SYSTEM AND METHOD FOR SUPPORTING AND MOVING BATTERY CELLS INTO THE BUILDING CHAMBER USING A GAS-REMOVING MASK

Abstract

The invention relates to a system and method for supporting and moving battery cells into a forming chamber using a degassing mask. The system comprises a tray (1) for supporting and moving multiple battery cells (2) into a forming chamber equipped with a degassing mask (23) configured to be mounted on the support structure (3) of the tray (1) in a predetermined position relative to that support structure (3). The degassing mask (23) comprises an air duct (24) which can be connected to a vacuum source and several suction nozzles (29) that act as plugs for the air vents (2B) of the battery cells (2) while moving the degassing mask (23) up the forming chamber. During the formation of the battery cells (2) inside the aforementioned forming chamber, the vent holes (2B) of the battery cells (2) are connected to a vacuum source, using the air duct (24) of the degassing mask (23), to vacuum out the gases generated inside the battery cells (2) during the formation process.

Description

[0001] SYSTEM AND METHOD FOR SUPPORTING AND MOVING ELECTRIC BATTERY CELLS UP TO A FORMING CHAMBER, WITH USE OF A DEGASSING MASK

[0002] TEXT OF THE DESCRIPTION

[0003] 5

[0004] Field of the Invention

[0005] The present invention regards a system for supporting and moving a plurality of electrical battery cells, usable for moving the battery cells into a formation chamber for battery cells and for supporting them during a 10 formation process inside said formation chamber.

[0006] Specifically, the invention refers to a system as mentioned in the foregoing, comprising a tray for supporting the cells including a support structure configured to hold a plurality of battery cells in predetermined positions with respect to the support structure.

[0007] 15 It is necessary to point out that the present invention is generally applicable to any kind of support tray, and more specifically to any type of support structure which may be provided for the tray, provided that it enables receiving and holding a plurality of battery cells in strictly predetermined positions with respect to the support structure.

[0008] 20

[0009] Known Art

[0010] A tray of the type mentioned in the foregoing is for example known from document CN 114843634A.

[0011] In the production of battery cells for electrical batteries, particularly 25 electrical batteries for vehicles with electrical powertrain or hybrid vehicles, it is necessary to subject the cells to a “formation” process, thereby meaning a process wherein the cells are “trained” by being repeatedly subjected to loading and unloading cycles. The formation process is performed within formation chambers which are kept at a controlled temperature, generally 30 in the range between 20°C and 60°C. The formation process of the cells consists in electrically contacting the two terminals of each battery cell with an electronic power unit, which subjects the cells to a repeated series of loading-unloading cycles. The formation process not only enables testing the manufactured cells, but is also useful to provide the cells with the 35 necessary performances and a suitable duration of their useful life. The battery cells are placed into the formation chamber after being arranged on one or more support trays which are received within the formation chamber, wherein the terminals of each cell contact corresponding terminals connected to the electronic power unit.

[0012] The support trays comprise a support structure wherein there are defined seats adapted to receive the cells to be formed.

[0013] The repeated loading and unloading cycles trigger, within the battery cells, chemical reactions which lead to the formation of flammable gases, i.a. of hydrogen.

[0014] For this reason, the known formation chambers are provided with a suction system for the gases produced during the formation step. Such systems generally require the presence of a suction port for each battery cell to be formed, which port is adapted to communicate with a degassing opening provided in the cell casing; this significantly complicates the general layout of the formation chamber. Said known solutions are therefore relatively complex and costly, and they require long times to implement the necessary connections of the battery cells with the suction system, which of course jeopardizes productivity.

[0015] Object of the Invention

[0016] Therefore, the invention aims at providing a system for supporting and moving a plurality of electrical battery cells, usable for moving the battery cells into a formation chamber for battery cells and for supporting them during a formation process inside said formation chamber, which enables performing the suction of the gases which develop in the battery cells during the formation process in a simple and reliable fashion.

[0017] A further object consists in providing a system as mentioned in the foregoing which may be implemented with simple and rapid operations.

[0018] Another object of the inventions consists in providing a system of the type mentioned in the foregoing which is adapted to be easily automated.

[0019] A further object consists in providing a system as mentioned in the foregoing which is also adapted to ensure a hermetical sealing of the holes provided in the battery cells for vacuuming the gases out of the cells, as long as the support tray, with the cells thereon, is outside the formation chamber, before being moved into the formation chamber. Summary of the Invention

[0020] In order to achieve one or more of the objects outlined in the foregoing, the object of the invention is a system for supporting and moving a plurality of electrical battery cells, usable for moving the battery cells into a formation chamber for battery cells and for supporting them during a formation process inside said formation chamber, said system comprising a support tray for the battery cells including a support structure configured to hold a plurality of battery cells in predetermined positions with respect to the support structure, and being characterized in that

[0021] - a degassing mask is associated with the tray and is configured to be mounted on the support structure of the tray in a predetermined position with respect to said support structure,

[0022] - said degassing mask comprises:

[0023] - a gas manifold,

[0024] - a plurality of suction nozzles communicating with said gas manifold, and configured to be positioned at respective degassing holes of the battery cells when the degassing mask is mounted on the support structure of the tray, and

[0025] - at least one discharge port, for putting the gas manifold into fluid communication with a vacuum source, said suction nozzles being configured to:

[0026] - keep said degassing holes of the battery cells isolated from the outer environment whilst moving the battery cells up to the formation chamber by means of said support tray, and

[0027] - by means of said gas manifold of the degassing mask, put the degassing holes of the battery cells into fluid communication with a vacuum source during the formation process of the battery cells within said formation chamber.

[0028] In an embodiment, the degassing mask has a frame including a plurality of hollow beams connected to each other, defining said gas manifold and carrying said suction nozzles, said at least one discharge port being associated to one of said beams of the frame of the degassing mask.

[0029] In an example, the frame of the degassing mask and the support structure of the tray comprise mutual engagement elements, configured to refer to a determined position the degassing mask on the tray.

[0030] In the preferred embodiment, each suction nozzle is provided in the form of a suction cup, having a hollow body of elastomeric material configured to sealably engage a portion of an upper wall of a respective battery cell received on said tray, around a respective degassing hole.

[0031] In an example, said at least one discharge port of the degassing mask is associated with a connection member engageable on said at least one discharge port, in order to put said at least one discharge port into fluid communication with a vacuum source. Moreover, said at least one discharge port comprises a normally closed valve, configured to open when the connection member engages said at least one discharge port. The degassing mask and said connection member have mutual engagement elements, for referring in position said connection member with respect to said at least one discharge port of the degassing mask.

[0032] Another object of the invention consists in a method for supporting and moving a plurality of battery cells of an electrical battery with the use of the system described in the foregoing.

[0033] Detailed Description of a Preferred Embodiment

[0034] Further features and advantages of the invention will become apparent from the description set forth in the following with reference to the annexed drawings, which are provided by way of non-limiting example only, and wherein:

[0035] - Figure 1 is a perspective view of a support tray to which, by way of example only, the present invention may by applied;

[0036] - Figure 2 is a top view of the support tray of Figure 1 ,

[0037] - Figure 3 is a cross-sectional view along line Ill-Ill of Figure 2,

[0038] - Figure 3A is a view of the detail denoted by arrow III in Figure 3,

[0039] - Figure 4 is a front view of the support tray of Figure 1 ,

[0040] - Figure 5 is a cross-sectional view along line V-V of Figure 4,

[0041] - Figure 6 is a view of the detail denoted by arrow VI in Figure 5,

[0042] - Figure 7 is a perspective view of a structural element of the support tray,

[0043] - Figure 8 is a perspective view of a functional element of the support tray, - Figures 9A, 9B, 9C are orthogonal views of the element of Figure

[0044] 8,

[0045] - Figures 10 and 11 are perspective views of further functional elements of the support tray,

[0046] - Figure 12 is a top view of the support tray, in a condition filled with a plurality of battery cells,

[0047] - Figure 13 is a perspective view of a distancing tool operable on the support tray,

[0048] - Figure 14 is a perspective view of a degassing mask which is a part of an embodiment of the system according to the invention,

[0049] - Figure 15 is a perspective view of said embodiment of the system according to the invention, in the condition wherein the degassing mask is mounted on the tray carrying the battery cells,

[0050] - Figure 16 is a perspective view, on an enlarged scale, of a detail of a suction cup carried by the degassing mask, in a condition of engagement on a respective battery cell,

[0051] - Figures 17, 18 are perspective views on an enlarged scale of further details of the degassing mask, and

[0052] - Figure 19 is a front cross-sectional view of a connection member associated with the degassing mask, for the connection of the degassing mask with a vacuum source.

[0053] As mentioned in the foregoing, the present invention is generally applicable to any type of support tray, and more specifically to any type of support structure which may be provided for the tray, provided that it enables receiving and holding a plurality of battery cells in strictly predetermined positions with respect to the support structure. By way of non-limiting example only, in the following there will be described a specific structure and configuration of a tray which is the object of a co-pending patent application of the same Applicant. For example, the invention is equally applicable to a further kind of tray, which again is the object of a further co-pending patent application of the same Applicant. Moreover, the possibility is not excluded to apply the present invention to a tray of any known type, provided that it is configured in such a way as to enable the battery cells carried by the tray to be each arranged in a determined position with respect to the structure of the tray. Such condition is essential for ensuring that, in the operative condition of the degassing mask, which is part of the system according to the invention, above the support structure of the tray, the suction nozzles carried by the degassing mask are located at the degassing holes of the battery cells.

[0054] Referring to Figures 1 -13, reference 1 generally denotes a support tray for the formation of cells 2 of an electrical battery.

[0055] The phrase “formation of battery cells” as used herein denotes a step of the manufacturing process of electrical batteries, for example as used in the automotive field, which consists in performing a repeated sequence of loading and unloading cycles on the battery cells, before they are assembled to compose the electrical battery. The formation step of the cells is essential in the production of electrical batteries, since it enables testing each cell and improving the useful life and the performance thereof.

[0056] Generally speaking, the step of cell formation is performed inside formation chambers, which are provided with at least one electronic power unit and a plurality of electrical terminals. In the formation chamber, the terminals of the battery cells contact the electrical terminals of the electronic power unit, in order to enable performing said loading and unloading cycles.

[0057] The battery cells to be tested are arranged into seats provided within support trays, which are configured to hold the cells during the formation step within the formation chamber.

[0058] The support tray 1 according to the present invention comprises a support structure 3, including a first main wall 4A and a second main wall 4B parallel and spaced apart from each other, which extend along a first direction A of the support tray 1 (see Figure 1 ).

[0059] The support structure 3 moreover comprises two end walls 5, which firmly connect the two main walls 4A, 4B.

[0060] In more detail, the end walls 5 extend along a second direction B, orthogonal to the first direction A, from a first end 5A attached to the first main wall 4A to a second end 5B attached to the second main wall 4B.

[0061] The support structure 3 moreover comprises one or more septa 6 (Figures 6 and 7) extending parallel to the end walls 5 along the second direction B, which divide the space defined between the two main walls 4A, 4B and by the two end walls 5 into a plurality of sectors 7 side by side with each other. The septa 6 firmly connect the two main walls 4A, 4B and extend from a first end 6A attached to the first main wall 4A to a second end 6B attached to the second main wall 4B.

[0062] The firm connection of the end walls 5 and of the septa 6 to the two main walls 4A, 4B may be implemented by any known technique, e.g. by means of a threaded connection or by welding.

[0063] Each sector 7 is configured to receive an array 200 (Figure 12) of battery cells 2 (Figure 6), wherein each array 200 of battery cells 2 comprises a plurality of cells 2 parallel to the main walls 4A, 4B and side by side with each other along the second direction B.

[0064] The support tray 1 moreover comprises a plurality of partitions 8, arranged within each sector 7 and extending parallel to the main walls 4A, 4B.

[0065] The set of the partitions 8 included within the same sector 7 defines a plurality of seats 9 side by side with each other, configured to receive respective battery cells 2.

[0066] In a preferred embodiment shown in Figure 7, the cross section of each septum 6 has a profile substantially shaped as an “upside-down T”, comprising a vertical wall 61 , which defines side surfaces 62 parallel to each other and facing respective sectors 7 along the second direction B of the tray 1 .

[0067] Each septum 6 moreover comprises a horizontal base 63, protruding along the first direction A beyond the side surfaces 62 of the vertical wall 61 , so as to define, in each of the two sectors 7 separated by the septum 6, a respective horizontal surface 64.

[0068] Correspondingly, each side wall 5 comprises a horizontal portion 51 protruding along the first direction A towards a respective sector 7, so as to define a horizontal surface 52 (Figure 3), and a vertical portion 53 defining a side surface 54 parallel to the side surfaces 62 of the septa 6 and facing a respective sector 7 of the tray 1 .

[0069] Referring to the Figures 7 to 11 , the partitions 8 in each sector 7 are slidably supported by the support structure 3 along the second direction B.

[0070] Specifically, in the case of the sectors 7 delimited by one of the side walls 5, each partition is supported on the horizontal surface 52 of the side wall 5 of the horizontal surface 64 of the respective septum 6, and it is laterally restrained by the side surface 54 of the side wall 5 and by the side surface 62 of the respective septum 6.

[0071] Correspondingly, in the case of sectors 7 delimited by two septa 6, each partition 8 is supported on the horizontal surfaces 64 of the two respective septa 6, and it is laterally restrained by the side surfaces 62 of the respective two septa 6.

[0072] In a preferred embodiment according to the present invention, each partition 8 comprises a main support element 80 (Figure 8) and an adaptor element 100 (Figure 10) removably connected to the main support element 80.

[0073] Referring to the Figures 8 to 9C, the main support element 80 of each partition 8 comprises a base 81 defining two support seats 81 A arranged at the opposite ends of the main element 80 along the first direction A, and configured to act as a slidable support base for the partition 8 on the horizontal surfaces 52 of the side walls 5 and / or on the horizontal surfaces 64 of the septa 6 of the respective sector 7.

[0074] Moreover, the main support element 80 of each partition 8 comprises two side formations 82 arranged at the opposite ends of the main element 80 along the first direction A, each defining at least one surface 82A configured to interface with the side surfaces 62 of the septa 6 and / or with the side surfaces 54 of the side walls 5, in such a way as to be supported along the first direction A.

[0075] The side formations 82 of the main support elements 80 moreover define surfaces 82B parallel to the main walls 4A, 4B and facing outwards with respect to the corresponding seat 9. The surfaces 82B of a main element 80 are configured to be abutment points of the partition with the same number of surfaces 82B of an adjacent partition 8.

[0076] Each main support element 80 moreover defines an internal face 83 facing towards a respective seat 9 of the sector 7, and an external face 84 facing towards the external face 84 of a main support element 80 of an adjacent partition 8.

[0077] The internal face 83 of the main support element comprises a seat 85, which defines two side surfaces 85Y extending parallel to the side walls 5, a horizontal surface 85X extending transversally to the side surfaces 85Y and a front surface 85Z extending parallel to the main walls 4A, 4B, and which is configured to receive a respective adaptor element 100 of the partition 80.

[0078] Referring to Figures 10 and 11 , each adaptor element 100 comprises a substantially flat external face 101 , an internal face 102 configured to receive a respective battery cell 2, a base 103 and, preferably, two fastening portions 104 arranged at the opposite ends of the adaptor element 100 along the first direction A.

[0079] Specifically, the adaptor element 100 is configured to be removably mounted on the respective main support element 80, in such a way that the adaptor element 100 simply rests with its base 103 on the surface 85X and is laterally restrained along the first direction A by the side surfaces 85Y of the main support element 80. In such a mounting arrangement, the external face 101 of the adaptor element directly faces the front surface 85Z of the respective main support element 80.

[0080] Preferably, the fastening portions 104 of the support element 100 engage respective seats 87 provided on respective side formations 82 of the corresponding main support element 80, in such a way as to prevent the translational movement of the adaptor element 100 with respect to the main support element 80 along the second direction B.

[0081] The internal face 102 of each adaptor element 100 comprises a seat 105, which defines two side surfaces 105Y extending parallel to the side walls 5, a horizontal surface 105X extending transversally to the side surfaces 105Y and a front surface 85Z extending parallel to the main walls 4A, 4B, and which is configured to receive a respective battery cell 2 to be formed which has a profile matching the profile defined by the surfaces 105X, 105Y of the seat 105.

[0082] A particularly advantageous feature according to the present invention regards the adaptability of the tray 1 to battery cells having different shapes and / or sizes. As a matter of fact, the adaptor elements 100 of the partitions 8 are interchangeable with each other, and may be implemented in such a way as to define seats 105 which are different as a function of the profile (the shape) and / or the size of the cell to be formed.

[0083] In a preferred embodiment, the main support elements 80 are made of a metal material, so as to impart strength to the partitions 8, whereas the adaptor elements 100 associated to the main elements 80 are made of a plastic material, so as to make the implementation of a variety of different adaptor elements 100 simple and economical.

[0084] Referring to Figures 2 to 6, the support tray 1 moreover comprises a pushing system 10, which is configured to apply a load onto the cell array 200 along the second direction B, so that they can slide along the direction B, together with the partitions 8 which support them, until they pressed together against one of the main walls 4A, 4B, thereby applying a compressive load onto the cells 2.

[0085] The pushing system 10 comprises, for each sector 7, an actuator 11 , arranged in the proximity of one of the two main walls 4A, 4B and including at least one screw 12, which may turn with respect to the support tray 1 around a respective axis C parallel to the second direction B, and a pushing plate 13 arranged parallel to the main walls 4A, 4B.

[0086] In the example shown in the Figures, each actuator 11 is arranged in the proximity of the first main wall 4A.

[0087] In a preferred embodiment according to the present invention, each actuator 11 comprises two screws 12, which are spaced apart from each other along the first direction A.

[0088] Each screw 12 extends along the second direction B through the main wall 4A, threadably engaging the internal thread of a threaded sleeve 20 which is firmly connected to the main wall 4A, so that a rotation of the screw 12 around its rotation axis C results in a forward movement thereof along the second direction B.

[0089] Preferably, each screw 12 defines an end portion 12C, which is accessible from the outside of the support structure 3 and which is configured to cooperate with a manual or automatic screwer which controls the rotation thereof around the axis C.

[0090] For each sector 7 an end partition 8A is defined which corresponds to the partition 8 which is nearest to the respective actuator 11 , and which is arranged facing the pushing plate 13.

[0091] With reference to the Figures, there is described the operation of the pushing system 10 for applying a preload onto the battery cells 2 along the second direction B.

[0092] In a first step, the pushing system 10 is in a configuration wherein the pushing plates 13 of each actuator 11 are distanced with respect to the end partition 8A of the corresponding sector 7.

[0093] In this step the partitions 8, which are slidable parallel to the second direction B on the horizontal surfaces 52, 64 of the side walls 5 and of the septa 6, are distanced from each other along the second direction B, so as to define the seats 9 for the cells 2 to be received.

[0094] In a preferred embodiment according to the present invention, the step of distancing the partitions 8 may be performed by a distancing tool 110 (Figure 13) which is provided with a plurality of distancing fingers 111.

[0095] Specifically, once all the partitions 8 have been positioned on the support structure 3 of the tray 1 , the distancing tool 110 is lowered above the partitions, so that the distancing fingers 11 of the tool 110 fit between one partition 8 and the other.

[0096] Once the distancing fingers 11 have been inserted, the tool 110 controls the translational movement of the partitions 8 along the second direction B, so as to distance the partitions 8 and prepare the tray 1 to receive the battery cells 2 to be formed.

[0097] The battery cells 2 are then placed into the respective seats 9 of the tray, by means of an automatic machine or manually, preferably while providing a clearance between the cells 2 and the seats 9, so as to make the insertion of the battery cells 2 easier.

[0098] When all the battery cells 2 to be formed have been placed on the support tray 1 , by acting on the end portions 12C the rotation of each screw 12 is controlled around the respective axis of rotation C.

[0099] Thanks to the mechanism described in the foregoing, the tightening of the screws 12 brings the end 12A of each screw in abutment with the pushing plate 13 of the corresponding actuator 11 , controlling a translational movement thereof along the second direction B.

[0100] Initially, when a pushing plate 13 contacts the respective end partition 8A of the same sector 7, the forward movement of the pushing plate 13 eliminates the clearance provided between the battery cells 2 and the seats 9 during the insertion step of the battery cells 2 into the tray 1 , thereby bringing to mutual abutment the surfaces 82B of the side formations 82 of the main support elements.

[0101] A further forward movement of the pushing plate 13 applies a load onto the cell array 200 along the second direction B, leading to a compression load adapted to compress all the cells 2 of a same array 200 as a whole towards the second main wall 4B. Said compression load is transmitted through the pairs of mutually contacting surfaces 82B of the main support elements 80.

[0102] Therefore, as a whole, the support tray 1 enables providing seats 9 for battery cells 2 having different sizes and shapes along the three spatial dimensions. As a matter of fact, as described in the foregoing, the partitions 8 of each sector 7 are arranged in such a way as to receive battery cells 2 having different thickness, by “thickness” meaning the encumbrance of the battery cell 2 along the second direction B. Moreover, the dimension of the seats 9 along the first direction A and along a vertical direction Z may be adapted by using adaptor elements 100 which are interchangeable with each other, and which have different horizontal surfaces 105X and vertical surfaces 105Y.

[0103] A further feature of the support tray 1 according to the present invention regards the ability thereof to withstand structural loads during the formation step of the battery cells 2 during the formation process.

[0104] As a matter of fact, during the formation process of the battery cells 2, within the cells 2 gases of different kinds develop, i.a. hydrogen.

[0105] Such gases, beside constituting a danger due to their high flammability, may build up within the cells 2 and cause the swelling (or “bulging”) thereof, which exerts a pressure on the partitions 8 of the tray 1 .

[0106] The formation process, moreover, requires keeping a controlled temperature in the formation chamber, preferably comprised between 20°C and 60°C.

[0107] As can be seen in Figure 8, a preferred embodiment according to the present invention envisages the presence, on each main support element 80 at the external face 84 thereof, of a plurality of ribs 86.

[0108] During the formation process of the cells 2, the ribs 86 of two mutually facing external faces 84 belonging to adjacent main elements 80 define a gap 22 therebetween, which performs a twofold function.

[0109] First of all, the presence of the gaps 22 favours the heat exchange between the cells 2 and the environment within the formation chamber, in such a way as so favour keeping, in a simpler and more uniform way, the selected temperature for the formation step of the cells 2. Secondly, the gaps 22 may act as a region wherein the partitions 8, under the effect of the stresses deriving from the gas production in the cells 2 during the formation step, may deform elastically.

[0110] Referring to Figure 12, each battery cell 2 comprises two electrical terminals 2A, which are configured to electrically contact respective electrical terminals of the electronic power unit within the formation chamber, and a degassing hole 2B configured to receive a respective suction port of a gas suction system of the formation chamber. During the formation process of the battery cells 2, within the cells 2 gases of different kinds develop, among which there are flammable gases, so that it is necessary to provide each battery cell with said degassing hole 2B, through which the gases which develop in the battery cell during the formation process within the formation chamber may be vacuumed by means of a gas suction system provided in the formation chamber. Moreover, even when the battery cells 2 are not arranged within the formation chamber, the degassing holes 2B of the cells are still needed, in order to let the gas disperse in the surrounding environment.

[0111] The main principle underlying the present invention consists in providing a single component, i.e. the degassing mask which is generally denoted with the reference 23 in the Figures 14-18, which is associated with the tray 1 supporting the battery cells 2 when the tray is still outside the formation chamber and which, once the tray 1 carrying the battery cells is moved into the formation chamber, perform the function of conveying the gases exiting the battery cells 2 towards the suction system.

[0112] To this end, the degassing mask 23 comprises a gas manifold 24 and a plurality of suction nozzles 29, each being in fluid communication with the gas manifold 24 and each being positioned so that, in a condition of the degassing mask 23 mounted on the support structure 3 of the tray 1 , each suction nozzle 29 is positioned at a respective degassing hole 2B of a battery cell 2. In the example shown, the degassing mask 23 has a frame made of hollow beams, which defines the gas manifold 24. Moreover, in the example shown, the suction nozzles 29 communicating with the discharge manifold are suction cups, carried by the frame of the degassing mask (Figures 14 and 15 show two embodiments which differ in the number of suction cup, the number of suction cups necessarily being the same as the number of battery cells 2 along each cell array, since it is necessary to provide one suction cup for each degassing hole 2B).

[0113] The advantage of such a solution resides in the fact that the suction cups 29 may perform both the function of suction nozzles, to vacuum the gases out of the battery cells 2 during the formation process in the formation chamber, and the function of maintaining the insulation of the degassing holes 2B of the battery cells 2 with respect to the outer environment whilst moving the tray 1 , with the battery cells thereon, up to the formation chamber, as well as the function of retaining elements, which firmly retain the degassing mask on the support structure 3 of the tray 1 during all the operations mentioned in the foregoing.

[0114] Of course, in the mounted condition of the degassing mask 23 on the support structure 3 of the tray 1 , it is necessary to ensure that each suction cup 29 is located at the degassing hole 2B of a respective battery cell 2. Consequently, two conditions must necessarily be met: i) the position of each battery cell 2 with respect to the support structure 3 of the tray 1 must be known and predetermined; ii) the position of the degassing mask 23 (and of the suction cups 29) with respect to the support structure 3 of the tray 1 must be known and predetermined.

[0115] The first condition (1 ) is certainly satisfied by the support tray 1 which has been described in the foregoing, since the tray is configured in such a way that, once the battery cells 2 have been received in the tray 1 and the pushing system 10 has been activated, the battery cells 2 reach a predetermined position with respect to the support structure 3. Of course, the same result may also be achieved with a tray of a type other than illustrated herein by way of example only.

[0116] In the example shown, said second condition (ii) concerning the positioning of the degassing mask 23 (and of the suction cups 29) with respect to the support structure 3 of the tray 1 is satisfied since the support structure 3 of the tray 1 is provided, at the four vertexes thereof (see Figure 1 ) with engagement seats 25A, for the engagement of corresponding reference pins (Figure 14) carried by the frame 24 of the degassing mask 23. The engagement of the reference pins 25 inside the engagement seats 25A prevents a relative movement between the degassing mask 23 and the tray 1 along two orthogonal horizontal directions, whereas the reference along the vertical direction is given by the engagement of the lower surface of the frame 24 against the upper surface of the support structure 3. Of course, it is possible to adopt variations wherein the reference pins 25 are carried by the support structure 3 of the tray, and the seats 25A are formed in the lower surface of the frame 24.

[0117] In the embodiment shown in the Figures, the frame 24 of the degassing mask 23 comprises two main hollow beams 27, parallel and spaced from each other, which are firmly connected by a plurality of auxiliary hollow beams 28. The auxiliary hollow beams 28 extend orthogonally to the main hollow beams 27, and each of them carries a plurality of suction nozzles 29.

[0118] When the degassing mask 23 is mounted on the support structure 3 of the tray 1 (Figure 15), the main hollow beams 27 of the frame 24 are arranged parallel to the main walls 4A, 4B along the first direction A above the support structure 3 of the tray. Correspondingly, in the mounted configuration of the degassing mask, the auxiliary hollow beams 28 are arranged parallel to the side walls 5 along the second direction B, so that each auxiliary hollow beam is located at a respective sector 7 of the tray 1 .

[0119] Referring to Figure 16, the suction cups 29 respectively have a hollow body configured to sealably engage a portion 2C of an upper wall of a respective battery cell 2 around the degassing hole 2B. The suction cups 29 perform both the function of suction nozzles, in order to vacuum the gases out of the battery cells 2 during the formation process in the formation chamber, and the function of keeping the degassing holes 2B of the battery cells 2 isolated with respect to the environment whilst moving the tray 1 , which carries the battery cells, up to the formation chamber, as well as the function of retaining elements, which firmly retain the degassing mask on the support structure 3 of the tray 1 during all the operations mentioned in the foregoing.

[0120] In the illustrated example, each suction cup 29 is arranged at a free end 30A of a respective duct 30 which is carried by the frame 24 and is adapted to put the inner cavity of the suction cup 29 into fluid communication with the internal space of the frame 24, which acts as a gas manifold.

[0121] Referring to Figure 17, each duct 30 is removably mounted on the gas manifold 24 and comprises, at a second end 30B, a threaded portion configured to engage a respective internal thread provided on the gas manifold 24. Such an arrangement makes the maintenance operations easier.

[0122] The degassing mask 23 has, in the illustrated example, two discharge ports 26 arranged at the central portions of the main beams 27 of the frame 24.

[0123] The discharge ports 26 are adapted to be put into fluid communication with a vacuum source (not shown) outside the degassing mask 23

[0124] - both when the tray 1 is still outside the formation chamber, in order to activate the suction cups 29 with the purpose of retaining the degassing mask 23 on the support structure 3 of the tray 1 , and with the purpose of keeping the degassing holes 2B isolated with respect to the external environment,

[0125] - and when the tray 1 is within the formation chamber, in order to convey the gases, by means of the degassing mask 23, towards a gas suction system provided in the formation chamber.

[0126] In the illustrated example the discharge ports 26, one of which is illustrated on an enlarged scale in Figure 18, are configured to receive respective connection members 31 (Figure 19) for the connection with the vacuum source. In the present example, each discharge port 26 comprises a discharge duct 32, adapted to be put into fluid communication with a connection duct 33 of the connection member 31 . Specifically, in the present example, the discharge duct 32 is configured to engage an inlet end 33A of the connection duct 33 of the connection member 31. In order to refer to position said connection duct 33 with respect to the discharge duct 32 of the discharge port 26, each discharge port 26 of the degassing mask 23 is provided with a pair of seats 34A on both sides of the discharge duct 32, which are configured to receive two reference pins 34 protruding downwards from the connection member 31 , on both sides of the connection duct 33. Of course, it is possible to envisage a modification wherein the reference pins are carried by the frame 24, and the seats are formed in the connection member 31 . In the example, the discharge port 26 comprises a raised flat portion 35, wherefrom the discharge duct 32 extends. Each discharge port 26 is associated with a valve of any known type (not shown), configured to be normally closed and to open when the discharge port 26 is engaged by a respective connection member 31 , in such a way as to enable the passage of fluid from the gas manifold 24 towards the vacuum source. In this way, when every discharge port 26 is engaged by the respective member 31 for the connection with the vacuum source, the valve associated with the discharge port 26 opens, thereby enabling vacuuming the internal cavity of the frame 24 which forms the gas manifold; thereafter, when each connection member 31 is disengaged from the respective discharge port 26, the valve associated with the discharge port 26 closes, thereby enabling keeping the environment inside the discharge manifold under vacuum.

[0127] The system described in the foregoing is used as explained in the following.

[0128] In a first step, a plurality of battery cells 2 are arranged on the tray 1 , and the pushing system 10 is activated (in the case of the presently illustrated example) in order to bring the battery cells to a predetermined final position thereof with respect to the support structure 3.

[0129] Thereafter, the degassing mask 23 is mounted onto the support structure 3 of the tray 1 (Figure 15) by engaging the reference pins 25 of the frame 24 into the respective seats 25A of the support structure 3 of the tray 1 , so as to refer the degassing mask 23 to a precise position with respect to the structure 3 of the tray 1 , and at the same time to contact the suction cups 29 with the portions 2C of the battery cells 2.

[0130] Thereafter, the space within the frame 24 of the degassing mask 23, which acts as a gas manifold, is connected with a vacuum source, by coupling the connection members 31 with the discharge ports 26, which causes the activation of the suction cups 29, so that the degassing mask is retained on the support structure 23 of the tray 1 . Once the vacuum has been achieved inside the gas manifold 24, the connection members 31 are disengaged from the discharge ports 26, and the space within the frame 24 remains under vacuum due to the closing of the valves associated with the discharge ports. In this condition, the frame 24 of the degassing mask 23 keeps on being stably retained on the support structure 3, and the suction cups keep the degassing holes 2B isolated with respect to the external environment. Thus, the tray 1 and the degassing mask 23 fixed thereto form a self-contained system, which can be easily moved up to the formation chamber.

[0131] When said system is inserted into the formation chamber, the degassing mask 23 is connected to a gas suction system which is provided in the formation chamber, by means of connection members similar to the connection members 31 described in the foregoing. In this way, during the formation process, the gases produced by the battery cells 2 are eliminated.

[0132] When the degassing mask is connected to the vacuum source, the applied vacuum may cause the suction of a part of the electrolytes present in the battery cells 2 in the liquid phase. Moreover, a part of the gases released by the battery cells 2 may condensate, thereby remaining trapped within the gas manifold 24.

[0133] Referring to Figure 17, in an embodiment according to the present invention, the degassing mask 23 comprises at least one drain hole 36, which is provided on a lower surface 37 of the gas manifold 24 and is configured to enable the operations of cleaning and emptying the hollow beams 27, 28, making the liquids accumulated in the gas manifold 24 flow out when the degassing mask is not mounted on the support structure 3 of the tray 1 .

[0134] Specifically, when the degassing mask is mounted on the support structure 3 of the tray, for example whilst moving the battery cells 2 up to the formation chamber or during the formation process, the drain hole 36 is normally hermetically sealed by a plug 38.

[0135] On the other hand, when the degassing mask 23 is disassembled from the support structure 3, for example at the end of the formation process in the formation chamber, the plug 38 is removed, in order to allow any liquid accumulated between the hollow beams 27, 28 of the gas manifold 24 to flow out through the drain hole 36.

[0136] Moreover, through the drain hole 36 it is possible to inject, into the gas manifold 24, reacting substances which are adapted to form a bond with the residual gaseous electrolyte particles, so as to obtain from the reaction a liquid product which can flow out through the hole 36.

[0137] In a practical constructive example, the tray 1 has a length, along the direction A, of 1640 mm, a width, along the direction B, of 1300 mm, and a height, along the vertical direction Z, of 158 mm. The tray has three septa 6 which define four sectors 7, each having sixteen seats 9 defined by thirty- two partitions 8.

[0138] The degassing mask 23 which may be associated with the tray 1 has a length, along the direction A, of 1200 mm, and a width, along the direction B, of 900 mm. The degassing mask 23 has four auxiliary hollow beams 28, each carrying 8 suction nozzles 29.

[0139] Of course, without prejudice to the principle of the invention, the constructive details and the embodiments may be amply varied with respect to what has been described and illustrated without departing from the extent of the invention, as defined in the claims that follow.

[0140] For example, the degassing mask may have a frame carrying a network of tubes which act as a discharge manifold, so that the discharge manifold is implemented as an element separated from the frame.

[0141] The suction nozzles 29 may not have the form of suction cups, but may be simply nozzles adapted to sealably engage into the degassing holes; in the latter case, the degassing mask should be provided with mechanical connection means, in order to be fixed to the support structure 3 of the tray 1 .

[0142] In the example illustrated in the foregoing, the means to refer to position the frame 24 of the degassing mask 23 on the support structure 3 of the tray 1 , as well as the means to refer to position the connection members 31 on the discharge ports 26, may be of any known type, which may be different from what has been illustrated herein.

[0143] Each degassing mask may have one or more discharge ports 26, configured and arranged in any fashion.

[0144] Finally, as repeatedly mentioned, the configuration of the tray 1 may also be completely different from what has been illustrated herein by way of example only, provided that it enables receiving and holding a plurality of battery cells in strictly predetermined positions with respect to the support structure of the tray.

Claims

CLAIMS1. A system for supporting and moving a plurality of electric battery cells (2), usable for carrying the battery cells (2) within a formation chamber for battery cells and for supporting them during a formation process inside said formation chamber, said system comprising:- a support tray (1 ) including a support structure (3) configured to hold a plurality of battery cells (2) in predetermined positions with respect to the support structure (3), said system being characterized in that a degassing mask (23) is associated to the tray (1 ), configured to be mounted on the support structure (3) of the tray (1 ) in a predetermined position with respect to said support structure (3), and in that said degassing mask (23) comprises:- a gas manifold (24),- a plurality of suction nozzles (29) communicating with said gas manifold (24) and configured to be positioned at respective degassing holes (2B) of the battery cells (2) when the degassing mask (23) is mounted on the support structure (2) of the tray (1 ),- at least one discharge port (26) for putting into fluid communication the gas manifold (24) with a vacuum source, said suction nozzles (29) being configured to:- keep said degassing holes (2B) of the battery cells (2) isolated with respect to the outer environment whilst moving the battery cells (2) up to the formation chamber, by means of said support tray (1 ),- by means of said gas manifold (24) of the degassing mask, put into fluid communication the degassing holes (2B) of the battery cells (2) with a vacuum source during the formation process of the battery cells (2) within said formation chamber.

2. The system according to claim 1 , characterized in that said degassing mask (24) has a frame including a plurality of hollow beams (27, 28) connected to each other, defining said gas manifold (24) and carrying said suction nozzles (29), said at least one discharge port (26) being associated to one of said beams (27, 28) of the frame of the degassing mask(23).

3. The system according to claim 2, characterized in that:- the support structure (3) comprises two main walls (4A, 4B) parallel and spaced apart from each other, firmly connected by two end walls (5) extending orthogonally to the two main walls (4A, 4B), and further including one or more septa (6) parallel to the end walls (5), which connect the two main walls (4A, 4B) and which divide the space defined by said main walls (4A, 4B) and by said end walls (5) into a plurality of sectors (7) side by side with each other, configured to receive respective cell arrays (200), each array (200) comprising a plurality of battery cells (2) oriented parallel to the main walls (4A, 4B);- a plurality of partitions (8), arranged inside each of said sectors (7), parallel to the main walls (4A, 4B), so as to define, in each septum (7), a plurality of seats (9) configured to receive respective battery cells (2) at predetermined positions with respect to the support structure (3),- said frame forming the gas manifold (24) of the degassing mask(23) comprises two main hollow beams (27) spaced from each other and firmly connected by a plurality of auxiliary hollow beams (28) orthogonal to the two main hollow beams (27), each auxiliary hollow beam carrying an aligned arrangement of suction nozzles (29), so that when the degassing mask is mounted on the support structure (3) of the tray (1 ), the main hollow beams (27) are arranged parallel to said main walls (4A, 4B) above the support structure (3) of the tray (1 ), and the suction nozzles (29) carried by the auxiliary hollow beams (28) are in fluid communication with said degassing holes (2B) of the battery cells 82) carried by the tray (1 ).

4. The system according to claim 3, characterized in that the frame(24) of the degassing mask (23) and the support structure (3) of the tray (1 ) comprise mutual engagement elements (25, 25A) configured to refer to a predetermined position the degassing mask (23) on the tray (1 ).

5. The system according to claim (4), characterized in that said mutual engagement elements (25, 25A) comprise a plurality of reference pins (25) arranged on one among said frame (24) and said support structure (3) of the tray (1 ) and a plurality of seats (25A) for the reference pins (25), arranged on the other one among said frame (24) and said support structure(3) of the tray (1 ).

6. The system according to any one of the preceding claims, wherein each suction nozzle (29) is in the form of a suction cup, having a hollow body configured to sealably engage a portion (2C) of an upper wall of a respective battery cell (2) arranged on said tray 81 ), around a respective degassing hole (2B).

7. The system according to claim 6, characterized in that each suction cup (29) is arranged at the end of a duct (30) removably connected to the gas manifold (24).

8. The system according to any one of the preceding claims, characterized in that a connection member (31 ) is associated to at least one discharge port (26) of the degassing mask (23), engageable on said at least one discharge port (26) for putting into fluid communication said discharge port (26) and said vacuum source, and in that the at least one discharge port (26) comprises a normally closed valve configured to open when said connection member (31 ) engages said at least one discharge port (26).

9. The system according to claim 8, characterized in that the degassing mask (23) and said connection member (31 ) have mutual engagement elements (34, 34A) for referring said connection member (31 ) with respect to said at least one discharge port (26) of the degassing mask (23).

10. The system according to claim 9, characterized in that the connection member (31 ) has a connection duct (33) engageable in fluid communication to said at least one discharge port (26) of the degassing mask (23) and the mutual engagement elements (34, 34A) for referring said connection member (31 ) with respect to said at least one discharge port (26) of the degassing mask (23) comprise a couple of reference pins (34) carried by said connection member (31 ) on both sides of said connection duct (33), and two corresponding seats (34A) arranged on the degassing mask (23) on both sides of said at least one discharge port (26), for receiving said reference pins (34).

11. The system according to claim 1 , wherein the gas manifold (24) of the degassing mask (23) comprises at least one drain hole (36) configured to drain any liquid accumulated within the gas manifold (24).

12. A method for supporting and moving a plurality of battery cells (2) within a formation chamber for battery cells and for supporting them during a formation process inside said formation chamber, wherein said method comprises providing a support tray (1 ) for the cells (2) including a support structure (3) configured to hold a plurality of battery cells (2) in predetermined positions with respect to the support structure (3), said method being characterized in that it comprises:- mounting a degassing mask (23) on the support structure (3) of the tray (1 ) in a predetermined position with respect to said support structure (3), said degassing mask (23) comprising:- a gas manifold (24),- a plurality of suction nozzles (29) communicating to said gas manifold (24) and arranged and configured so that when the degassing mask (23) is mounted on the support structure (3) of the tray (1 ), the suction nozzles (29) engage respective degassing holes (2B) of the battery cells (2) and keep them isolated with respect to the outer environment whilst moving the battery cells (2) up to the formation chamber by means of said support tray (1 ),- when the battery cells (2) on said stray (1 ) are within a formation chamber and undergo a process of formation, the degassing holes (2B) of the battery cells (2) are put into fluid communication to a vacuum source, by means of said gas manifold (24) of the degassing mask (23), to vacuum the gases out of the battery cells (2) that form within the battery cells (2) during the formation process.

13. The method according to claim 12, characterized in that:- each suction nozzle (29) is in the form of a suction cup, having a hollow body configured to sealably engage a portion (2C) of an upper wall of a respective battery cell (2) arranged on said tray 81 ), around a respective degassing hole (2B).- after that the degassing mask (23) has been mounted on the support structure (3) of the tray (1 ), the suction cups constituting the suction nozzles (29) are put into fluid communication to a vacuum source to hold the degassing mask (23) on said support structure (3) of the tray (1 ) whilstthe tray (1) with the battery cells (2) is being moved up to the formation chamber.

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