Process arrangement and method for manufacturing at least one battery cell

Abstract

The invention relates to a process arrangement for producing at least one battery cell (3), comprising an electrolyte filling station in which liquid electrolyte is injected into the cell housing of the battery cell (3), a wetting station in which electrolyte injected into the cell housing soaks or wets the electrode / separator arrangement contained therein, a formation / aging station in which the battery cell (3) is subjected to charging and discharging processes, and a battery cell carrier (1) with which, in a transfer step, the battery cell (3) is transferred over a transfer time and distance from the electrolyte filling station to the wetting station. According to the invention, a charging / discharging source (9), in particular a battery pack, is assigned to the battery cell carrier (1), by means of which the battery cell (3) is charged during the transfer step.

Description

[0001] The invention relates to a process arrangement and a method for producing at least one battery cell according to the preamble of claim 1 and claim 10.

[0002] In a process sequence for manufacturing a battery cell, after the cell housing has been populated, an electrolyte injection is performed in an electrolyte filling station, in which the liquid electrolyte is injected into the cell housing. The battery cell is then transferred to a wetting station, where the electrolyte injected into the cell housing soaks or wets the electrode / separator assembly contained therein. The battery cell is then transferred to a formation / aging station, where the battery cell is subjected to charging and discharging processes. In large-scale production, the transfer of battery cells from the electrolyte filling station to the wetting station is fully automated using a battery cell carrier that carries a large number of battery cells to be completed.

[0003] The above process sequence results in the following four problems: A first problem is galvanic copper corrosion after electrolyte injection during the wetting process. After the battery cell is filled with electrolyte and not yet charged, a small potential difference of approximately 1.5V exists between the copper substrate foil and the active material (i.e., graphite layer) of the anode of the electrode / separator assembly. This small potential difference can cause copper to galvanically corrode. Copper ions become embedded in the active material, creating holes in the copper substrate. This can lead to the copper foil tearing or even electrolyte leakage.

[0004] When the anode and cathode are connected (without external charge), a potential difference exists between the cathode and the copper substrate foil in the anode. This can also cause copper ions to migrate toward the cathode.

[0005] Once the electrolyte is filled and the battery cell is maintained under ideal conditions, copper corrosion can still occur. This means that the electrolyte wetting period should not exceed three days at room temperature. If wetting occurs at high temperatures (approximately 45°C), it should not be maintained for longer than two days under ideal conditions.

[0006] Copper corrosion is assumed to begin at more than 3V for the anode versus L / Li+; however, in the presence of a non-aqueous electrolyte and in the presence of HF, copper corrosion occurs as low as 2V. This means that after electrolyte soaking, if the battery cells are stored for a long time (approximately four days) at a high temperature of approximately 50°C, copper corrosion is possible. Copper forms a layer on the anode, separator, and cathode. This increases the likelihood of lithium plating during the formation process.

[0007] A second problem is insufficient electrolyte wetting. If the electrolyte does not properly penetrate the separator and electrode pores due to a shorter wetting time, the formation process is insufficient. The SEI is not fully formed, and the battery cell's full capacity cannot be achieved. Depending on the viscosity of the electrolyte and the pores in the separator and electrode, three to four days are typically required for the wetting process. If the soaking time is shortened due to the risk of copper corrosion, the battery cell's full capacity will not be achieved.

[0008] To accelerate the wetting process, high temperatures of around 50°C and mechanical pressure are applied to the battery cell. The high temperature can cause the lithium salt LiPF6 to decompose, reducing the ion mobility of the battery cell. Mechanical pressure can damage the separator.

[0009] A third problem is that copper dendrites can cause short circuits. At low voltage (when uncharged or below the lower discharge voltage of 2V), copper ions participate in the charging and discharging process together with lithium ions. After a few cycles, copper dendrites form, which can pierce the separator and cause a short circuit. This means that copper dendrites can reduce the safety of the battery cell.

[0010] A fourth problem is that the current formation process requires a lot of space and is very costly. The formation process is carried out in vertical high-bay racks where the battery cells are kept in the aging process for several days. Here, the battery cells are not charged and discharged, as there are no connection terminals. Only the battery cells are kept at a constant temperature. Furthermore, maintaining a uniform temperature for all racks in the vast formation area is very costly. During the formation process, the battery cells must be transferred to another battery cell carrier where a uniform compressive force can be applied and where each battery cell can be charged. This means that the battery cells must be transferred between battery cell carriers several times, which can damage the battery cells.

[0011] In the prior art, battery cell testing methods are also performed outside the formation / aging station. The battery cells are removed from the formation / aging station and placed in a test chamber to perform a cycling or calendering test at various temperatures and C-rates. Therefore, the battery cells are removed from the battery cell carrier and inserted into a new battery cell carrier to then begin the test in the test chamber. This process is time-consuming and can lead to numerous errors.

[0012] US 2022 / 0166076 A1 discloses an adjustable-angle battery holder. In the battery holder, the spacing between the clamping plates of a plurality of terminal blocks is increased by a slide actuator of the battery holder. Furthermore, the clamping plates are inserted into a plurality of compartments of a battery carrier. The clamping plates are clamped by the slide actuator. The battery holder is intended for the placement of the batteries. A compression force is applied to form the batteries during battery cell formation. US 2018 / 0191023 A1 discloses a device with a battery cell holder that is used in a formation / aging process during cell production.

[0013] The object is to provide a process arrangement and a method for manufacturing at least one battery cell, in which anode-side copper corrosion in the electrode / separator arrangement after the electrolyte filling process is prevented and / or the functionality of the battery cell carrier is increased compared to the prior art.

[0014] The object is achieved by the features of claim 1 or 10. Preferred developments of the invention are disclosed in the subclaims.

[0015] The invention relates to a process arrangement for manufacturing at least one battery cell. The process arrangement consists of an electrolyte filling station in which liquid electrolyte is injected into the cell housing of the battery cell, a wetting station in which the electrolyte injected into the cell housing soaks or wets the electrode / separator assembly contained therein, and a formation / aging station in which the battery cell is subjected to charging and discharging processes. Furthermore, the process arrangement comprises a battery cell carrier with which the battery cell is transferred in a transfer step over a transfer time and distance from the electrolyte filling station to the wetting station. According to the characterizing part of claim 1, a charging / discharging source is assigned to the battery cell carrier.With the help of the charge / discharge source, the battery cell is charged during the transfer step in order to prevent, in particular, galvanic corrosion of an anode from the electrode / separator arrangement, in particular between a copper substrate foil and an active material of the anode coated thereon.

[0016] According to the invention, the battery cell is charged to approximately 2.5V for LFP and a maximum of 3V for NMC. The voltage in the battery cell is too low to initiate SEI development. The charging process according to the invention is carried out before the wetting process, specifically during the transfer time of the battery cell carrier from the electrolyte filling station to the wetting station. The transfer time can be extended by means of a buffer time. Normally, the transfer time is approximately four hours. During this time, the battery cell is transported in the battery cell carrier, where it is charged to the required voltage. In this way, the battery cell arrives at the wetting station with a pre-charged voltage. No additional charging time is required, as this already occurs during the transport of the battery cell.

[0017] After charging is complete during transport, the battery cell carrier can be detached from the mobile charging / discharging source. The battery cell carrier is then stored on vertical shelves at room temperature and subsequently wetted or saturated with electrolyte at high temperature. No charging occurs during the wetting process. Because the battery cell already has a charge higher than the minimum discharge voltage, no galvanic corrosion occurs. Such galvanic corrosion is most likely to occur at a voltage below 1.5V, which is why the battery cell is charged with a voltage at least higher than this voltage.

[0018] In a first embodiment, the battery cell carrier can have terminals for the positive and negative poles to which the battery cell is attached (after electrolyte injection). The terminals in the battery cell carrier are connected so that all battery cells are connected in series. The battery cell carrier has an output with a positive and negative pole; internally, this output is connected to the positive and negative poles of the individual battery cells. This means that the battery cells in the battery cell carrier can be connected in parallel. The battery cell carrier, with the battery cells contained therein, is connected to an external battery pack. The battery cell carrier is clamped to the battery pack so that the power connections of the battery cell carrier are connected to the connections of the battery pack. Both the battery cell carrier and the battery pack move from the electrolyte injection point to the immersion area.Even during the buffer area, both the battery cell carriers and the battery pack are connected to each other.

[0019] In high-volume production, the battery cell typically spends about three to four hours in the transfer and buffer area. During this time, the individual battery cells are charged to at least 1.5V by the external battery pack (connected to the battery cell carrier). This charging occurs at a C-rate of approximately 1C. This allows the transport and buffer time to be used to charge the battery cells. Once the battery cell is charged, the battery cell carrier is detached from the battery pack and then stored in vertical storage for wetting. The detached battery pack returns to the electrolyte injection station to connect to a new battery cell carrier.

[0020] According to a second design variant, the battery cell carrier and the battery pack are continuously connected to each other throughout all process steps. This means that the battery cell carrier charges and discharges the battery cells throughout the entire formation process, as well as during the other process stations if necessary. The battery cells are charged by the battery pack built into the battery cell carrier. If the battery cells need to be discharged during the formation / aging process, they transfer the energy to the battery pack built into the battery cell carrier. This means that the energy is not lost. The energy absorbed by the battery cell carrier is returned to the charging / discharging source. Furthermore, several charging and discharging processes can be performed during the aging process after formation to build up a uniform SEI and CEI around the active anode and cathode materials.During formation and aging, no loading and unloading stations are required inside the racks.

[0021] A key aspect of the invention relates to the design, functionality, and permanent attachment of the battery pack to the battery cell carrier. The battery pack can consist of a number of battery cells or battery modules that can be controlled via a management system. Similarly, a management system can also be assigned to the battery cells located in the battery cell carrier so that all battery cells are charged and discharged evenly. It is also important that the voltage of the battery cell to be charged in the battery pack / battery cell carrier is always higher than the voltage of the battery cell to be charged in the battery cell carrier / battery pack. Therefore, during the charging process, all battery pack battery cells are connected in series to achieve a higher voltage. During the discharging phase, the battery cells in the battery cell carrier should have a higher voltage than the battery pack battery cells.To do this, some battery pack cells are connected in parallel so that their voltage is lower than the voltage of all the battery cells in the battery cell carrier. The battery cells in the battery cell carrier are always connected in series.

[0022] During charging, the battery cells swell; during discharging, they contract. The battery cell carrier can be equipped with a servomotor that creates a uniform compression pressure during swelling. The servomotor is powered by power supplied by the battery pack. The battery cell carrier can also be encapsulated within a housing to prevent thermal propagation of the battery cells. Furthermore, the battery cell carrier has a temperature-controlled system to carry out the formation / aging process at the desired temperature without being influenced by the outside atmosphere. A temperature sensor inside the battery cell carrier indicates the onset of thermal runaway; in this case, the battery pack attached to the battery cell carrier can be released and detach from the battery cell carrier.In this way, the battery cell carrier is insulated and the battery cells to be formatted are located in the enclosure so that heat cannot spread to other battery cell carriers.

[0023] In summary, the battery cell carrier has the following features: A battery pack is integrated into the battery cell carrier so that the battery cells (in the battery cell carrier) can be charged or discharged. The voltage of the battery pack is adjustable so that the battery cells (in the battery cell carrier) can release energy during charging and absorb energy during discharging. The battery cells can be placed in an enclosure. Although the battery pack is integrated into the battery cell carrier, it can also be removed from it as soon as an unacceptably high temperature increase is detected. A gas sensor is placed in the battery cell carrier to detect the onset of thermal propagation. The enclosure is gas-tight and has heating units that can maintain the required temperature regardless of the outside temperature. The energy for the heating is supplied by the battery pack attached to the battery cell carrier.A BMS system in the battery pack ensures even charging and discharging of all battery pack battery cells. A BMS system in the battery cell carrier ensures even charging and discharging of the battery cells (in the battery cell carrier). The battery cell carrier can be equipped with a servo-controlled motor that exerts even pressure on all battery cells to compensate for swelling. Tests for OCV (open circuit voltage), ACIR (alternating current internal resistance), DCIR (direct current internal resistance), and impedance are performed directly in the battery cell carrier without removing the battery cells from the battery cell carrier. During the formation / aging process and the test sequences, the battery cells remain in the battery cell carrier; this means the battery cells do not need to be removed.The required charging / discharging energy is saved with high efficiency because the battery pack supplies direct current to the battery cells being charged and simultaneously draws direct current when the battery cells are being discharged in the battery cell carrier. A first embodiment focuses only on charging the battery cells to approximately 2V to prevent galvanic copper corrosion. A second embodiment concerns the formation / aging process, during which the battery cells also remain in the battery cell carrier. A core of the invention is that the battery cell carrier is equipped with its own battery pack, which has the ability to change its voltage during the charging and discharging process.

[0024] Once the battery cells are inserted into the battery cell carrier after the initial electrolyte injection (during cell assembly), they remain in the carrier throughout the formation / aging process. The battery pack supplies the battery cells in the carrier with charging energy. During the discharge process, the battery cells in the carrier transfer energy to the battery pack. In this way, a large portion of the energy is recovered. The battery cells are charged to 1.5V during transfer to the wetting station, thus eliminating the risk of copper corrosion and SEl breakdown at low voltage during the wetting process. The battery cells in the carrier are continuously monitored for voltage. Any voltage drop is compensated by charging from the battery pack. This can also occur during the formation / aging process.The battery cell is kept at a uniform temperature by heating it with heating units. It is easy to maintain a uniform temperature in the battery cell carrier and throughout the formation / aging process. The pressure within the battery cell is kept constant during charging and discharging. This constant pressure can also be maintained during the aging process. This means that the battery cell always has a counterpressure during the formation / aging process to compensate for swelling.

[0025] The risk of thermal runaway in the battery cells within the battery cell tray is assessed by monitoring the temperature and gas evolution due to venting. In the event of a fault, the battery pack is disconnected and moved to a safe distance from the battery cell tray. The containment attached to each battery cell protects the other battery cells in the battery cell tray from thermal propagation. The charge and discharge cycle is also performed during the formation / aging process, so that a fine-grained SEI is formed. This reduces cell impedance. The battery cell tray continuously provides current and voltage signals, allowing tests such as OCV and DCIR without removing battery cells from the battery cell tray. Tests requiring alternating current, such as ACIR and EIS tests, can also be performed without removing the battery cells from the compartment.There's an inverter here that converts DC signals into AC signals. The battery pack voltage is adjustable so that the voltage of the battery cell carrier is higher than the voltage of the battery cells in the battery cell carrier. Similarly, the battery pack voltage is kept lower while the battery cells in the compartment are discharging.

[0026] The advantages of the invention are summarized below: Copper corrosion during formation can be prevented by charging the battery cell to 1.5V during transport before soaking. During the formation / aging process, the battery cells can be charged and discharged in the battery cell tray. This reduces the internal resistance of the battery cells due to uniform SEI and CEI formation. Energy is saved because the energy is transferred between the battery pack and the battery cell tray. A battery system that has reached its end of life in motor vehicles can also be used as the battery pack. A uniform temperature is maintained in the battery cell tray, while a uniform temperature is also maintained during the formation / aging process. All tests can be performed in the battery cell tray. The battery cells do not need to be removed from the battery cell tray.This means the risk of damage during handling is lower. The risk of thermal runaway can be easily detected by temperature and gas sensors. In this case, the battery pack would be deactivated. The battery cell carrier is equipped with a management system. This means that cell balancing of the battery cells is possible. During the formation / aging process, the battery cells are subjected to contact pressure. The battery cells can be charged during a transfer. This shortens the formation cycle time. The battery cells in the battery cell carrier are constantly monitored for their voltage. Any voltage drop is compensated by charging from the battery pack. This can also be done during the formation / aging process.

[0027] An embodiment of the invention is described below with reference to the accompanying figures. They show: Fig. 1 to 7b different views of a battery cell carrier according to the invention.

[0028] In the Fig. 1 shows a top view of a battery cell carrier 1. The battery cell carrier 1 is used in a process arrangement for manufacturing battery cells. The process arrangement consists of an electrolyte filling station, in which the liquid electrolyte is injected into the cell casing of the battery cell 3, a wetting station, in which the electrolyte injected into the cell casing soaks or wets the electrode / separator assembly contained therein, and a formation / aging station, in which the battery cells 3 are subjected to charging and discharging processes. In this process arrangement, the battery cell carrier 1 forms a transfer means that transfers the battery cells 3 between the individual processing stations.

[0029] The following is based on the Fig. 1, the structure and function of the battery cell carrier 1 are described. Accordingly, the battery cell carrier has a threaded spindle 11, which is a component of a pressing mechanism described later. The threaded spindle 11 extends along a carrier's longitudinal center axis. On both sides of the threaded spindle 11 (ie in the Fig. 1 above and below the threaded spindle 11) there is a row of battery cells 3. Each of the battery cell rows closes on its Fig. 1 right side with two still unpopulated spaces 13. Therefore, the bottom-side electrical contacts 18 are visible, via which the battery cells 3 with their (only in the Fig. 2b and Fig. 3b) cell terminals 12 can be brought into electrical contact with a charge / discharge circuit. The charge / discharge circuit also has Fig. 1 on the left side of the battery cell carrier 1 each have an electrical connection 5 for the Fig. 1 upper battery cell row and an electrical connection 7 for the Fig. 1 lower battery cell row. The two carrier terminals 5, 7 are in electrical contact with a battery pack 9 ( Fig. 4 or Fig. 5) can be brought.

[0030] Viewed in the longitudinal direction x of the carrier, the battery cells 7 are arranged in pairs, one behind the other. Each pair of battery cells is assigned a pressure plate 15, which is threadedly engaged with the threaded spindle 11. The threaded spindle 11 can be rotated by an electric motor (not shown) to exert contact pressure on the battery cells 3.

[0031] The battery cell carrier 1 is also assigned a battery management system (BMS) for each battery cell row. Furthermore, each battery cell row is assigned a gas sensor 17 and a load sensor 19, which are signal-connected to the respective BMS management system. The gas sensor 17 is in fluid communication with the battery cells 3 via gas lines 16.

[0032] As can be seen from the Fig. 4 or Fig. As further shown in Figure 5, the battery cell carrier 1 can be mechanically and electrically coupled to the battery pack 9. The mechanical coupling is realized by locking elements 23, which are pivotally connected to the battery cell carrier 1 and can be brought into positive engagement with the battery pack 9. The electrical coupling is realized by a connector 25, which connects the terminals of the battery pack 9 to the terminals 5, 7 of the battery cell carrier 1.

[0033] In addition, the battery cell carrier 1 has a heating unit 20 for each battery cell pair, which can be controlled via the respective battery management system (BMS). Furthermore, each battery cell 3 is assigned a temperature sensor 22, which is also in signal communication with one of the two BMS management systems.

[0034] In the Fig. 1, a uniform pressure is applied to the battery cells 3 with the help of the servo motor (not shown) and the threaded spindle 11; in addition, temperature and gas measurements as well as a measurement of the compressive force are carried out by the force sensor 19. The battery cells 3 used here are prismatic battery cells with both cell terminals 12 on the same cell side. The battery cells 3 can be inserted into a battery cell carrier 1, with their cell terminals pointing downwards towards the bottom contacts 18 in the battery cell carrier 1. An electrolyte injection opening 6 and a vent valve 8 are positioned on the opposite side of the respective battery cell 3. Other positions for the vent valve 8 and the electrolyte injection opening 6 are also possible. The battery cells 3 are heated by the heating units 20 located in the battery cell carrier 1. This creates a uniform temperature inside the battery cell.In this way, formation can be carried out at a higher temperature. Furthermore, it is also possible to use the battery cell carrier during the high-temperature aging process and during high-temperature tests. It is important that the battery cells 3 do not have to be removed from the battery cell carrier 1 for formation and a test sequence. The battery cell carrier 1 can be used universally in all formation, aging, and testing processes. Fig. 1, the upper battery cell row and the lower battery cell row are separated from each other and controlled by a separate BMS management system. The battery cells 3 in each of the battery cell rows are connected in series. The two battery cell rows can be charged and / or discharged separately; alternatively, they can be charged and discharged separately to different voltages. There is a separate power supply for the upper and lower battery cell rows. The BMS management system receives a signal from the temperature sensor 22 and the gas sensor 17 and switches off the battery pack 9. The BMS management system also performs cell balancing. The force sensor 19 detects and monitors the compressive force generated by the servo motor and the lead screw 11.

[0035] In the Fig. 2a to 3b show a housing 27 or capsule arrangement that protects individual battery cells 3 in the battery cell carrier 1 from thermal runaway of neighboring battery cells 3. The capsule 27 is airtight, so that no air can penetrate from the outside. This means that even if a damaged battery cell 3 experiences thermal runaway, only the oxygen available in the housing 27 of this battery cell 3 is consumed, not oxygen from the outside.

[0036] In the Fig. 4 and Fig. 5 shows the battery pack 9, which is mounted on the battery cell carrier 1. Accordingly, the battery cell carrier 1 is motion-coupled to the battery pack 9. Furthermore, the battery pack 9 can be decoupled from the battery cell carrier 1, for example, if the battery cells 3 in the battery cell carrier 1 have an excessively high temperature at which gas is released.

[0037] In the Fig. Figures 6 to 7c show how the voltage of the battery pack 9 can be changed by changing the wiring of the battery pack battery cells 10 or battery pack battery modules. During charging of the battery cells 3 located in the battery cell carrier 1, all battery pack battery cells 10 are connected in series, so that the battery pack voltage is higher than the required voltage achieved during charging of the battery cells 1. During the discharging process, some battery pack battery modules 10 in the battery pack 9 are switched off or connected in parallel. This means that the battery pack voltage drops and the battery cells 3 in the battery cell carrier 1 can now charge the battery pack battery modules 10. The battery cells 3 and the battery pack battery cells 10 therefore charge / discharge each other during the discharging and charging process. This leads to significant energy savings.

[0038] As from the Fig. 1, the battery cells 3 are placed in the battery cell carrier 1 such that the cell terminals of the battery cells 3 fit onto the bottom contacts 18 in the battery cell carrier 1. The bottom contacts 18 are gold-plated to ensure good, oxide-free electrical contact. The electrolyte injection opening 6 and the vent valve 8 are located on the top side of the respective battery cell 3. The universally applicable battery cell carrier 1 according to the invention can be used in a technical implementation, for example, for 48 or even 96 battery cells 3. According to the Fig. 1, a stationary plate is located on the right side of each battery cell pair. The movable pressure plate 15, located on the left side of each battery cell pair, is moved by the threaded spindle 11 (driven by the servo motor) and exerts a compressive force on the battery cells 3 and the stationary plate. A pressure cushion is located between the plates and the battery cells 3 to ensure a uniform compressive force across the entire battery cell surface.

[0039] The Fig. The upper and lower battery cell rows are electrically separated from each other. The battery cells in the upper and lower battery cell rows are each connected in series. Each of the battery cells receives power from a main power input and is then charged. The BMS management system monitors the voltage of each battery cell and also performs cell balancing. The power supply for the upper and lower battery cell rows is independent of each other.

[0040] Temperature and voltage sensors are attached to each battery cell 3. They send a signal to the battery cell management system, which coordinates with the BMS management system and maintains the voltage and temperature of the battery cells 3 evenly. If the temperature of a battery cell 3 is excessively high, charging is stopped and the battery pack 9 is deactivated. Voltage signals are also sent externally so that a record of the open-circuit voltage of each battery cell can be obtained. It is also possible to perform a DCIR test without removing the battery cell from the test. ACIR and impedance tests require an AC power source. This can be connected, for example, to an inverter that converts the direct current from the battery pack 9 into alternating current, allowing the test to be performed.

[0041] The heating units 20 (e.g., heating cartridges) are each attached to the fixed plate and set the desired temperature at the battery cell 3 during the formation, wetting, and aging processes. The electrical energy for the heating cartridges is also supplied by the integrated battery pack 9. Insulation on the outside of the plate prevents heat loss to the atmosphere. The temperature sensors 22 in each battery cell 3 also monitor the temperature on the battery cell carrier 1, ensuring that the desired temperature is maintained. If the temperature is higher or lower, the heating cartridges are supplied with more power by the BMS management system.

[0042] The battery cell carrier 1 is made of cast aluminum and is connected to the battery pack 9 at the side or bottom. Fig. 4 and Fig. 5, the integrated battery pack 9 is attached to the side of the battery cell carrier 1.

[0043] According to the Fig. 2a and Fig. 2b is the housing 27 in a view from above ( Fig. 2a) and in a side view ( Fig. 2b). The housing 27 is constructed in two parts with a stationary part 31 (on the right in the figures) and a movable part 29 (on the left in the figures). Fig. 2a and Fig. 2b, the housing 27 is open; the battery cell 3 is located in the battery cell carrier 1. Pivotable flaps 33 are arranged on the two parts 29, 31. In the Fig. 2a and Fig. 2b, the housing 27 is open. In contrast, in the Fig. 3a and Fig. 3b the flaps 33 are swung in; ie the housing 27 is hermetically closed.

[0044] As can be seen from the Fig. 2a to 3b, the battery cells 3 are hermetically sealed from the outside by the housing 27 during the formation / aging process. When the housing 27 is closed, a compressive stress is exerted on the battery cell 3 arranged therein; the two parts 29, 31 of the housing 27 are fixed to one another and together form an airtight capsule arrangement. Sealing material is located between the two parts 29, 31, which additionally ensures airtightness. The sealing material is attached to the fixed part 31. The housing 27 is provided with an inner coating which, in the event of thermal runaway, generates charcoal that surrounds the battery cell 1 and prevents the ingress of oxygen. The battery pack 9 is secured by the mechanical locking element 23 ( Fig. 4 or Fig. 5) can be connected to the battery cell carrier 1. The locking element 23 is part of the battery cell carrier 1. It is moved towards the horizontal position ( Fig. 5) to couple the battery pack 9 to the battery cell carrier 1. Other clamping mechanisms are also conceivable. In the event of a thermal runaway, the locking element 23 releases and rotates into its vertical position. The battery pack 9 is then free and rolls away to a safe distance from the battery cell carrier 1.

[0045] In the Fig. 4 is the electrical output of the battery pack 9 and is connected to the electrical terminal 4, 5 of the battery cell carrier 1. Since the battery cell carrier 1 has two independent terminals 4, 5, there is a power distribution in which the current from the battery pack 9 is redirected to two DC outputs.

[0046] According to the invention, the battery pack 9 and the battery cell carrier 1 can be transferred as a single unit. It is possible to use battery packs 9 that have reached the end of their service life for automotive applications. In this way, the battery cells 3 that are no longer suitable for automotive applications can be used in the manufacturing process for new battery cells 3.

[0047] In the Fig. Figure 6 shows the battery pack 9 with four battery pack modules 10 that can be connected in parallel or series. Series connection is preset as standard in the battery pack 9. Additionally, power lines are provided that connect the modules 10 in parallel; pin connections P1 to P5 are also provided, which are released by control to implement a series or parallel connection.

[0048] By switching on or off the parameters shown in the diagram of the Fig. 7a, various parallel and series connections can be realized using the management system of the battery pack 9. The coupling and decoupling of pins P1 to P5 can be achieved, for example, by magnetic force generated by an electromagnet 37 ( Fig. 7a or Fig. 7b). The electromagnets 37 are powered by a 12V starter battery 38 and then magnetized and demagnetized. This pushes or pulls pins P1 to P5, which connect the high-voltage conductors.

[0049] The battery pack 9 consists of the battery modules 10, which can be configured in various parallel and series combinations by connecting a pin P1 to P5 to high-voltage terminals. This pin P1 to P5 can, for example, connect all modules 10 in series and provide a high voltage, enabling faster charging. Or it can connect half of the modules 10 in parallel, thus doubling the capacity of the battery pack 9. The pins P1 to P5 are switched on and off by a magnetic field. The local magnetic field is generated by a controlled current in a pin activation device 39. This current is controlled by a microprocessor. The pin activation device 39 is an integral part of the battery pack 9. Once the pins P1 to P5 are activated, they remain in this position due to the locking mechanism. Similarly, once the pins P1 to P5 are released, they remain in this released position due to a locking mechanism.The pin activation device 39 is an integrated part of the battery pack 9 and can activate pins P1 to P5 via microprocessor signals. Power can be supplied by the 12V starter battery 39. The respective pins P1 to P5 can be switched on or off when the module 10 is not in use. The BMS management system must also be configured if various parallel and series connections have been activated. Pins P1 to P5 should have a locking mechanism. This means they remain engaged or disengaged until the next signal is received. A battery pack 9 with four modules 10 is shown here. This principle can also be used for a larger number of modules 10. Here, magnetic force is used to engage and disengage the pins. Mechanical force can also be used with the help of air springs or lever mechanisms. The module voltage and capacity are fixed.The energy of battery pack 9 is equal to the sum of the energy of the battery modules 10. As soon as the voltage of battery pack 9 is increased, the insulation must be designed for the highest voltage. It is also important that when the capacity of battery pack 9 is increased, the cable diameters are designed for the highest current. When battery pack 9 charges the battery cells 3 in battery cell carrier 1, all battery cells 9 are connected in series so that the voltage is at its highest. When the battery cells 3 in battery cell carrier 1 discharge their energy, this energy is fed into battery pack 9. Here, for example, two battery modules 10 can be connected in parallel or in series so that the voltage drops and the battery cells in battery cell carrier 1 transfer their energy to battery pack 9.In this way, the energy can be transferred between the battery cells 3 in the battery cell carrier 1 and the battery modules 10 in the integrated battery pack 9 without major losses. List of reference symbols 1 battery cell carrier 3 battery cells 5 electrical carrier connection 6 Injection opening 7 electrical carrier connection 8 vent valve 9 Battery pack 10 battery pack battery modules 11 Threaded spindle 12 cell terminal 13 empty space not yet equipped with a battery cell 3 15 printing plate 16 Gas pipeline 17 Gas sensor 18 bottom contacts 19 Load sensor 20 heating unit 21 Enclosure 22 Temperature sensor 23 locking element 25 electrical connectors 27 Enclosure 29 moving part 31 stationary part 33 flap 37 Electromagnet 38 starter battery 39 PIN activation device P1 to P5 pins BMS management system 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 2022 / 0166076 A1

[0012] US 2018 / 0191023 A1

[0012]

Claims

[1] Process arrangement for the production of at least one battery cell (3), with an electrolyte filling station in which liquid electrolyte is injected into the cell housing of the battery cell (3), with a wetting station in which electrolyte injected into the cell housing soaks or wets the electrode / separator arrangement contained therein, with a formation / aging station in which the battery cell (3) is subjected to charging and discharging processes, and with a battery cell carrier (1) with which the battery cell (3) is transferred in a transfer step over a transfer time and distance from the electrolyte filling station to the wetting station, characterized bythat the battery cell carrier (1) is assigned a charging / discharging source (9), in particular a battery pack, by means of which the battery cell (3) is charged during the transfer step, in particular to prevent galvanic corrosion of an anode of the electrode / separator arrangement, in particular between a copper substrate foil and an active material of the anode, and that in particular the battery cell (3) is charged up to a limit voltage of preferably 1.5 V in order to prevent galvanic corrosion, and that in particular the battery cell carrier (1) can be used universally in all wetting, formation, aging and cell testing processes. [2] Process arrangement according to claim 1, characterized bythat the battery cell carrier (1), at least during the transfer step, is movement-coupled to the charging / discharging source (9), and that in particular at the end of the transfer step the charging / discharging source (9) can be mechanically and electrically decoupled from the battery cell carrier (1), can be returned to the electrolyte filling station in a reversing movement, and there can be coupled again to a battery cell carrier (1) for a subsequent transfer step, and / or that in the event of a thermal runaway of the battery cell (3), the charging / discharging source (9) can be decoupled from the battery cell carrier (1). [3] Process arrangement according to claim 1, characterized bythat the charging / discharging source (9) of the battery cell carrier (1) remains coupled to the battery cell carrier (1) after the end of the transfer step, i.e. during the wetting process and the formation / aging process, and that in particular the charging / discharging source (9) is a battery pack with a plurality of battery modules (10) which can be switched between a charging mode and a discharging mode, with each battery pack battery modules (10) having an adapted charging or discharging circuit, and that in particular when the battery cell (3) is discharged during the formation / aging process, the battery cells release the electrical energy to the charging / discharging source (9), so that complete energy recovery takes place with the aid of the electrical coupling of the charging / discharging source (9) to the battery cell (3). [4] Process arrangement according to claim 3, characterized byin that, in the charging circuit active in the charging mode, the battery pack battery modules (10) are connected in series in order to provide a charging voltage which is greater than the voltage of the battery cell (3) located in the battery cell carrier (1), and in that, in particular, in the discharging circuit active in the discharging mode, at least some of the battery pack battery modules (10) are connected in parallel, so that the voltage in the battery pack (9) is lower than the voltage of the battery cell (3) located in the battery cell carrier (1). [5] Process arrangement according to one of the preceding claims, characterized by that the battery cell carrier (1) has at least one management system (BMS) with which in particular at least one pressure plate (15) can be controlled, which keeps the battery cell (3) located in the battery cell carrier (1) under uniform voltage during the charging / discharging processes. [6] Process arrangement according to claim 5, characterized bythat the battery cell carrier (1) has at least one load or force sensor (19) which is in signal connection with the management system (BMS) for monitoring the contact pressure exerted by the pressure plate (15) on the battery cell (3). [7] Process arrangement according to claim 5 or 6, characterized by that the battery cell carrier (1) has at least one gas sensor (17) which is in signal connection with the management system (BMS) for monitoring gas development in the battery cell carrier (1) in order to detect a defect in the battery cell (3), in particular a thermal runaway. [8] Process arrangement according to claim 5, 6 or 7, characterized by that the battery cell carrier (1) has at least one temperature sensor (22) which is in signal connection with the management system (BMS) for monitoring the temperature of the battery cell (3) located in the battery cell carrier (1). [9] Process arrangement according to one of claims 5 to 8, characterized by that the management system (BMS) monitors the electrical voltage of the battery cell (3) located in the battery cell carrier (1) in order to control the charging / discharging process, in particular a cell balancing of the battery cells (3) located in the battery cell carrier (1). [10] Method for manufacturing at least one battery cell (3) by means of a process arrangement according to one of the preceding claims.

Images