grain sizes than the corresponding workpiece produced by rolling and / or casting and / or after-annealing.

[0035] According to a preferred embodiment, a grain size of the material of the lead-containing plate for the battery having at least one projection is in a range of 10 µm to 40 µm.

[0036] According to a preferred embodiment, at least once before the repeated execution of steps e) and f), in step d), a different deformable intermediate plate than that used in previously performed steps e) and f) is arranged between the workpiece and the upper tool or the lower tool. In this case, the different deformable intermediate plate can, in particular, be designed such that it is deformable differently than the intermediate plate used in the previously performed steps e) and f).

[0037] According to a preferred embodiment, after carrying out a last repetition of steps e) and f), the at least one recess is completely filled with a part of the material of the workpiece.

[0038] According to a preferred embodiment, after carrying out a last repetition of steps e) and f), a length and / or a width of the workpiece machined by means of the method is shortened to a predetermined length and / or a predetermined width, in particular using a punching tool, in order to obtain a lead-containing plate having at least one projection and having a predetermined length and / or a predetermined width for a battery.

[0039] According to a preferred embodiment, in step a) a lead-containing workpiece is provided with a profile whose thickness measured in or along the first direction, in particular after the workpiece has been arranged between the lower tool and the upper tool in step c), varies in a cross section along a plane spanned by the first direction and the second direction along the second direction.

[0040] The corresponding shaping for the lead-containing workpiece can be achieved by using a die shaped according to the desired profile in a case where the lead-containing workpiece is produced using an extrusion process or provided in step a), and by using a longitudinal rolling process carried out according to the desired profile in a case where the lead-containing workpiece is produced using a rolling process or provided in step a).

[0041] According to a preferred embodiment, in step a), a lead-containing workpiece is provided with a profile whose thickness is greater in two regions arranged substantially symmetrically around a center of the lead-containing workpiece arranged with respect to the second direction than in other regions. The thickness difference between the two regions arranged substantially symmetrically around the center of the lead-containing workpiece arranged with respect to the second direction and the other regions can be, for example, 0.3 mm to 2 mm.

[0042] In one embodiment, this can achieve a reduction in the required number of forming steps or the required number of repetitions of steps e) and f). Alternatively or additionally, this can achieve a reduction in the force required to form the lead-containing workpiece by the press, thereby allowing a more cost-effective and / or lighter press to be used in the implementation of the method according to the invention.

[0043] A method according to a preferred embodiment for producing a bipolar plate for a battery, in particular a bipolar battery, for example a bipolar lead battery, comprises in particular: - Providing a substrate with at least one opening, in particular a through opening, - Providing a lead-containing plate having at least one projection produced by means of a method described above for producing a lead-containing plate or foil for a battery having at least one projection, - Providing a further lead-containing plate or foil having at least one projection produced by means of a method described above for producing a lead-containing plate or foil having at least one projection for a battery or providing a substantially flat, lead-containing plate or foil, and - Arranging the lead-containing plate having the at least one projection on a main surface of the substrate such that the at least one projection extends into the at least one opening of the substrate, arranging the further lead-containing plate having the at least one projection on another main surface of the substrate such that the at least one projection extends into the at least one opening of the substrate, and establishing an electrically conductive connection between one end of the at least one projection of the lead-containing plate having the at least one projection and one end of the at least one projection of the further lead-containing plate having the at least one projection,wherein the end of the at least one projection of the lead-containing plate having the at least one projection and the end of the at least one projection of the further lead-containing plate having the at least one projection face each other, and applying a first active material to a main surface of the further lead-containing plate having the at least one projection facing away from the substrate and applying a second active material to a main surface of the lead-containing plate having the at least one projection facing away from the substrate, or, - Arranging the lead-containing plate having the at least one projection on a main surface of the substrate such that the at least one projection extends through the at least one opening of the substrate, arranging the substantially flat, lead-containing plate on another main surface of the substrate and establishing an electrically conductive connection between an end of the at least one projection of the lead-containing plate having the at least one projection facing the substantially flat, lead-containing plate and the substantially flat, lead-containing plate, and applying a first active material to a main surface of the substantially flat, lead-containing plate facing away from the substrate and applying a second active material to a main surface of the lead-containing plate having the at least one projection facing away from the substrate.

[0044] In this case, a respective adhesive layer can be applied or arranged between the main surface of the substrate and the lead-containing plate having the at least one projection and / or between the other main surface of the substrate and the further lead-containing plate having the at least one projection in order to fasten the lead-containing plate having the at least one projection and / or the further lead-containing plate having the at least one projection to the substrate, or a respective adhesive layer can be applied or arranged between the main surface of the substrate and the lead-containing plate having the at least one projection and / or between the other main surface of the substrate and the substantially flat, lead-containing plate in order to fasten the lead-containing plate having the at least one projection and / or the substantially flat, lead-containing plate to the substrate.

[0045] In one embodiment, the first active material is a positive active material or a cathode material and the second active material is a negative active material or an anode material, while in another embodiment, the first active material is a negative active material or an anode material and the second active material is a positive active material or a cathode material.

[0046] The substantially flat, lead-containing plate or foil can, in particular, comprise or be formed from the same material or a substantially identical material as the workpiece or the lead-containing plate having the at least one projection, and, apart from the projections, have the same or substantially the same dimensions as the lead-containing plate having the at least one projection. Furthermore, the substantially flat, lead-containing plate or foil can be produced by an extrusion process using an extrusion device, such as a die shaped according to the substantially flat profile of the substantially flat, lead-containing plate, or by a rolling and / or casting process and / or post-annealing.

[0047] In the event that the further lead-containing plate having the at least one projection is used in the method, the height of the at least one projection of the lead-containing plate having the at least one projection and the height of the at least one projection of the further lead-containing plate having the at least one projection are preferably selected such that they are equal to or substantially equal to half a thickness of the substrate, or, if one or two adhesive layers are applied for fastening the lead-containing plate having the at least one projection and / or the further lead-containing plate having the at least one projection to the substrate, equal to or substantially equal to half the sum of the thicknesses of the substrate and the adhesive layer(s).In another embodiment, in this case, the height of the at least one projection of the lead-containing plate having the at least one projection and the height of the at least one projection of the further lead-containing plate having the at least one projection can be selected such that the sum of the two heights is equal to or substantially equal to the thickness of the substrate, or, if one or two adhesive layers are applied for fastening the lead-containing plate having the at least one projection and / or the further lead-containing plate having the at least one projection to the substrate, is equal to or substantially equal to a sum of the thicknesses of the substrate and the adhesive layer(s).

[0048] In the case where the substantially planar lead-containing plate is used in the method, the height of the at least one projection of the lead-containing plate having the at least one projection is preferably selected such that it is equal to or substantially equal to the thickness of the substrate, or, if one or two adhesive layers are applied for fastening the lead-containing plate having the at least one projection and / or the substantially planar lead-containing plate to the substrate, equal to or substantially equal to a sum of the thicknesses of the substrate and the adhesive layer(s).

[0049] In one embodiment, the substrate may, for example, be formed from, comprise, or consist of an electrically insulating material, such as plastic. In one embodiment, the substrate may comprise an electrically insulating material that forms or at least substantially forms an outer shape of the substrate, and in which electrically conductive elements, such as electrically conductive particles, electrically conductive fibers, and / or a conductive powder, are provided, preferably homogeneously distributed.

[0050] The production of the electrically conductive connection between the end of the at least one projection of the lead-containing plate having the at least one projection and the end of the at least one projection of the further lead-containing plate having the at least one projection or the production of the electrically conductive connection between the end of the at least one projection of the lead-containing plate having the at least one projection facing the substantially flat, lead-containing plate and the substantially flat, lead-containing plate can be carried out using a suitable connection technique, preferably welding, in particular resistance welding, or soldering.

[0051] The application of the first and / or second active material, in particular in order to form a layer of the first or second active material, may, for example, comprise coating the respective main surface with a paste comprising the first or second active material and a subsequent thermal treatment.

[0052] According to a preferred embodiment, the method for producing a bipolar plate for a battery further comprises: - Providing a framework, and - Arranging the frame in such a way that, in the finished bipolar plate, the frame laterally surrounds the substrate, the lead-containing plate having the at least one projection, the further lead-containing plate having the at least one projection or the substantially planar lead-containing plate, the first active material and the second active material in such a way that a free space above exposed surfaces of the first and second active material is laterally delimited by the frame.

[0053] The frame, which is rectangular, for example, is preferably made of an electrically insulating material and serves in particular as a housing for the remaining components of the bipolar plate.

[0054] The thicknesses and the arrangements of the substrate, the lead-containing plate having the at least one projection, the further lead-containing plate having the at least one projection or the substantially planar, lead-containing plate, the first active material and the second active material are preferably selected such that a total thickness of the arrangement is smaller than a thickness of the frame and in particular selected such that the free space above the exposed surfaces of the first and second active material is laterally delimited by the frame.

[0055] According to a preferred embodiment of the method for producing a bipolar plate for a battery, providing the frame comprises providing a frame formed integrally with the substrate, or providing the frame comprises providing a frame with an internal groove, wherein a lateral portion of the substrate is inserted into the groove.

[0056] A method according to a preferred embodiment for producing a battery, in particular a bipolar battery, for example a bipolar lead battery, comprises: - stacking a plurality of bipolar plates produced by means of a method for producing a bipolar plate as described above such that the respective first active materials of the individual bipolar plates point in the same direction to form a stack of bipolar plates, wherein a respective electrolyte is arranged between a respective pair of adjacent bipolar plates, in particular between the mutually facing first and second active materials of the adjacent bipolar plates, such that the respective electrolyte is in contact both with the first active material of one bipolar plate of the pair of bipolar plates and with the second active material of the other bipolar plate of the pair of bipolar plates, and - Producing an electrically conductive connection between the first active material arranged on the main surface of a first bipolar plate of the stack of bipolar plates facing away from the stack of bipolar plates and a first terminal of the battery, and

[0057] Producing an electrically conductive connection between the second active material arranged on the main surface of a last bipolar plate of the stack of bipolar plates facing away from the stack of bipolar plates and a second connection pole of the battery.

[0058] In this case, preferably several bipolar plates, each of which preferably has a frame, are stacked on top of one another in such a way that a stack of bipolar plates is formed.

[0059] A respective spacer frame can be provided or arranged between the respective frames of adjacent bipolar plates, which spacer frame separates the respective frames of the adjacent bipolar plates from one another and is preferably connected to the two frames of the adjacent bipolar plates in such a way that a space is formed between the two adjacent bipolar plates, in particular between the mutually facing first and second active materials of the adjacent bipolar plates, which space is in particular sealed in a fluid-tight manner and in which the respective electrolyte can be accommodated, inserted or arranged.

[0060] A respective end plate can be provided or arranged at a respective end of the stack of bipolar plates, wherein a respective spacer frame can be provided or arranged between a circumferential projection or circumferential frame of a respective end plate and the frame of the respective adjacent bipolar plate, which spacer frame separates the respective frame of the respective bipolar plate and the circumferential projection or circumferential frame of the respective end plate from one another, and is preferably connected to the respective frame of the respective bipolar plate and the circumferential projection or circumferential frame of the respective end plate in such a way that a space is formed between the respective end plate and the respective adjacent bipolar plate, which space is in particular sealed in a fluid-tight manner.

[0061] On a side of a respective end plate facing a respective adjacent bipolar plate, a respective positive or negative end plate active material (end plate cathode material or end plate anode material) can be provided or applied, which is assigned to the respective end plate, wherein a respective connection plate can be arranged between the respective end plate and the respective end plate active material, which connection plate can be connected, in particular in an electrically conductive manner, to the respective end plate active material and to a respective first or second connection pole of the battery (positive or negative connection pole of the battery) formed within the scope of the method for producing the battery.

[0062] In the space between the respective end plate and the respective adjacent bipolar plate or between the respective end plate active material assigned to a respective end plate and the first or second active material of the respective adjacent bipolar plate, a respective electrolyte can be arranged, which can be at least partially surrounded by a respective spacer frame and / or can be held by it and / or can be accommodated by it, and preferably can also be at least partially surrounded by a frame of the adjacent bipolar plate and / or by the circumferential projection or circumferential frame of the respective end plate.

[0063] In one embodiment, the electrolyte can be a solid-state electrolyte, such as a thin ceramic or sulfide solid-state electrolyte, which, for example, is inserted or arranged in a receiving space of the spacer frame or is held by it. In another embodiment, the electrolyte can be a liquid electrolyte, wherein a separator, for example in the form of a glass (fiber) mat, can be provided, which is impregnated with the liquid electrolyte and can, for example, be received, inserted, or arranged in the receiving space of the spacer frame.

[0064] Here, the respective electrolyte arranged between adjacent bipolar plates is in contact both with the first active material of one bipolar plate of the adjacent bipolar plates and with the second active material of the other bipolar plate of the adjacent bipolar plates in order to electrically conductively connect the respective adjacent bipolar plates.

[0065] Furthermore, the respective electrolyte arranged between a respective bipolar plate and a respective end plate is in contact both with the first or second active material of the respective bipolar plate and with the respective end-plate active material associated with the respective adjacent end plate in order to electrically conductively connect the respective bipolar plate to the respective adjacent terminal plate. In this way, the two terminal plates, and thus also the first and second terminal poles of the battery, are electrically conductively connected to one another via the end-plate active materials, the electrolytes, and the plurality of bipolar plates.

[0066] According to one embodiment, at least one of the spacer frames can be omitted. In this case, the frames of the adjacent bipolar plates and / or the respective circumferential projection or frame of a respective end plate are connected to the frame of the adjacent bipolar plate, in particular connected in a fluid-tight manner, in order to form a respective space in which the respective electrolyte is accommodated, inserted, or arranged.

[0067] According to one embodiment, the method for producing the battery further comprises providing a housing, in particular a multi-part housing, and arranging the housing such that it encloses and / or surrounds the end plates, the plurality of bipolar plates arranged therebetween, and optionally the spacer frames. In this case, the first and second terminal poles of the battery can be formed on an outer side of the housing or outside the housing.

[0068] A battery, in particular a bipolar battery, for example a bipolar lead battery, according to a preferred embodiment is produced using a method for producing a battery, in particular a bipolar battery, as described above.

[0069] Further advantageous developments of the present invention will become apparent from the following description of preferred embodiments. The following shows, partially schematically: Fig. 1 is a flow chart illustrating a method for producing a lead-containing plate having at least one projection for a battery according to a preferred embodiment, Fig. 2 representations illustrating various phases of the method for producing a lead-containing plate for a battery having at least one projection, Fig. 3 is a plan view of a lead-containing plate having at least one projection, which is produced by the method according to the invention, Fig. 4 is a cross-sectional view of a bipolar plate for a battery according to a preferred embodiment, and Fig. 5 a cross-sectional view of a battery according to a preferred embodiment.

[0070] Fig. 1 shows a flow chart to illustrate a method for producing a lead-containing plate 100 or foil 100 having at least one projection 110 for a battery 200 according to a preferred embodiment, which is shown in Fig. 3 or Fig. 5. The lead-containing plate / foil 100 having at least one projection 110 is particularly intended for use in a bipolar plate and in a bipolar battery 200, such as a bipolar lead battery, in which several pairs of a plate / foil 100 and another plate / foil 100 or a substantially planar, lead-containing plate 150 (see Fig. 4 and Fig. 5) are stacked on top of each other, and the at least one projection 110 serves as a current path between the two plates 100,150 of a respective pair.

[0071] In step S10 of the flowchart of the Fig. 1 is made with reference to Fig. 2A, a lead-containing workpiece 30 is provided. The lead-containing workpiece 30 can be a pure lead material with 100% or almost 100% lead content. However, the provided lead-containing workpiece 30 can also be a lead alloy that contains an additional material in addition to lead. The additional material can preferably reduce the formation of a passivation layer or its thickness, which usually occurs with pure lead material, and / or increase the strength of the workpiece 30, and / or reduce corrosion of the workpiece 30. For this purpose, the additional material can preferably contain calcium and / or zinc and / or silver and / or another suitable metal.Preferably, the lead-containing workpiece 30 is a lead-tin alloy with a tin content of 0.8% to 1.5%, preferably 1.4% tin content, which in one embodiment may additionally contain calcium, for example with a calcium content of 0.05% to 0.1%, preferably 0.08% calcium content, and / or other metals such as silver or antimony.

[0072] The provided lead-containing workpiece 30 is preferably a continuous material such as a lead-containing plate, as in Fig. 2A, which is preferably cuboid-shaped or rectangular and can have dimensions of approximately 0.5-1.1 mm x 70-150 mm x 70-500 mm, in one embodiment 0.9 mm x 70-75 mm x 175-180 mm. According to one embodiment, the workpiece 30, which is formed as a lead-containing plate, is or is produced by casting and / or rolling and, if appropriate, post-annealing.

[0073] In a preferred embodiment, the lead-containing workpiece 30 is or is produced by extrusion using a corresponding extrusion device. By extrusion, a lead-containing extrudate can be produced or provided as workpiece 30 that is softer or has greater extensibility than a corresponding lead-containing plate that is or is produced by casting and / or rolling. As a result, the workpiece 30 produced by extrusion, in the form of a lead-containing extrudate, can advantageously be dispensed with after-annealing, as is usually required for the lead-containing plate produced by casting and / or rolling in order to obtain the material properties with regard to deformability required for subsequent steps of the process.In addition, the workpiece 30 produced by extrusion and formed as a lead-containing extrudate advantageously has smaller grain sizes than the corresponding workpiece 30 produced by rolling and / or casting and optionally post-annealing.

[0074] In step S20, a tool comprising a lower tool 10 and an upper tool 20, in particular a press tool, preferably a hydraulic press or an eccentric press, as in Fig. 2A. Here, the lower tool 10 has at least one recess 11, which is intended for a part of the workpiece 30 or a part of the material of the workpiece 30 to flow into it in order to form the at least one projection 110. The at least one recess 11 can preferably be formed by means of a bore through the lower tool 10, into which a pin, preferably a ground pin, projects from below by a predetermined amount depending on the specifications, whereby a depth of the recess 11 is adjustable. The pin can be moved during the process and in particular after completion of the lead-containing plate 100 such that it partially or completely fills the bore, and thus functions as an ejector.

[0075] The tool preferably has six such recesses 11, wherein the diameters of the recesses 11 are adapted to the diameters of the projections 110 to be formed and can preferably be approximately 9 mm. In an embodiment not shown, the upper tool 20 can additionally or alternatively have such recesses 11.

[0076] In step S30, the lead-containing workpiece 30 is placed between the lower tool 10 and the upper tool 20. Here, the workpiece 30 is, as in Fig. 2A, arranged such that it does not overlap with the at least one recess 11 along a first direction Z, along which a relative movement between the upper tool 20 and the lower tool 10 is carried out in a later step S60 or pressing step S60 or embossing step S60.

[0077] In step S40, the Fig. In the embodiment illustrated in FIG. 2A, a deformable, in particular elastically deformable, and preferably planar intermediate plate 40 is arranged between the workpiece 30 and the upper tool 20. In the other embodiment, not shown, in which the at least one recess 11 is provided in the upper tool 20, the deformable intermediate plate 40 is arranged between the workpiece 30 and the lower tool 10.

[0078] In step S50, a first strip 50 or center strip 50 and at least one second strip 51 are spaced apart from each other along a second direction X, which is perpendicular to the first direction Z, in which Fig. 2A, two second strips 51 or two side strips 51 are arranged between the intermediate plate 40 and the upper tool 20. In the other embodiment, not shown, however, a first strip 50 or center strip 50 and at least one second strip 51 are arranged spaced from one another along the second direction X, preferably two second strips 51 or two side strips 51, between the intermediate plate 40 and the lower tool 10. Here, the first strip 50 is arranged such that it overlaps with the workpiece 30 along the first direction Z, preferably in a center of the workpiece 30, and the at least one second strip 51 is arranged such that it does not overlap with the workpiece 30 along the first direction Z.In case two second strips 51 are used, the first strip 50 is arranged such that it is arranged along the second direction X between the two second strips 51, wherein the two second strips 51 are arranged symmetrically with respect to the first strip 50.

[0079] In one embodiment, the first strip 50 and / or the at least one second strip 51 can be fastened to the intermediate plate 40 in order to form a combined component consisting of the combination of the intermediate plate 40, the first strip 50 and / or the at least one second strip 51, or a combination of the intermediate plate 40, the first strip 50 and / or the at least one second strip 51 can be designed as a one-piece component, so that steps S40 and S50 are carried out simultaneously. Furthermore, a holding device can be provided on the tool, by means of which the position of the combined component or the one-piece component is fixed along the second direction X. In this way, a high level of repeatability can be achieved in the successive production of several of the lead-containing plates 100 having at least one projection 110.

[0080] In another embodiment, a holding device can also be provided on the tool, by means of which the position of the first strip 50 and / or the at least one second strip 51 is fixed along the second direction X. In this way, a high repeatability can also be achieved in the production of several of the lead-containing plates 100 having at least one projection 110.

[0081] In a step S60 or pressing step S60 or embossing step S60, as in Fig. 2B illustrates, a relative movement along the first direction Z between the upper tool 20 and the lower tool 10 is carried out, in which a distance between the upper tool 20 and the lower tool 10 is reduced in order to exert pressure on the workpiece 30 via the intermediate plate 40, the first bar 50 and the at least one second bar 51 and thereby cause a flow movement of the material of the workpiece 30 in the second direction X.

[0082] During this relative movement, the position of the lower tool 10 preferably remains unchanged, while the upper tool 20 is moved in the direction of the lower tool 10. Furthermore, guide bores (not shown) may be provided in the upper tool 20 and / or in the lower tool 10, through which a pin or a column passes in order to guide the relative movement through a column guide.

[0083] According to the invention, at least steps S50 and S60 are carried out several times or repeatedly, preferably at least 5 times, preferably at least 10 times, particularly preferably at least 18 times in succession, in order to cause at least a part of the material of the workpiece 30 to flow into the at least one recess 11, and thus to produce the lead-containing plate or foil 100 having the at least one projection 110.

[0084] In a preferred embodiment, step S40 can also be performed repeatedly prior to at least one repetition of steps S50 and S60. In other words, in this embodiment, before the repeated execution of steps S50 and S60, a different intermediate plate 40 can be used than in a previous repetition of at least steps S50 and S60. Here, steps S50 and S60 are preferably performed at least 5 times, preferably at least 10 times, particularly preferably at least 18 times in succession, and step S40 is performed at least once.

[0085] In a preferred embodiment, the first strip 50 and the at least one second strip 51 are positioned with respect to the second direction X and the widths of the first strip 50 and / or the at least one second strip 51 are selected along the second direction X during the individual repetitions in such a way that the at least one recess 11 is successively filled with a part of the material of the workpiece 30.

[0086] Preferably, as can be seen from a comparison between the Fig. 2C and Fig. 2D, which illustrate a repeated execution of steps S40, S50 and S60, with the Fig. 2A and Fig. 2B illustrates that a different, preferably flat intermediate plate 40 than in the previously performed step S40 and respective first strips 50 are used, the width of which, measured in the second direction X, increases with increasing number of repetitions.

[0087] Furthermore, as shown by a comparison between the Fig. 2C and Fig. 2D with the Fig. 2A and Fig. 2B illustrates, preferably at least one of the at least one second strips 51 is arranged at a different position with respect to the second direction X than during a previous execution of step S50, in order to cause at least a portion of the material of the workpiece 30 to flow into the at least one recess 11 to form the at least one projection 110. In this case, the at least one of the at least two second strips 51 can be arranged in at least one repetition of step S50 such that it has a greater distance from the first strip 50 and / or from the other of the at least two strips 51, measured along the second direction X, than during a previous execution of step S50.

[0088] In particular, as in the Fig. 2A to 2D illustrates, in at least one repetition, preferably in each repetition, of step S50, the first strip 50 and two second strips 51 arranged such that the first strip 50 is arranged between the two second strips 51, wherein the two second strips 51 are arranged such that in the directly following step S60, the flow movement of the material of the workpiece 30 is prevented by a deformation of the intermediate plate 40 caused by the two second strips 51 as in the Fig. 2B and Fig. 2D illustrates that the flow of a part 32 of the material of the workpiece 30 into the at least one recess 11 is at least limited along the second direction X, and thus a flow of a part 32 of the material of the workpiece 30 into the at least one recess 11 is forced, as in Fig. 2D illustrated.

[0089] Furthermore, as in the Fig. 2A to 2D illustrates in step S50 the first bar 50 and the two second bars 51 are arranged parallel to each other, wherein the first bar 50 is arranged in the middle between the two second bars 51, and a distance between the two second bars 51 in at least one repetition, preferably in each repetition of step S50 is greater than in a previous execution of step S50.

[0090] As in the Fig. 2B and Fig. 2D illustrates that when step S60 is carried out at least once, the intermediate plate 40 is deformed such that during or after step S60 is carried out, an accumulation of a part of the material of the workpiece 30, namely hills 31, is formed between the first strip 50 and the two second strips 51, wherein a thickness of the material of the workpiece 30 at a position arranged between the first strip 50 and the two second strips 51 is greater than at a position at which the first strip 50 overlaps the workpiece along the first direction Z and / or is greater than at a position at which the at least one second strip 51 overlaps the workpiece 30 along the first direction Z.

[0091] The tool provided in step S20 preferably comprises a device (not shown), which is preferably designed in the form of limiting plates and is configured to limit a flow movement of the material of the workpiece 30 during step S60 in a third direction Y, which is perpendicular to the first direction Z and perpendicular to the second direction X, in order to obtain a lead-containing plate 100 having at least one projection 110 and having a predetermined length for a battery 200. Preferably, this device is further configured to limit the flow movement of the material of the workpiece 30 in the second direction X during step S60.

[0092] After performing the last repetition of steps S50 and S60, the at least one recess 11 is completely filled with a portion 32 of the material of the workpiece 30 (not shown), and thus the plate 100 having at least one projection 110 for a battery 200 is produced. If necessary, a length and / or a width of the plate 100 produced in this way can be shortened in an optional subsequent work step using a suitable tool, for example, a punching tool, such that the plate 100 subsequently has a predetermined length and / or a predetermined width.

[0093] According to an embodiment not illustrated, in step S10 a lead-containing workpiece 30 is provided with a profile whose thickness measured in or along the first direction Z, in particular after the workpiece 30 has been arranged between the lower tool 10 and the upper tool 20 in step S30, varies in a cross section along a plane spanned by the first direction Z and the second direction X along the second direction X.

[0094] The corresponding shaping for the lead-containing workpiece 30 can be achieved by using a die shaped according to the desired profile in a case where the lead-containing workpiece 30 is manufactured using an extrusion process or provided in step S10, and by using a longitudinal rolling process carried out according to the desired profile in a case where the lead-containing workpiece 30 is manufactured using a rolling process or provided in step S10.

[0095] In this case, preferably in step S10, a lead-containing workpiece 30 is provided with a profile whose thickness is greater in two regions arranged substantially symmetrically around a center of the lead-containing workpiece 30 arranged with respect to the second direction X than in other regions. The thickness difference between the two regions arranged substantially symmetrically around the center of the lead-containing workpiece arranged with respect to the second direction X and the other regions can be, for example, 0.3 mm - 2 mm.

[0096] Fig. 3 shows a plan view of a lead-containing plate having at least one projection, which is produced by the method according to the invention.

[0097] The lead-containing plate 100 for a battery 200, in particular a bipolar battery, for example a bipolar lead battery, which has at least one projection 110, has a plurality of projections 110, in the present case six, arranged in two rows and three columns, the height of which is preferably in a range from 0.4 mm to 1.5 mm, preferably in a range from 1.0 mm to 1.2 mm, and particularly preferably 1.1 mm, and the diameter of which is in a range from about 7-25 mm, and preferably about 8 to 10 mm.

[0098] Fig. 4 schematically shows a cross-sectional view of a bipolar plate for a battery according to a preferred embodiment, which comprises a lead-containing plate having at least one projection produced by the method according to the invention for producing a lead-containing plate for a battery having at least one projection and can be produced using the method according to the invention for producing a bipolar plate.

[0099] The bipolar plate 500 has a preferably rectangular and electrically insulating frame 400 with an internal groove 401, a substrate 300 with at least one opening 303, in particular a plurality of openings 303, in particular through-opening(s), a lead-containing plate 100 produced according to the inventive method for producing a lead-containing plate for a battery having at least one projection and having at least one projection 110, a substantially planar, lead-containing plate or foil 150, a first (positive or negative) active material 301 and a second active material 302, wherein the second active material 302 is a negative active material when the first active material 301 is a positive active material, and the second active material 302 is a positive active material when the first active material 301 is a negative active material.

[0100] When carrying out the method according to the invention for producing the bipolar plate 500, the frame 400, the substrate 300, the lead-containing plate 100 having at least one projection 110, and the substantially flat, lead-containing plate or foil 150 can be provided.

[0101] The substantially flat, lead-containing plate or foil 150 may, in particular, comprise or be formed from the same material or a substantially identical material as the workpiece 30 or the lead-containing plate 100 having the at least one projection 110, and, apart from the projections 110, may have the same or substantially the same dimensions as the lead-containing plate 100 having the at least one projection 110. Furthermore, the substantially flat, lead-containing plate or foil 150 may be produced by an extrusion process using an extrusion device, such as a die shaped according to the substantially flat profile of the substantially flat, lead-containing plate, or by a rolling and / or casting process and / or post-annealing.

[0102] The frame 400 is arranged such that the substrate 300, the lead-containing plate 100 having at least one projection 110, the substantially planar lead-containing plate 150, the first active material 301, and the second active material 302 are each laterally surrounded by the frame 400, which is preferably formed from an electrically insulating material and serves in particular as a housing for the remaining components of the bipolar plate 500. An outer lateral portion of the substrate 300 is received in the groove 401 of the frame 400, or inserted into it, whereby the substrate 300 is held and supported by the frame 400.

[0103] In one embodiment, the substrate 300 may, for example, be formed from, comprise, or consist of an electrically insulating material, such as plastic. In one embodiment, the substrate 300 may comprise an electrically insulating material that forms or at least substantially forms an outer shape of the substrate 300, and in which electrically conductive elements, such as electrically conductive particles, electrically conductive fibers, and / or a conductive powder, are provided, preferably homogeneously distributed.

[0104] On one main surface of the substrate 300, the lead-containing plate 100 having the at least one projection 110 is or will be arranged or applied or provided in such a way that the projections 110 each extend into and preferably through a corresponding opening 303, in particular a through-opening, of the substrate 300, wherein the substantially flat, lead-containing plate 150 is or will be arranged or applied or provided on the other main surface of the substrate 300, which faces away from the one main surface of the substrate 300, and the end of a respective one of the projections 110 facing the substantially flat, lead-containing plate 150 is or will be electrically conductively connected to the substantially flat, lead-containing plate 150 using a suitable joining technique, preferably welding, in particular resistance welding, or soldering.

[0105] In this case, a respective adhesive layer (not shown) can be applied or arranged between the main surface of the substrate 300 and the lead-containing plate 100 having the at least one projection 110 and / or between the other main surface of the substrate 300 and the substantially flat, lead-containing plate 150 in order to attach the lead-containing plate 100 having the at least one projection 110 and / or the substantially flat, lead-containing plate 150 to the substrate 300.

[0106] The height of the at least one projection 110 of the lead-containing plate 100 having the at least one projection 110 is preferably selected such that it is equal to or substantially equal to a thickness of the substrate 300, or, if one or two adhesive layers are applied for fastening the lead-containing plate 100 having the at least one projection 110 and / or the substantially planar, lead-containing plate 150 to the substrate 300, equal to or substantially equal to a sum of the thicknesses of the substrate 300 and the adhesive layer(s).

[0107] The first active material 301 is or will be provided or applied on a main surface of the substantially flat, lead-containing plates 150 facing away from the substrate 300, and the second active material 302 is or will be provided or applied on a main surface of the lead-containing plate 100 having the at least one projection 110 facing away from the substrate 300. The application of the first and / or second active material 301, 302, in particular to form a layer of the first or second active material 301, 302, can, for example, comprise coating the respective main surface with a paste comprising the first or second active material 301, 302, followed by a subsequent thermal treatment.

[0108] Here, the thicknesses and arrangements of the substrate 300, the lead-containing plate 100 having the at least one projection 110, the substantially planar lead-containing plate 150, the first active material 301 and the second active material 302 are selected such that a total thickness of the arrangement is smaller than a thickness of the frame 400 and, in particular, are selected such that a free space above the exposed surfaces of the first and second active materials 301, 302 is laterally delimited by the frame 400.

[0109] In an embodiment not shown, the substrate 300 can be formed integrally with the frame 400, i.e. the substrate 300 and the frame can be formed together by a single part.

[0110] Additionally or alternatively, in an embodiment not shown, the bipolar plate 500 may comprise, instead of the substantially planar, lead-containing plate or foil 150, a further lead-containing plate 100 having at least one projection 110, which may be provided when carrying out the method according to the invention for producing the bipolar plate 500.

[0111] In this case, in the method, the further lead-containing plate 100 having the at least one projection 110 is provided and arranged on the other main surface of the substrate 300 in such a way that the respective projections 110 extend into the corresponding openings 303 of the substrate 300, wherein an electrically conductive connection is produced between the end of the at least one projection 110 of the lead-containing plate 100 having the at least one projection 110 and the end of the at least one projection 110 of the further lead-containing plate 100 having the at least one projection 110 using a suitable joining technique, preferably welding, in particular resistance welding, or soldering.

[0112] In this case, a respective adhesive layer can be applied or arranged between the main surface of the substrate 300 and the lead-containing plate 100 having the at least one projection 110 and / or between the other main surface of the substrate 300 and the further lead-containing plate 100 having the at least one projection 110 in order to fasten the lead-containing plate 100 having the at least one projection 110 and / or the further lead-containing plate 100 having the at least one projection 110 to the substrate 300.

[0113] In this case, the height of the at least one projection 110 of the lead-containing plate 100 having the at least one projection 110 and the height of the at least one projection 110 of the further lead-containing plate 100 having the at least one projection 110 are preferably selected such that they are equal to or substantially equal to half a thickness of the substrate 300, or, if one or two adhesive layers are applied for fastening the lead-containing plate 100 having the at least one projection 110 and / or the further lead-containing plate 100 having the at least one projection 110 to the substrate 300, equal to or substantially equal to half the sum of the thicknesses of the substrate 300 and the adhesive layer(s).In another embodiment, in this case, the height of the at least one projection 110 of the lead-containing plate 100 having the at least one projection 110 and the height of the at least one projection 110 of the further lead-containing plate 100 having the at least one projection 110 can be selected such that the sum of the two heights is equal to or substantially equal to the thickness of the substrate 300, or, if one or two adhesive layers are applied for attaching the lead-containing plate having the at least one projection 110 and / or the further lead-containing plate 100 having the at least one projection 110 to the substrate 300, is equal to or substantially equal to a sum of the thicknesses of the substrate 300 and the adhesive layer(s).

[0114] Furthermore, in this case, the first active material 301 is provided or applied on the main surface of the further lead-containing plate 100 facing away from the substrate 300 and having at least one projection 110.

[0115] In the method according to the invention for producing the bipolar plate 500 for a battery 200, in particular a bipolar battery, in particular the substrate 300 with at least one opening 303, the lead-containing plate 100 having at least one projection 110 produced by means of the above-described method for producing a lead-containing plate 100 having at least one projection for a battery 200, and the further lead-containing plate 100 having at least one projection 110 produced by means of the above-described method for producing a lead-containing plate 100 having at least one projection for a battery 200, or the substantially flat, lead-containing plate 150 are provided.

[0116] Furthermore, in the method according to the invention for producing a bipolar plate 500 for a battery 200, in particular - arranging the lead-containing plate 100 having the at least one projection 110 on a main surface of the substrate 300 such that the at least one projection 110 extends into the at least one opening 303 of the substrate 300, arranging the further lead-containing plate 100 having the at least one projection 110 on another main surface of the substrate 300 such that the at least one projection 110 extends into the at least one opening 303 of the substrate 300, and establishing an electrically conductive connection between one end of the at least one projection 110 of the lead-containing plate 100 having the at least one projection 110 and one end of the at least one projection 110 of the further lead-containing plate 100 having the at least one projection,wherein the end of the at least one projection 110 of the lead-containing plate 100 having the at least one projection and the end of the at least one projection 110 of the further lead-containing plate 100 having the at least one projection face each other, and applying a first active material 301 to a main surface of the further lead-containing plate 100 having the at least one projection facing away from the substrate 300 and applying a second active material 302 to a main surface of the lead-containing plate 100 having the at least one projection facing away from the substrate 300, or, - arranging the lead-containing plate 100 having the at least one projection 110 on a main surface of the substrate 300 such that the at least one projection 110 extends through the at least one opening 303 of the substrate 300, arranging the substantially planar, lead-containing plate 100 on another main surface of the substrate 300 and establishing an electrically conductive connection between the end of the at least one projection 110 of the lead-containing plate 100 having the at least one projection 110 facing the substantially planar, lead-containing plate 150 and the substantially planar, lead-containing plate 150, and applying a first active material 301 to a main surface of the substantially planar, lead-containing plate 150 facing away from the substrate 300, and applying a second active material 302 to a main surface of the lead-containing plate having the at least one projection facing away from the substrate 300 100.

[0117] The method according to the invention for producing a bipolar plate 500 for a battery 200 can further comprise, in particular, providing the frame 400 and arranging the frame 400 such that, in the finished bipolar plate 500, the frame 400 laterally surrounds the substrate 300, the lead-containing plate 100 having the at least one projection 110, the further lead-containing plate 100 having the at least one projection 110 or the substantially planar, lead-containing plate 150, the first active material 301 and the second active material 302 such that a free space above exposed surfaces of the first and second active materials 301, 302 is laterally delimited by the frame 400.

[0118] In this case, the provision of the frame 400 may comprise providing a frame 400 formed integrally with the substrate 300, or the provision of the frame 400 may comprise providing a frame 400 with an internal groove 401, wherein a lateral portion of the substrate 300 is inserted into the groove 401.

[0119] Fig. 5 schematically shows a cross-sectional view of a battery according to a preferred embodiment, which can be produced using the method for producing a battery according to the invention.

[0120] The battery 200, in particular a bipolar battery, for example a bipolar lead battery, has several of the Fig. 4, wherein for reasons of clarity only two bipolar plates 500-1, 500-2 are shown in Fig. 5. Here, the bipolar plates 500-1, 500-2 are or will be stacked one above the other in such a way that the main surfaces of the first active material 301-1, 301-2 of a respective bipolar plate 500-1, 500-2 facing away from the substrate 300-1, 300-2 are directed in the same direction, in the example in Fig. 5 to the left, point or show.

[0121] Between the respective frames 400-1, 400-2 of adjacent bipolar plates 500-1, 500-2, a respective spacer frame 600-1 is or will be provided or arranged, which separates the respective frames 400-1, 400-2 of the adjacent bipolar plates 500-1, 500-2 from each other, and is or will preferably be connected to the two frames 400-1, 400-2 of the adjacent bipolar plates 500-1, 500-2 in such a way that a space is or will be formed between the two adjacent bipolar plates 500-1, 500-2, in particular between the mutually facing first and second active materials 301-2, 302-1 of the adjacent bipolar plates 500-1, 500-2, which space can in particular be sealed in a fluid-tight manner, and in which the electrolyte described later is accommodated or inserted. or is ordered.

[0122] At a respective end of the stack of bipolar plates 500-1, 500-2, a respective end plate 800-1, 800-2 is or will be provided or arranged, wherein between a circumferential projection or circumferential frame of a respective end plate 800-1, 800-2 and the frame 400-1, 400-2 of the respective adjacent bipolar plate 500-1, 500-2, a respective spacer frame 600-2, 600-3 is or will be provided or arranged, which separates the respective frame 400-1, 400-2 of the respective bipolar plate 500-1, 500-2 and the circumferential projection or circumferential frame of the respective end plate 800-1, 800-2 from one another, and preferably in such a way with the respective frame 400-1, 400-2 of the respective bipolar plate 500-1, 500-2 and the circumferential projection or circumferential frame of the respective end plate 800-1, 800-2 is or will be connected, such that a space is or will be formed between the respective end plate 800-1, 800-2 and the respective adjacent bipolar plate 500-1, 500-2.which can in particular be sealed fluid-tight, and in which the electrolyte described later is accommodated, inserted or arranged.

[0123] On a side of the respective end plate 800-1, 800-2 facing the respective adjacent bipolar plate 500-1, 500-2, a respective (positive or negative) end plate active material 801-1, 801-2 is or will be provided or applied, wherein between the respective end plate 800-1, 800-2 and the respective end plate active material 801-1, 801-2 a respective connection plate 802-1, 802-2 is or will be arranged, which is or will be connected in particular in an electrically conductive manner to the respective end plate active material 801-1, 801-2 and a respective first or second connection pole (not shown) of the battery 200 (positive or negative connection pole of the battery 200).

[0124] Furthermore, between the first active material 301-2 of a respective bipolar plate 500, in Fig. 5, for example, the bipolar plate 500-2, and the second active material 302-1 of a respective adjacent bipolar plate 500, in Fig. 5 for example the bipolar plate 500-1, and between the respective end plate active material 801-1, 801-2 assigned to a respective end plate 800-1, 800-2 and the first or second active material 301-1, 302-2 of the respective adjacent bipolar plate 500-1, 500-2, a respective electrolyte 700-1, 700-2, 700-3 is arranged, which is at least partially surrounded by a respective spacer frame 600-1, 600-2, 600-3 and / or is held by it and / or is received by it, and preferably also by at least one frame 400-1, 400-2, in the case of the electrolyte 700-1 preferably by both frames 400-1, 400-2 of the adjacent bipolar plates 500-1, 500-2, and in In this case, the electrolyte 700-2, 700-3 is also at least partially surrounded by the circumferential projection or circumferential frame of the respective end plate 800-1, 800-2.

[0125] In one embodiment, the electrolyte 700-1, 700-2, 700-3 can be designed as a solid-state electrolyte, such as a thin ceramic or sulfide solid-state electrolyte, which is inserted or arranged, for example, in a receiving space of the spacer frame 600-1, 600-2, 600-3 or is held by it. In another embodiment, not shown, the electrolyte 700-1, 700-2, 700-3 can be designed as a liquid electrolyte, wherein a separator, for example in the form of a glass (fiber) mat, can be provided, which is impregnated with the liquid electrolyte and can be received, inserted, or arranged, for example, in the receiving space of the spacer frame 600-1, 600-2, 600-3.

[0126] Here, the respective electrolyte 700-1 arranged between adjacent bipolar plates 500 is in contact with the first active material 301-2 of one bipolar plate 500, in Fig. 5 of the bipolar plate 500-2, as well as in contact with the second active material 302-1 of the respective adjacent bipolar plate 500, in Fig. 5 of the bipolar plate 500-1 in order to electrically connect the respective adjacent bipolar plates.

[0127] Furthermore, the respective electrolyte 700-2, 700-3 arranged between a respective bipolar plate 500-1, 500-2 and a respective end plate 800-1, 800-2 is in contact both with the first or second active material 301-1, 302-2 of the respective bipolar plate 500-1, 500-2, and in contact with the respective end plate active material 801-1, 801-2 assigned to the respective adjacent end plate 800-1, 800-2 in order to electrically conductively connect the respective bipolar plate 500-1, 500-2 to the respective adjacent connection plate 802-1, 802-2. In this way, the two connection plates 802-1, 802-2, and thus also the first and second connection poles (not shown) of the battery 200 are electrically conductively connected to one another via the end plate active materials 801-1, 801-2, the electrolytes 700-1, 700-2, 700-3 and the bipolar plates 500-1, 500-2.

[0128] In an embodiment not shown, the substrate 300 can be formed integrally with the frame 400, i.e. the substrate 300 and the frame can be formed together by a single part.

[0129] Additionally or alternatively, in an embodiment not shown, at least one of the spacer frames 600-1, 600-2, 600-3 can be omitted. In this case, the frames 400-1, 400-2 of the adjacent bipolar plates 500-1, 500-2 and / or the respective circumferential projection or frame of a respective end plate 800-1, 800-2 are or will be connected to the frame 400-1, 400-2 of the adjacent bipolar plate 500-1, 500-2, in particular connected in a fluid-tight manner, in order to form a respective space in which the respective electrolyte is or will be received, inserted, or arranged.

[0130] Additionally or alternatively, in an embodiment not shown, the battery 200 may further comprise a housing, in particular a multi-part housing, which encloses and / or surrounds the end plates 800-1, 800-2, the bipolar plates 500-1, 500-2 arranged therebetween and optionally the spacer frames 600-1, 600-2, 600-3, and which is provided when carrying out the method for producing the battery 200 and arranged such that it encloses and / or surrounds the end plates 800-1, 800-2, the bipolar plates 500-1, 500-2 arranged therebetween and optionally the spacer frames 600-1, 600-2, 600-3.

[0131] Additionally or alternatively, in an embodiment not shown, at least one of the bipolar plates 500-1, 500-2 may comprise, instead of the substantially planar, lead-containing plate or foil 150, the further lead-containing plate 100 having the at least one projection 110, the structure and manufacture of which are described with reference to Fig. 4 is described.

[0132] The method according to the invention for producing a battery 200, in particular a bipolar battery, comprises in particular: - Stacking a plurality of bipolar plates 500, 500-1, 500-2 produced by means of a method described above for producing a bipolar plate for a battery such that the respective first active materials 301, 301-1, 301-2 of the individual bipolar plates 500 point in the same direction to form a stack of bipolar plates 500, 500-1, 500-2, wherein a respective electrolyte 700-1 is arranged between a respective pair of adjacent bipolar plates 500, 500-1, 500-2, in particular between the mutually facing first and second active materials of the adjacent bipolar plates 500-1, 500-2, such that the respective electrolyte 700-1 is in contact with both the first active material 301, 301-1, 301-2 of a bipolar plate 500, 500-1, 500-2 of the pair of bipolar plates 500, 500-1, 500-2 as well as in contact with the second active material 302, 302-1, 302-2 of the other bipolar plate 500, 500-1, 500-2 of the pair of bipolar plates 500, 500-1, 500-2,and, - Producing an electrically conductive connection between the first active material 300, 300-1, 300-2 arranged on the main surface of a first bipolar plate 300, 300-1, 300-2 of the stack of bipolar plates 500, 500-1, 500-2 facing away from the stack of bipolar plates 500, 500-1, 500-2 and a first connection pole of the battery 200, and producing an electrically conductive connection between the second active material 300, 300-1, 300-2 arranged on the main surface of a last bipolar plate 300, 300-1, 300-2 of the stack of bipolar plates 500, 500-1, 500-2 facing away from the stack of bipolar plates 500, 500-1, 500-2 and a second connection pole the battery 200. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 8,357,469 B2

[0003] US 9,634,319 B2

[0003]

Claims

[1] A method for producing a lead-containing plate (100) for a battery (200) having at least one projection (110), comprising the steps: a) providing a workpiece (30) containing lead, b) providing a tool having a lower tool (10) and an upper tool (20), wherein the lower tool (10) and / or the upper tool (20) has at least one recess (11), c) arranging the workpiece (30) between the lower tool (10) and the upper tool (20), d) arranging a deformable intermediate plate (40) between the workpiece (30) and the upper tool (20) or the lower tool (10), e) arranging a first strip (50) and at least one second strip (51) between the intermediate plate (40) and the upper tool (20) or the lower tool (10) on a side of the intermediate plate (40) facing away from the workpiece (30), f) performing a relative movement along a first direction (Z) between the upper tool (20) and the lower tool (10), in which a distance between the upper tool (20) and the lower tool (10) is reduced in order to exert pressure on the workpiece (30) via the intermediate plate (40), the first bar (50) and the at least one second bar (51) and thereby cause a flow movement of the material of the workpiece (30) in a second direction (X) which is perpendicular to the first direction (Z), wherein in step e) the first strip (50) and the at least one second strip (51) are arranged spaced apart from one another along the second direction (X), and steps e) and f) are repeated several times to cause at least a portion of the material of the workpiece (30) to flow into the at least one recess (11) to form the at least one projection (110). [2] Method according to claim 1, wherein in at least one repetition of step e) a first strip (50) is arranged with a width which, measured along the second direction (X), is greater than a width of a first strip (50) arranged in a previous implementation of step e). [3] Method according to one of the preceding claims, wherein in at least one repetition of step e) at least one of the at least one second strip (51) is arranged with respect to the second direction (X) at a different position than in a previous execution of step e). [4] Method according to one of the preceding claims, wherein in step c) the workpiece (30) is arranged such that it does not overlap with the at least one recess (30) along the first direction (Z). [5] Method according to one of the preceding claims, in which in step e) a first strip (50) and two second strips (51) are arranged such that the first strip (50) is arranged between the two second strips (51) and the two second strips (51) are arranged such that in the directly following step f) the flow movement of the material of the workpiece (30) in the second direction (X) is at least limited by a deformation of the intermediate plate (40) caused by the two second strips (51). [6] Method according to claim 5, wherein in step e) the first strip (50) and the two second strips (51) are arranged parallel to each other, the first strip (50) is arranged in the middle between the two second strips (51), and a distance between the two second strips (51), measured along the second direction (X), is greater in at least one repetition of step e) than in a previous implementation of step e). [7] Method according to claim 6, wherein in step e) the two second strips (51) are arranged symmetrically with respect to the first strip (50). [8] Method according to one of the preceding claims, wherein a position of the first strip (50) and / or the at least one second strip (51) in the second direction (X) is fixed by means of a holding device or the first strip (50) and / or the at least one second strip (51) is fastened to the intermediate plate (40). [9] Method according to one of the preceding claims, in which the intermediate plate (40) is deformed when step f) is carried out at least once and, after step f) has been carried out, a thickness of the material of the workpiece (30) at a position arranged between the first strip (50) and at least one of the at least one second strip (51) is greater than at a position at which the first strip (50) overlaps the workpiece (30) along the first direction (Z) and / or is greater than at a position at which the at least one second strip (51) overlaps the workpiece (30) along the first direction (Z). [10] Method according to one of the preceding claims, wherein in step b) a tool is provided with a device which is adapted to limit a flow movement of the material of the workpiece (30) during step f) in a third direction (Y) which is perpendicular to the first direction (Z) and perpendicular to the second direction (X) in order to obtain a lead-containing plate (100) having at least one projection (110) and having a predetermined length for a battery (200). [11] Method according to one of the preceding claims, in which step a) comprises extruding a lead-containing material in order to obtain a lead-containing workpiece formed as a lead-containing extrudate, and in step c) the lead-containing extrudate is arranged between the lower tool (10) and the upper tool (20). [12] Method according to one of the preceding claims, wherein a grain size of the material of the lead-containing plate (100) for the battery (200) having at least one projection (110) is in a range of 10 µm to 40 µm. [13] Method according to one of the preceding claims, in which at least once before the repeated execution of steps e) and f) in step d) a different deformable intermediate plate (40) than in previously carried out steps e) and f) is arranged between the workpiece (30) and the upper tool (20) or the lower tool (10). [14] Method according to one of the preceding claims, wherein after carrying out a last repetition of steps e) and f), the at least one recess (11) is completely filled with a part of the material of the workpiece (30). [15] Method according to one of the preceding claims, in which, after carrying out a last repetition of steps e) and f), a length and / or a width of the workpiece (30) machined by means of the method is shortened to a predetermined length and / or a predetermined width, in particular using a punching tool, in order to obtain a lead-containing plate (100) having at least one projection (110) and having a predetermined length and / or a predetermined width for a battery (200). [16] Method according to one of the preceding claims, wherein in step a) a lead-containing workpiece (30) is provided with a profile whose thickness measured in the first direction (Z) varies in a cross-section along a plane spanned by the first direction and the second direction (X) along the second direction. [17] Method according to claim 16, wherein in step a) a lead-containing workpiece (30) is provided with a profile whose thickness is greater in two regions arranged substantially symmetrically around a center of the lead-containing workpiece (30) arranged with respect to the second direction (X) than in other regions. [18] Method for producing a bipolar plate (500) for a battery (200), in particular a bipolar battery, comprising: - providing a substrate (300) with at least one opening (303), - Providing a lead-containing plate (100) having at least one projection (110) produced by a method according to one of the preceding claims, - Providing a further lead-containing plate (100) produced by a method according to one of the preceding claims and having at least one projection (110) or providing a substantially flat, lead-containing plate (150), and - Arranging the lead-containing plate (100) having the at least one projection (110) on a main surface of the substrate (300) such that the at least one projection (110) extends into the at least one opening (303) of the substrate (300), arranging the further lead-containing plate (100) having the at least one projection (110) on another main surface of the substrate (300) such that the at least one projection (110) extends into the at least one opening (303) of the substrate (300), and establishing an electrically conductive connection between one end of the at least one projection (110) of the lead-containing plate (100) having the at least one projection (110) and one end of the at least one projection (110) of the further lead-containing plate (100) having the at least one projection,wherein the end of the at least one projection (110) of the lead-containing plate (100) having the at least one projection and the end of the at least one projection (110) of the further lead-containing plate (100) having the at least one projection face each other, and applying a first active material (301) to a main surface of the further lead-containing plate (100) having the at least one projection facing away from the substrate (300) and applying a second active material (302) to a main surface of the lead-containing plate (100) having the at least one projection facing away from the substrate (300), or, - Arranging the lead-containing plate (100) having the at least one projection (110) on a main surface of the substrate (300) such that the at least one projection (110) extends through the at least one opening (303) of the substrate (300), arranging the substantially planar, lead-containing plate (100) on another main surface of the substrate (300) and establishing an electrically conductive connection between the end of the at least one projection (110) of the lead-containing plate (100) having the at least one projection (110) facing the substantially planar, lead-containing plate (150) and the substantially planar, lead-containing plate (150), and applying a first active material (301) to a main surface of the substantially planar, facing away from the substrate (300),lead-containing plate (150) and applying a second active material (302) to a main surface of the lead-containing plate (100) facing away from the substrate (300) and having the at least one projection. [19] The method of claim 18, further comprising - providing a frame (400), and - Arranging the frame (400) in such a way that, in the finished bipolar plate (500), the frame (400) laterally surrounds the substrate (300), the lead-containing plate (100) having the at least one projection (110), the further lead-containing plate (100) having the at least one projection (110) or the substantially planar, lead-containing plate (150), the first active material (301) and the second active material (302) in such a way that a free space above exposed surfaces of the first and second active materials (301, 302) is laterally delimited by the frame (400). [20] Method according to claim 19, in which - providing the frame (400) comprises providing a frame (400) formed integrally with the substrate (300), or - providing the frame (400) comprises providing a frame (400) with an internal groove (401), and a lateral portion of the substrate (300) is inserted into the groove (401). [21] Method for producing a battery (200), in particular a bipolar battery, comprising: - Stacking a plurality of bipolar plates (500, 500-1, 500-2) produced by a method according to one of claims 18 to 20 such that the respective first active materials (301, 301-1, 301-2) of the individual bipolar plates (500) point in the same direction to form a stack of bipolar plates (500, 500-1, 500-2), wherein a respective electrolyte (700-1) is arranged between a respective pair of adjacent bipolar plates (500, 500-1, 500-2) such that the respective electrolyte (700-1) is in contact with both the first active material (301, 301-1, 301-2) of a bipolar plate (500, 500-1, 500-2) of the pair of bipolar plates (500, 500-1, 500-2) and in contact with the second active material (302, 302-1, 302-2) of the other bipolar plate (500, 500-1, 500-2) of the pair of bipolar plates (500, 500-1, 500-2), and - Producing an electrically conductive connection between the first active material (300, 300-1, 300-2) arranged on the main surface of a first bipolar plate (300, 300-1, 300-2) of the stack of bipolar plates (500, 500-1, 500-2) facing away from the stack of bipolar plates (500, 500-1, 500-2) and a first connection pole of the battery (200), and producing an electrically conductive connection between the second active material (300, 300-1, 300-2) arranged on the main surface of a last bipolar plate (300, 300-1, 300-2) of the stack of bipolar plates (500, 500-1, 500-2) facing away from the stack of bipolar plates (500, 500-1, 500-2). 300-2) and a second terminal of the battery (200). [22] Battery (200), in particular a bipolar battery, which is manufactured using a method according to claim 21.

Images