Electric cell lid

Abstract

A battery cell cover includes a cover body; and an electrical terminal extending through an aperture in the cover. The electrical terminal includes: a crimp connector including a connector base disposed adjacent to an inner surface of the cover and a post extending from the connector base and passing through a hole in the cover; a seal extending around a periphery of a post of the crimp connector, where an inner portion of the seal is disposed between the cover and the connector base, a central portion of the seal is disposed between the cover and the post, and an outer portion of the seal is disposed on an outer surface of the cover; and a gasket disposed around a periphery of the post and disposed on an outer portion of the seal.

Description

(19) State Intellectual Property Office (12) Invention Patent Application (10) Application Publication Number (43) Application Publication Date (21) Application Number 202480035573.X (22) Application Date 2024.05.29 (30) Priority Data 63 / 505,903 2023.06.02 US (85) PCT International Application Entering National Phase Date 2025.11.27 (86) PCT International Application Application Data PCT / US2024 / 031409 2024.05.29 (87) PCT International Application Publication Data WO2024 / 249479 EN 2024.12.05 (71) Applicant Constant Voltage Charging Co., Ltd. Address USA (72) Inventor V. Villaraighavan (74) Patent Agency Beijing Linda Liu Intellectual Property Agency (General Partnership) 11277 Patent Attorneys Zhang Huihua and Yue Hongjie (51) Int.Cl. H01M 50 / 567 (2006.01) H01M 50 / 564 (2006.01) H01M 50 / 543 (2006.01) H01M 50 / 176 (2006.01) H01M 50 / 174 (2006.01) H01M 50 / 172 (2006.01) H01M 50 / 15 (2006.01) H01M 50 / 147 (2006.01) H01M 50 / 188 (2006.01) H01M 50 / 186 (2006.01) (54) Invention Title: Battery Cell Cover (57) Abstract: A battery cell cover includes a cover body; and an electrical terminal extending through a hole in the cover body. The electrical terminal includes: a crimp connector including a connector base disposed adjacent to an inner surface of the cover body and a post extending from the connector base and through a hole in the cover body; a seal extending around the periphery of the post of the crimp connector, wherein an inner portion of the seal is disposed between the cover body and the connector base, a central portion of the seal is disposed between the cover body and the post, and an outer portion of the seal is disposed on an outer surface of the cover body; and a gasket disposed around the periphery of the post and disposed on the outer portion of the seal.Claims 2 pages, Description 7 pages, Drawings 12 pages, CN 121548913 A 2026.02.17 CN 1 21 54 89 13 A 1. A battery cell cover, comprising: a cover body; an electrical terminal extending through a hole in the cover body, the electrical terminal comprising: a crimp connector including a connector base disposed adjacent to an inner surface of the cover body and a post extending from the connector base and through the hole in the cover body; a seal extending around the periphery of the post of the crimp connector, wherein an inner portion of the seal is disposed between the cover body and the connector base, a central portion of the seal is disposed between the cover body and the post, and an outer portion of the seal is disposed on an outer surface of the cover body; and a gasket disposed around the periphery of the post and disposed on the outer portion of the seal, wherein the post of the crimp connector has a protrusion extending circumferentially around the post, wherein the gasket is disposed between the protrusion and the outer portion of the seal. 2. The battery cell cover of claim 1, wherein the protrusion of the crimp connector extends around the entire periphery of the post. 3. The battery cell cover of claim 1 or 2, wherein the protrusion of the crimp connector contacts the gasket. 4. The battery cell cover of any preceding claim, wherein the gasket is disposed in a recess defined in the outer portion of the seal. 5. The battery cell cover of any preceding claim, wherein the seal comprises: a washer ring disposed around the periphery of the post, wherein at least some of the washer rings are disposed between the connector base and the cover body; and a spacer ring disposed around the periphery of the post, wherein at least some of the spacer rings are disposed on the outer surface of the cover body. 6. The battery cell cover of claim 5, wherein the washer ring and the spacer ring contact each other in the space between the cover body and the post of the crimp connector. 7. The battery cell of claim 5 or 6, wherein the gasket is disposed in a recess defined in the surface of the spacer ring. 8. The battery cell of any one of claims 5 to 7, wherein the washer ring comprises an elastomeric material. 9. The battery cell according to any one of claims 5 to 8, wherein the gasket ring comprises rubber. 10. The battery cell cover according to any one of the preceding claims, wherein the gasket ring and the insulating ring comprise an electrically insulating material. 11. The battery cell cover according to any one of the preceding claims, wherein the cover body comprises a base and an insulating layer, wherein the bottom surface of the base contacts the top surface of the insulating layer, and wherein the outer surface of the cover body includes the top surface of the base, and wherein the inner surface of the cover body includes the bottom surface of the insulating layer.12. The battery cell cover of claim 11, wherein the edge of the base defines the hole, and wherein the seal includes a portion of the insulating layer extending from the bottom surface of the base to the top surface of the base around the edge of the base. 13. The battery cell cover of claim 12, wherein the gasket is disposed in a recess in the top surface of the portion of the insulating layer extending to the top surface of the base. 14. The battery cell cover of claim 12 or 13, wherein the insulating layer is injection molded. Claims 1 / 2 Page 2 CN 121548913 A 15. The battery cell cover of any one of claims 12 to 14, wherein the edge of the base is angled relative to the plane of the base. 16. The battery cell cover of claim 15, wherein the edge of the base is angled toward the plate of the crimp connector. 17. The battery cell cover of claim 15 or 16, comprising a washer ring disposed around the periphery of the post of the crimp connector, wherein at least a portion of the washer ring is disposed between the post and the angled edge of the base. 18. The battery cell cover according to any one of claims 12 to 17, wherein the insulating layer comprises an electrically insulating material. 19. The battery cell cover according to any one of claims 12 to 18, wherein the insulating layer comprises plastic. 20. The battery cell cover according to any one of claims 12 to 19, wherein the base comprises a corrosion-resistant material. 21. The battery cell cover according to any one of the preceding claims, wherein the gasket comprises stainless steel. 22. The battery cell cover according to any one of the preceding claims, wherein the connector base and post of the crimp connector comprise a conductive material. 23. The battery cell cover according to any one of the preceding claims, wherein the connector base and post of the crimp connector comprise aluminum or copper. 24. The battery cell cover according to any one of the preceding claims, comprising a bursting disc and a vent shroud, each extending through a corresponding hole in the cover body. 25. A prismatic battery cell comprising: a housing defining an internal space; an anode and a cathode disposed within the internal space of the housing; and a battery cell cover according to any one of the preceding claims disposed on the housing, wherein electrical terminals are electrically connected to the anode or the cathode. 26. The prismatic battery cell of claim 25, wherein the electrical terminals are hermetically sealed.27. A method of sealing a battery cell cover, comprising: forming a cover stack by configuring a base adjacent to an insulating layer, each of the base and the insulating layer including aligned plurality of holes; assembling electrical terminals through the cover stack by: arranging a post of a crimp connector through a gasket and holes from the insulating layer side of the cover stack, such that the base of the crimp connector abuts the insulating layer; arranging a top insulating layer and a gasket ring onto the post extending through the holes from the base side of the cover stack; and crimping the top of the post to hermetically seal the electrical terminals in the battery cell cover. 28. A method of manufacturing a battery cell cover, comprising: configuring a pair of crimp connectors in two holes of a base including a plurality of holes; forming an insulating layer by injection molding an electrically insulating material around the base and the crimp connectors; arranging a gasket ring onto a post of the crimp connector extending through the holes; and crimping the top of the post to hermetically seal the electrical terminals in the battery cell cover. Claims 2 / 2 Page 3 CN 121548913 A Battery Cell Cover

[0001] Priority Claim

[0002] This application claims priority to U.S. Patent Application No. 63 / 505,903, filed June 2, 2023, pursuant to Title 35, Section 119(e) of the United States Code, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure generally relates to the technical field of sealing technology for energy storage devices. Background Art

[0004] The primary power source for electric vehicles is lithium-ion batteries, and therefore, the continuous improvement of the performance of these batteries is an important goal for the industry.

[0005] Prismatic battery cells are an example of battery cells used in this field. Prismatic battery cells include a laminated stack of anode-separator-cathode (ASC) assemblies. Prismatic battery cells are rectangular battery cells enclosed in a rigid housing and have been increasingly used in the vehicle industry. The ASC assembly includes an anode tab, a cathode tab, a cell head, and an anode sealing gasket. The cell is closed by a cell cover or cap having a rectangular flat plate shape. The cell cover seals the opening of the cell housing across the upper end of the housing or alternatively along the side wall surface of the housing. Summary of the Invention

[0006] This disclosure relates to a cell cover for a prismatic cell having electrical terminals extending from the internal electrodes of the cell to the outside of the cell, while isolating the electrodes from each other and from the cell housing. The electrical terminals are assembled and mechanically crimped to hermetically seal the cover, thereby preventing leakage and thus maintaining the internal pressure of the cell.

[0007] In a first aspect, the cell cover includes a cover body; and electrical terminals extending through a hole in the cover body.The electrical terminal includes: a crimp connector comprising a connector base disposed adjacent to an inner surface of a cover and a post extending from the connector base and through a hole in the cover; a seal extending around the periphery of the post of the crimp connector, wherein an inner portion of the seal is disposed between the cover and the connector base, a central portion of the seal is disposed between the cover and the post, and an outer portion of the seal is disposed on an outer surface of the cover; and a gasket disposed around the periphery of the post and disposed on the outer portion of the seal. The post of the crimp connector has a protrusion extending circumferentially around the post, wherein the gasket is disposed between the protrusion and the outer portion of the seal.

[0008] An embodiment of the first aspect may include any combination of one or two or more of the following features.

[0009] The protrusion of the crimp connector extends around the entire periphery of the post.

[0010] The protrusion of the crimp connector contacts the gasket.

[0011] The gasket is disposed in a recess defined in the outer portion of the seal.

[0012] The seal includes: a washer ring arranged around the periphery of the post, wherein at least some of the washer rings are arranged between the connector base and the cover; and an isolation ring arranged around the periphery of the post, wherein at least some of the isolation rings are arranged on the outer surface of the cover. In some cases, the washer ring and the isolation ring contact each other in the space between the cover and the post of the crimp connector. In some cases, a gasket is arranged in a recess defined in the surface of the isolation ring. In some cases, the washer ring comprises an elastomeric material. In some cases, the washer ring comprises rubber.

[0013] The washer ring and the isolation ring comprise an electrically insulating material.

[0014] The cover includes a base and an isolation layer, wherein the bottom surface of the base contacts the top surface of the isolation layer, and wherein the outer surface of the cover includes the top surface of the base, and wherein the inner surface of the cover includes the bottom surface of the isolation layer. In some cases, the edge of the base defines an aperture, and the seal includes a portion of the insulating layer extending from the bottom surface of the base to the top surface of the base around the edge of the base. In some cases, a gasket is arranged in a recess defined in the top surface of the portion of the insulating layer extending to the top surface of the base. In some cases, the insulating layer is injection molded. In some cases, the edge of the base is angled relative to the plane of the base. In some cases, the edge of the base is angled toward the plate of the crimp connector. In some cases, the battery cell cover includes a washer ring arranged around the periphery of the post of the crimp connector, wherein at least a portion of the washer ring is arranged between the angled edge of the post and the base. In some cases, the insulating layer includes an electrically insulating material. In some cases, the insulating layer includes plastic. In some cases, the base includes a corrosion-resistant material.

[0015] The gasket includes stainless steel.

[0016] The connector base and post of the crimp connector include conductive materials.

[0017] The connector base and post of the crimp connector comprise aluminum or copper.

[0018] The battery cell cover includes a burst disc and a vent shroud, each extending through a corresponding hole in the cover body.

[0019] In a second aspect, the prismatic battery cell includes a housing defining an internal space; an anode and a cathode disposed within the internal space of the housing; and a battery cell cover according to the first aspect disposed on the housing, wherein electrical terminals are electrically connected to the anode or cathode.

[0020] In an embodiment of the second aspect, the electrical terminals are hermetically sealed.

[0021] In a third aspect that can be combined with the first or second aspect, a method of sealing a battery cell cover includes: forming a cover stack by configuring a base adjacent to an insulating layer, each of the base and the insulating layer including a plurality of aligned holes; assembling electrical terminals through the cover stack by: arranging a post of a crimp connector through a gasket and a hole from the insulating layer side of the cover stack, such that the base of the crimp connector abuts against the insulating layer; arranging a top insulating layer and a gasket ring onto a post extending through the hole from the base side of the cover stack; and pressing the top of the crimp post to hermetically seal the electrical terminals in the battery cell cover.

[0022] In a fourth aspect that can be combined with any of the first to third aspects, a method of manufacturing a battery cell cover includes: arranging a pair of crimp connectors in two holes of a base including a plurality of holes; forming an insulating layer by injection molding an electrically insulating material around the base and the crimp connectors; arranging a gasket ring onto a post extending through the hole of the crimp connector; and pressing the top of the crimp post to hermetically seal the electrical terminals in the battery cell cover.

[0023] Specific embodiments of the subject matter described in this specification can be implemented to achieve one or more of the following technical advantages.

[0024] The battery cell cover according to this disclosure effectively seals the battery, for example, helping to prevent leakage, maintain internal battery cell pressure, and prevent malfunctions such as explosions.

[0025] The battery cell cover achieves low resistivity in the crimp terminal portion, thereby minimizing cost and increasing the production capacity of the cover manufacturing.

[0026] The mechanical crimp terminals of the battery cell cover reduce manufacturing time and cost compared to other assembly methods (e.g., welding of terminals).

[0027] The mechanical crimp terminals hermetically seal the battery cell cover to prevent gas escape and to prevent environmental contamination from the electrolyte solution or generated gases stored in the battery cell specification (page 2 / 7, CN 121548913 A).

[0028] Details of one or more embodiments are set forth in the drawings and the following description. Other features and advantages will be apparent from the specification, drawings, and claims. Brief Description of the Drawings

[0029] FIG1 is a perspective view and an exploded perspective view of the battery cell cover.

[0030] Figure 2 is a side cross-sectional view of the battery cell cover and an enlarged view of the assembled external terminals.

[0031] FIG. 3A is a perspective view of the overmolded separator.

[0032] FIG. 3B is a side cross-sectional view of the battery cell cover including the overmolded separator.

[0033] FIG. 3C is an enlarged view of the external terminals of the battery cell cover of FIG. 3C.

[0034] FIG. 4A is a perspective view of the recessed base and the overmolded separator.

[0035] FIG. 4B is a side cross-sectional view of the battery cell cover including the recessed base and the overmolded separator.

[0036] FIG. 4C is an enlarged view of the external terminals of the battery cell cover of FIG. 4B.

[0037] FIG. 5A is a side cross-sectional view of the battery cell cover.

[0038] FIG. 5B is an enlarged view of the external terminals of the battery cell cover of FIG. 5A.

[0039] FIG. 6 is a flowchart of a method for sealing the battery cell cover.

[0040] FIG. 7 is a flowchart of a method for manufacturing the battery cell cover by mechanical pressing.

[0041] In the drawings, the same reference numerals denote the same elements. Detailed Description

[0042] This disclosure relates to a battery cell cover for a prismatic battery cell having electrical terminals extending from internal electrodes of the battery cell to the outside of the battery cell, while isolating the electrodes from each other and from the battery cell housing. The electrical terminals are assembled and mechanically crimped to hermetically seal the cover to prevent leakage.

[0043] According to one embodiment, this disclosure provides a battery cell cover comprising a base fitted on an insulating layer having a hole through which a pair of external terminals extend. Specifically, a post of each external terminal extends through a corresponding hole in the base and the insulating layer, and a gasket, a top insulating layer, and a gasket ring are fitted around the post to hermetically seal the post in its hole. Additionally, the top of the post is crimped to further provide stability to the seal. The terminals are made of a conductive material with low resistivity (e.g., less than 10 μΩ / cm). A gasket ring is sandwiched between a top insulating ring and a bottom insulating layer to form a hermetically sealed seal (e.g., an airtight seal) to prevent liquid or gas from leaking from the inside of the battery cell. In some examples, the electrical cover includes a pair of conductive plates that contact the bottom of a pair of external terminals to extend the electrical contact area between the terminals of the cover and the electrode stack within the battery cell. The battery cell cover also includes a bursting disc for preventing gas buildup and subsequent explosion, and a vent shroud for protecting the bursting disc from corrosion and premature venting.

[0044] In another embodiment, the present disclosure provides the battery cell cover described above, wherein the bottom insulating layer is injection-molded through two holes in the base. A post is then placed through the stack, and a cleaning ring is pressed onto the post, thereby clamping the overmolded portion of the insulating layer relative to the post. The overmolded portion is configured to replace the top insulating ring and gasket.

[0045] In another embodiment, the present disclosure provides the battery cell cover described above, and two holes in the base through which the post extends, characterized by having recessed portions and an injection-molded insulating layer.The recessed portion increases the sealing strength of the electrical terminals passing through the cover stack.

[0046] Referring to FIG1, an assembled perspective view (left) of the battery cell cover 100 for a prismatic battery cell and an exploded perspective view (right) on page 3 / 7 of the specification, CN 121548913 A, are depicted. The battery cell cover 100 includes a base 5 fitted over a bottom insulating layer 6. The base 5 and the insulating layer 6 form a cover body that seals the battery cell on which the cover 100 is mounted. When the cover is on the battery cell, the insulating layer 6 faces the interior of the battery cell, and the base 5 faces the exterior.

[0047] The base 5 and the insulating layer 6 each have a plurality of holes of different diameters (e.g., four holes in the example of FIG1), which are aligned (e.g., aligned). The holes receive components to maintain the relative positioning of the components mounted in the base 5 and the insulating layer 6. The outermost holes of the base 5 and the insulating layer 6 in FIG1 are sized to receive corresponding posts of a pair of external electrical terminals 110. Each terminal 110 includes a crimp connector 4 having a post 101 extending from a connector base 102. Terminals 110 form positive and negative connection terminals, respectively connected to a cathode layer and an anode layer contained in a battery cell, on which a cover 100 is mounted.

[0048] The crimp connector 4 of FIG. 1 is shown in a “crimped” form, for example, where the post 101 is crimped after a crimping process. This crimping configuration hermetically seals the terminal, for example, such that the battery cell cover 100 provides a hermetically and liquidally tight seal for the battery cell. Typically, the post 101 of the crimp connector 4 is cylindrical with smooth sidewalls before the final assembly of the cover 100. The smooth sidewalls facilitate mounting the post 101 through corresponding holes in the external terminal 110 prior to mechanical crimping to hermetically seal the terminal 110 relative to airflow.

[0049] To assemble the cover 100, a sealing assembly including a gasket ring 3, a spacer ring 2, and a gasket 1 is fitted onto each post 101. For example, a washer ring 3 is arranged on a corresponding post 101, and the post 101 extends through a corresponding hole, thereby compressing the washer ring 3 between the base 5 and the connector base 102. A spacer ring 2 and a gasket ring 1 are fitted to the portion of each post 101 extending from the base 5. The washer ring 3 is sandwiched between the spacer ring 2, the cover base 5, and the connector base 102. After assembly, the posts 101 of the crimp connector 4 are mechanically crimped, which forces the gasket ring 1 of each crimp connector 4 toward the corresponding spacer ring 2, pressing the spacer ring 2 against the top surface of the cover base 5, pressing the gasket ring 3 against the cover base 5 and the connector base 102, and hermetically sealing the external terminal 110.

[0050] The battery cell cover 100 includes a bursting disc 9 for preventing explosion and a vent 8 made of, for example, a transparent plastic sheet to protect the bursting disc 9 from corrosion and premature venting. The disc 9 is press-fitted into the corresponding hole in the base 5 and configured to withstand the gas pressure inside the prismatic battery cell.

[0051] Plates 7 are disposed below the base 102 of each crimp connector 4. These plates extend the electrical connection area between the terminal 110 and the electrode stack in the prismatic battery cell on which the cover 100 is mounted.

[0052] The crimp connectors 4 and plates 7 are made of conductive and durable materials such as aluminum, copper, stainless steel, or alloys thereof to provide electrical connection with the anode and cathode materials in the prismatic battery cell on which the cover 100 is mounted. In some examples, the anode terminal and the cathode terminal are made of different materials; for example, the anode terminal 110 is copper and the cathode 110 is aluminum. The base 5 is made of a durable and rigid material that resists corrosion from gases and liquids contained within the prismatic battery cell. The insulating layer 6 is made of an electrically insulating, substantially rigid material, such as plastic, which serves to electrically isolate the base 5 from the external terminal 110. Examples of materials for constructing the insulating layer 6 include, but are not limited to, polyetheretherketone (PEEK), phenolic resin, polyethylene, or polycarbonate.

[0053] Referring to FIG2, a cross-sectional view of the battery cell cover 100 and an enlarged view of the terminal 110 according to view A are depicted. The terminal 110 is shown extending through the base 5 and the insulating layer 6, such that the connector base 102 and the plate 7 are disposed on the side of the cover 100 having the insulating layer 6, while the post 101 of the crimp connector 4 extends through the insulating layer 6 and the base 5 and protrudes beyond the base 5 on the opposite side of the cover.

[0054] The enlarged view depicts the configuration details of the left terminal 110 in the cross-sectional view, but both terminals 110 use the same components and are assembled in the same manner. As can be seen in the enlarged view of the terminal 110, the post 101 includes a crimp portion 103, which is a protrusion extending around the entire periphery of the post 101 and has a diameter larger than the diameter of the rest of the post 101. For example, the diameter of the crimped portion 103 is 1% to 25% larger than the diameter of the uncrimped portion of the post 101. The crimped portion 103 presses and maintains pressure on a ring surrounding the post 101, the ring comprising a gasket ring 1, a spacer ring 2, and a washer ring 3.

[0055] Before crimping, the post 101 is cylindrical, for example, comprising smooth sidewalls, and does not include the crimped portion 103, which facilitates the arrangement of the gasket ring 1, the spacer ring 2, and the washer ring 3 on the post 101. After the ring is assembled, the top of the post 101 is crimped to create the crimped portion 103 surrounding the periphery of the post 101. The formation of the crimped portion 103 forces the gasket ring 1 into a notch defined in the top portion of the spacer ring 2, thereby enabling the crimped portion 103 to maintain pressure on the rings 1-3, which creates an airtight seal between the battery cell side and the top side of the cover 100. To resist buckling and deformation during crimping of the post 101 and to help maintain the crimped construction of the post 101, the gasket ring 1 is made of a durable, hard material (such as stainless steel).

[0056] As shown in the enlarged view, the washer ring 3 is shaped to mate with a hole in the isolation layer 6 and extends at least partially into a smaller diameter hole in the base 5. In other words, the outer diameter of the washer ring 3 is designed to be received by the hole in the isolation layer 6, while being larger than the diameter of the corresponding aligned hole in the base 5. This dimensionality ensures that the outer edge of each washer ring 3 contacts the inner surface of the corresponding hole in the isolation layer 6 and the underside of the base 5, for example, one side of the base 5 that contacts the isolation layer 6. The inner diameter of the washer ring 3 is designed to allow the post 101 to pass through. The washer ring 3 is made of a flexible material (e.g., an elastomer such as rubber) that is compressible to provide an hermetically tight seal between the post 101 and the base 5 and the isolation layer 5.

[0057] The outer diameter of the top isolation ring 2 is larger than the diameter of the corresponding hole in the base 5, and at its inner diameter, the isolation ring 2 extends at least partially into the hole in the base 5. This configuration causes the top insulating ring 2 to contact the upper surface of the base 5 (e.g., the surface opposite to the insulating layer 6) and the post 101, such that when the pressing portion 103 applies pressure to the gasket ring 1, the insulating ring 2 and the gasket ring 3 abut against the insulating layer 6, the base 5, and the post 101 to create a fluid-tight (e.g., hermetically or liquidally tight) seal. The top insulating ring 2 is made of the same material as the insulating layer 6.

[0058] Referring to Figures 3A-3C, in one embodiment, the battery cell cover 300 has an insulating layer 306 that is injection-molded onto the base 5, such that the overmolded portion 307 of the insulating layer 306 extends from the bottom surface of the base 5 around the edge of a defined hole in the base 5 and extends to the top surface of the base 5. The overmolded portion replaces the gasket ring 3 and the insulating ring 2 of the cover 100 of Figures 1-2, and can reduce the number of assembly steps when assembling the cover. The overmolded portion 307 defines a central hole through which the post 101 of the corresponding crimp connector 4 extends. In some examples, the region through which the overmolded portion 307 extends through the base 5 has a shape substantially similar to the top insulating ring 2 of FIG. 1.

[0059] Referring specifically to FIG. 3B, a side cross-sectional view of a battery cell cover 300 having an overmolded insulating layer 306 is depicted. An enlarged view of a terminal 310 is depicted in FIG. 3C.

[0060] The external terminal 310 of the cover 300 includes a gasket ring 1 and a crimp connector 4 having a post 101, a base 102, and a crimp portion 103, for example, as discussed above with respect to FIG. 1-2. The gasket ring 1 is fitted to the portion of each post 101 extending from the base 5. After assembly, the post 101 is mechanically pressed, thereby pressing the gasket ring 1 into a notch in the top surface of the overmolded portion 307 and pressing the overmolded portion 307 against the connector base 102, thereby hermetically sealing the external terminals. The battery cell cover 300 may include a vent 8 and a disc 9 of the cover 100, but these components are not shown.

[0061] Referring to Figures 4A-4C, in one embodiment, the battery cell cover 400 has a base 405, which includes a recessed edge 408 defining a hole for receiving a crimp connector 404. The recessed edge 408 is angled downward relative to the plate of the base 405 (e.g., toward the connector base 402). The recessed edge 408 extends around the entire periphery of the hole through the base 405. Furthermore, an insulating layer 406 is injection-molded around the base 405, and an overmolded portion 407 of the insulating layer 406 extends from the bottom surface of the base 405 around the recessed edge 408 of the base 405 to the top surface of the base.

[0062] Figure 4B shows a side cross-sectional view of the battery cell cover 400, and Figure 4C shows an enlarged view of a terminal 410. The external terminals 410 of the cover 400, as described on page 5 / 7 of the specification (CN 121548913 A), include a gasket ring 1 and a crimp connector 404 having posts 401, a base 402, and a crimp portion 403, as discussed above with reference to Figures 1-2. A recessed edge 408 of the base 405 is disposed in an overmolded portion 407 of the insulating layer 406. The gasket ring 1 is fitted to a portion of each post 401 extending from the base 405. After assembly, the posts 401 are mechanically crimped, pressing the gasket ring 1 into a notch in the top surface of the overmolded portion 407 and pressing the overmolded portion 407 against the connector base 402, thereby hermetically sealing the external terminals. The battery cell cover 400 may include a vent 8 and a disc 9 of the cover 100, but these components are not shown.

[0063] The base 402 of each crimp connector 404 includes a recess 411 having a shape corresponding to the shape of the overmolded portion 407 of the insulating layer 406 and facilitating the retention of the overmolded portion 407 of the insulating layer 406 against the base 402 and post 401 of the crimp connector 404. The battery cell cover 400, including the combination of the recessed edge 408 and the recess 411, provides an hermetically sealed external terminal 410 within the battery cell cover 400.

[0064] In one embodiment, the battery cell cover has a base including a recessed edge defining an orifice for receiving a crimp connector and an associated insulating washer ring shaped as the recessed orifice. Referring to FIG. 5A, the battery cell cover 500 has a base 505, such as base 405, including a recessed edge 508. The recessed edge 508 is angled downward (e.g., toward the connector base 502) and extends through the base 505 around the entire periphery of the orifice of the terminal 510. The external electrical terminal 510 is formed using an isolation ring 507 and a washer ring 512 shaped to conform to the edge 508.

[0065] FIG5B shows an enlarged side cross-sectional view of one of the electrical terminals 510 of FIG5A.The external terminals 510 of the cover 500 include a gasket ring 1 and a crimp connector 504, the crimp connector 504 having a post 501, a base 502, and a crimp portion 503, for example, as discussed above with reference to Figures 1-2. A recessed edge 508 of the base 505 is disposed between an isolation ring 507 and a washer ring 512. The gasket ring 1 is fitted to the portion of each post 501 extending from the base 505. After assembly, the posts 501 are mechanically crimped, thereby pressing the gasket ring 1 into a notch in the top surface of the isolation ring 507, and the washer ring 512 abuts against the connector base 502, thereby hermetically sealing the external terminals. The battery cell cover 500 may include a vent 8 and a disc 9 of the cover 100, but these components are not shown.

[0066] The base 502 of each crimp connector 504 includes a recess 511 having a shape corresponding to the shape of the overmolded portion 507 of the insulating layer 506, and the recess 511 helps to hold the overmolded portion 507 of the insulating layer 506 against the base 502 and the post 501 of the crimp connector 504. The battery cell cover 500, which includes a combination of a recessed edge 508, an insulating ring 507, a washer ring 512, and a recess 511, provides an hermetically sealed external terminal 510 in the battery cell cover 500.

[0067] A method for sealing a battery cell cover by mechanically crimping the post of a crimp connector to form a hermetically sealed external terminal is disclosed herein. A flowchart illustrating the steps of this method 600 is shown in FIG. 6. Method 600 includes forming a cover stack by configuring the base adjacent to the insulating layer, each of the base and the insulating layer including a plurality of aligned holes (step 602).

[0068] The method includes assembling electrical terminals through the cover stack (step 604). Step 604 includes the following sub-steps:

[0069] Step 604 includes arranging a post of a crimp connector through a hole in the cover gasket, as well as in the insulating layer and the base (step 606). The base of the crimp connector abuts against the insulating layer and gasket when the bottom insulating layer is placed. The post extends through the gasket ring and the base.

[0070] Step 604 includes arranging a top insulating ring and a gasket ring from the base side of the cover stack onto the post extending through the hole (step 608). The top insulating ring is positioned to contact the gasket ring and the gasket ring positioned on the top insulating ring.

[0071] Step 604 includes crimping the top of the post, thereby hermetically sealing the electrical terminals in the battery cell cover (step 610).

[0072] This document discloses a method for manufacturing a battery cell cover by injecting a molded electrical insulating material around a base and a crimp connector and mechanically crimping the posts of the crimp connector to form a hermetically sealed external terminal. Figure 7 shows a flowchart of the steps of this method 700, as shown on pages 6 / 7 of the specification, CN 121548913 A.

[0073] The method includes configuring a pair of crimp connectors within two holes in the base (step 702).The crimp connector is configured to extend through the hole a distance sufficient to allow a gasket ring to be mounted on top of the post after an injection overmolding process. In some examples, this process includes closing the base and crimp connector in an injection mold that defines a cavity shaped similar to the isolation layer to be formed. The cavity defines an overmolded portion of the isolation layer extending through the hole in the base.

[0074] The method includes forming an isolation layer by injection molding an electrically insulating material around the base and the crimp connector (step 704). For example, those electrically insulating materials described herein are injection molded into the cavity between the base and the crimp connector. The injection-molded material is allowed to cure, and if so, the mold is removed. The resulting isolation layer includes an overmolded portion surrounding a portion of a circumferential section of the post and extends through the hole in the base.

[0075] The method includes disposing a gasket ring onto the post of the crimp connector extending through the hole (step 706). The gasket ring is disposed on the post, contacting the overmolded portion of the bottom isolation layer extending through the hole.

[0076] The method includes crimping the top of the post to hermetically seal the electrical terminals in the battery cell cover (step 708).

[0077] While this specification contains numerous details, these should not be construed as limiting the scope of the claims, but rather as descriptions of features specific to particular examples. Certain features described in this specification in the context of individual embodiments may also be combined. On the other hand, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments.

[0078] Many embodiments have been described. However, it should be understood that various modifications may be made without departing from the spirit and scope of this disclosure. Therefore, other embodiments are within the scope of the appended claims.Instruction manual page 7 / 7, page 10, CN 121548913 A, Figure 1; Instruction manual figure 1 / 12, page 11, CN 121548913 A, Figure 2; Instruction manual figure 2 / 12, page 12, CN 121548913 A, Figure 3A; Instruction manual figure 3 / 12, page 13, CN 121548913 A, Figure 3B; Instruction manual figure 4 / 12, page 14, CN 121548913 A, Figure 3C; Instruction manual figure 5 / 12, page 15, CN 121548913 A, Figure 4A; Instruction manual figure 6 / 12, page 16, CN 121548913 A, Figure 4B; Instruction manual figure 7 / 12, page 17, CN 121548913 A, Figure 4C; Instruction manual figure 8 / 12, page 18, CN 121548913 A, Figure 5A; Instruction manual figure 9 / 12, page 19, CN 121548913 A, Figure 5B. Figure 6 of the instruction manual, page 10 / 12, CN 121548913 A; Figure 7 of the instruction manual, page 11 / 12, CN 121548913 A; Figure 8 of the instruction manual, page 12 / 12, CN 121548913 A.

Claims

1. A battery cell cover comprising: a cover body; an electrical terminal extending through an aperture in the cover body, the electrical terminal comprising: a crimp connector comprising a connector base disposed proximate an inner surface of the cover body and a post extending from the connector base and through the aperture in the cover body; a seal extending around a perimeter of the post of the crimp connector, wherein an inner portion of the seal is disposed between the cover body and the connector base, a central portion of the seal is disposed between the cover body and the post, and an outer portion of the seal is disposed on an outer surface of the cover body; and a gasket disposed around a perimeter of the post and on the outer portion of the seal, wherein the post of the crimp connector has a protrusion extending circumferentially around the post, wherein the gasket is disposed between the protrusion and the outer portion of the seal.

2. The battery cell cover of claim 1, wherein the protrusion of the crimp connector extends around an entire perimeter of the post.

3. The battery cell cover of claim 1 or 2, wherein the protrusion of the crimp connector contacts the gasket.

4. The battery cell cover of any one of the preceding claims, wherein the gasket is disposed in a notch defined in the outer portion of the seal.

5. The battery cell cover of any one of the preceding claims, wherein the seal comprises: a grommet ring disposed around a perimeter of the post, wherein at least some of the grommet ring is disposed between the connector base and the cover body; and a spacer ring disposed around a perimeter of the post, wherein at least some of the spacer ring is disposed on the outer surface of the cover body.

6. The battery cell cover of claim 5, wherein the grommet ring and the spacer ring contact in a space between the cover body and the post of the crimp connector.

7. The battery cell of claim 5 or 6, wherein the gasket is disposed in a notch defined in a surface of the spacer ring.

8. The battery cell of any one of claims 5 to 7, wherein the grommet ring comprises an elastomeric material.

9. The battery cell of any one of claims 5 to 8, wherein the grommet ring comprises rubber.

10. The battery cell cover of any one of the preceding claims, wherein the grommet ring and the spacer ring comprise an electrically isolating material.

11. The battery cell cover of any one of the preceding claims, wherein the cover body comprises a base and an isolation layer, wherein a bottom surface of the base contacts a top surface of the isolation layer, and wherein the outer surface of the cover body comprises a top surface of the base, and wherein the inner surface of the cover body comprises a bottom surface of the isolation layer.

12. The battery cell cover of claim 11, wherein an edge of the base defines the aperture, and wherein the seal comprises a portion of the isolation layer extending around the edge of the base from the bottom surface of the base to the top surface of the base. ​ 13. The battery cell cover of claim 12, wherein the gasket is disposed in a notch defined in a top surface of the portion of the isolation layer that extends to the top surface of the base.

14. The battery cell cover of claim 12 or 13, wherein the isolation layer is injection molded.

15. The battery cell cover of any of claims 12-14, wherein the edge of the base is angled relative to a plane of the base.

16. The battery cell cover of claim 15, wherein, The edge of the base is angled toward a plate of the crimp connector.

17. The battery cell cover of claim 15 or 16, comprising a grommet ring disposed around a perimeter of the post of the crimp connector, wherein at least a portion of the grommet ring is disposed between the post and the angled edge of the base.

18. The battery cell cover of any of claims 12-17, wherein the isolation layer comprises an electrically isolating material.

19. The battery cell cover of any of claims 12-18, wherein the isolation layer comprises a plastic.

20. The battery cell cover of any of claims 12-19, wherein the base comprises a corrosion resistant material.

21. The battery cell cover of any of the preceding claims, wherein the gasket comprises stainless steel.

22. The battery cell cover of any of the preceding claims, wherein the connector base and post of the crimp connector comprise an electrically conductive material.

23. The battery cell cover of any of the preceding claims, wherein the connector base and post of the crimp connector comprise aluminum or copper.

24. The battery cell cover of any of the preceding claims, comprising a burst disc and a vent cover each extending through a corresponding hole in the cover body.

25. A prismatic battery cell, comprising: a housing defining an interior space; an anode and a cathode disposed in the interior space of the housing; and the battery cell cover of any of the preceding claims disposed on the housing, wherein the electrical terminal is electrically connected to the anode or the cathode.

26. The prismatic battery cell of claim 25, wherein the electrical terminal is hermetically sealed.

27. A method of sealing a battery cell cover, comprising: forming a cover stack by configuring a base adjacent to an isolation layer, each of the base and the isolation layer comprising a plurality of holes aligned; assembling an electrical terminal through the cover stack by: from an isolation layer side of the cover stack, disposing a post of a crimp connector through a grommet and a hole such that a base of the crimp connector abuts the isolation layer; from a base side of the cover stack, disposing a top isolation layer and a gasket ring onto the post extending through the hole; and crimping a top of the post, thereby hermetically sealing the electrical terminal in the battery cell cover.

28. A method of manufacturing a battery cell cover, comprising: configuring a pair of crimp connectors within two holes of a base comprising a plurality of holes; forming an isolation layer by injection molding an electrically isolating material around the base and the crimp connectors; ​ ​ arranging a grommet ring on a post of the crimp connector extending through the hole; and crimping a top of the post, thereby hermetically sealing the electrical terminal in the battery cell cover.

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