Method for producing a prismatic battery cell

Abstract

The invention relates to a method for producing a prismatic battery cell (2), wherein an electrode stack (16) is provided with first electrodes (6) and second electrodes (8) which are stacked one over the other. Arresters (10) of the first electrodes (6) protrude beyond an end face (18) of the electrode assembly (16) in the longitudinal direction (L), and arresters (10) of the first electrodes (6) are compacted and welded together, in particular by means of ultrasonic welding. The compacted arresters (10) are arranged on a flat lateral surface (24) of a contact element (26) of a cell cover (28) of a cell housing (30), said contact element forming a cell terminal, and the compacted arresters are welded to the contact element (26), in particular by means of laser welding. The cell cover (28) is arranged on the electrode stack (16), in particular the cell cover is pushed thereon, such that the cell cover (50), in particular the lateral surface (24), is parallel to the end face (18). The invention additionally relates to such a prismatic battery cell (2) and to a motor vehicle comprising such a battery cell (2).

Description

[0001] Description

[0002] Method for producing a prismatic battery cell

[0003] The invention relates to a method for producing a prismatic battery cell, in which conductors of the first electrodes are compacted and welded to a contact plate. Furthermore, the invention relates to a prismatic battery cell produced according to the method.

[0004] An electrically powered motor vehicle typically has a traction battery (high-voltage battery, HV battery) that supplies energy to an electric motor to drive the motor vehicle. An electrically powered motor vehicle is understood to mean, in particular, an electric vehicle that stores the energy required for propulsion solely in the traction battery (BEV, battery electric vehicle), an electric vehicle with a range extender (REEV, range extended electric vehicle), a hybrid vehicle (HEV, hybrid electric vehicle), a plug-in hybrid vehicle (PHEV, plug-in hybrid electric vehicle), and / or a fuel cell vehicle (FCEV, fuel cell electric vehicle), which temporarily stores the electrical energy generated by a fuel cell in the traction battery.

[0005] Such a traction battery typically comprises several battery cells, in particular lithium-ion battery cells, which are electrically connected to one another in series and / or in parallel.

[0006] Battery cells are classified into different types depending on their design. For example, a pouch cell (coffee bag cell) has a foil, in particular an aluminum composite foil, as a casing in which the battery cell's electrodes are enclosed. A cylindrical battery cell, in contrast, comprises a comparatively rigid housing, in particular made of sheet metal, with the housing essentially having a circular-cylindrical shape. Also known are so-called prismatic battery cells, whose housings are also comparatively rigid, in particular made of sheet metal, and are essentially cuboid-shaped.

[0007] A battery cell is known from DE 102021 114 887 A1. It comprises a housing and, arranged therein, a plurality of electrodes with at least one anode and at least one cathode. The housing has a shell part with at least one open end face, wherein the end face is closed by a multi-layer cover element. A first layer of an electrically conductive material is connected to the anodes or the cathodes.

[0008] DE 102019 102 032 A1 relates to an energy storage cell with a plurality of electrodes of a first polarity and a plurality of electrodes of a second polarity, wherein the electrodes are arranged in an electrode stack. The electrodes of the first polarity each have a first conductor lug protruding from the electrode stack on a first side of the electrode stack, and the electrodes of the second polarity each have a second conductor lug protruding from the electrode stack on a second side of the electrode stack opposite the first. The electrode stack is arranged in a housing that is electrically conductively connected to the first conductor lugs.

[0009] DE 10 2021 108 104 A1 describes a method for producing a component, wherein the component comprises a plurality of stacked cell foils and at least one contact sheet. The cell foils form a foil stack in a connecting section, and the foil stack is connected to the contact sheet by at least one weld seam.

[0010] The invention is based on the object of providing a particularly suitable method for producing a prismatic battery cell. Furthermore, such a battery cell and an electrically powered motor vehicle comprising such a battery cell are to be provided.

[0011] With regard to the method, the object is achieved according to the invention by the features of claim 1. With regard to the battery cell, the object is achieved according to the invention by the features of claim 9, and with regard to the motor vehicle by the features of claim 10. Advantageous embodiments and further developments are the subject of the dependent claims. The statements made in connection with the method also apply mutatis mutandis to the battery cell, and vice versa.

[0012] The method serves to produce a prismatic battery cell. This is expediently designed as a lithium-ion battery cell. Preferably, the battery cell is intended and configured for a traction battery of an electrically powered motor vehicle.

[0013] First, an electrode stack is provided, comprising first electrodes and second electrodes stacked one above the other in a direction referred to here and below as the stacking direction or the vertical stacking direction. Thus, the electrode stack is formed from a number of first electrodes and a number of second electrodes, with the electrodes arranged one above the other in the stacking direction. The first and second electrodes are expediently arranged alternately, with a separator being arranged between each first electrode and the second electrode adjacent to it.

[0014] For example, each of the first electrodes is designed as an anode and each of the second electrodes as a cathode.

[0015] Each electrode is suitably sheet-like. The respective electrode is formed from a foil-like substrate, in particular from a metal foil. The respective substrate comprises a (first) section coated with an active material, and a second section, in particular molded onto this section, a conductor. The conductor is also referred to as a flag. The coated section of the substrate of each of the electrodes expediently has a rectangular base area. Preferably, the base area is not square; in other words, the rectangular base area has different side lengths. In the electrode stack, the first sections of the electrodes each span an area perpendicular to the stacking direction. Expediently, the conductor does not extend over the entire length of the corresponding side.

[0016] The conductor preferably stands on the shorter side of the rectangular first section of the respective substrate.

[0017] Suitably, in the electrode stack, the conductors of the first electrodes extend away from the first section of the respective substrate in a direction referred to as the longitudinal direction, which is perpendicular to the stacking direction, and the conductors of the second electrodes extend away from the first section of the respective substrate opposite to the longitudinal direction. Thus, the conductors of the first electrodes are arranged one above the other in the stacking direction, and the conductors of the second electrodes are arranged one above the other in the stacking direction. The conductors of the first electrodes are arranged on the side of the electrode stack referred to as the first end face, and the conductors of the second electrodes are arranged on the second end face of the electrode stack opposite the first end face, i.e. oriented parallel to the first end face and perpendicular to the stacking direction.

[0018] In summary, the conductors of the first electrodes extend upwards in the longitudinal direction of the first end face of the electrode stack, and the conductors of the second electrodes extend upwards in the opposite direction to the longitudinal direction of the second end face. The longitudinal direction is the direction along one of the, in particular longer, edges of one of the substrates, from the second to the first end face.

[0019] According to the method, the conductors of the first electrodes are compacted and welded together. The compacting and welding can be performed sequentially. Particularly preferably, the conductors of the first electrodes are ultrasonically welded together. The compacting and welding are then expediently performed together during the ultrasonic welding process. Preferably, the ultrasonic tools act directly on the conductors. In other words, no protective element, in particular a protective film or protective plate, is used, which is inserted between the respective ultrasonic tool and the conductors and welded to the conductor.

[0020] It is advisable to subsequently trim the compacted conductors of the first electrodes, i.e. cut to size, in particular cut off, so that the free ends of the conductors are aligned with each other in the stacking direction.

[0021] Subsequently, the conductors of the first electrodes are welded to one another (and expediently cut to size) to a contact element of a cell cover of a cell housing, which is electrically conductive. In particular, the conductors are laser-welded to the contact plate. For this purpose, the compacted region of the conductors is first arranged on a flat side surface of the contact element. In particular, the compacted region of the conductors lies, preferably directly, i.e. immediately, on the flat side surface. The conductors are then welded to this side surface in the region arranged on it. Particularly preferably, when laser welding the contact element and the conductor, that region of the conductors is welded which is also compacted and / or ultrasonically welded; in other words, during laser welding, the laser acts on the ultrasonically welded and / or compacted region of the conductors.Since the distance between the arresters is comparatively small in the compacted / ultrasonic welded area, this enables particularly reliable joining of the arresters to the contact element.

[0022] The contact element forms a (cell) terminal. The contact element is therefore electrically connected to the conductors of the first electrodes, wherein the contact element can be electrically and / or mechanically contacted from the outside of the cell when the battery cell is assembled, in particular in order to connect the contact element to a conductor rail of a battery circuit. The contact element is expediently designed as a single piece (monolithic), in particular as a metal part. The contact element extends through the cell cover. The flat side surface to which the conductors are welded forms the inside of the battery cell of the contact element. The conductors are therefore welded to the inside of the cell of the contact element. For example, the contact element comprises a plate-shaped section which forms the flat side surface, wherein a suitable pin-shaped extension projects upwards therefrom and extends through the cell cover.

[0023] In particular, the contact element is designed as a single piece, i.e., monolithic. Furthermore, the cell cover is conveniently designed as a single assembly, meaning it is pre-assembled. The components of the cover therefore do not need to be joined together after welding.

[0024] The cell cover is then positioned on the electrode stack such that the cell cover, in particular the flat side surface of its contact element to which the conductors are welded, is parallel to the first end face. To this end, the conductors of the first electrodes, in particular in their non-compacted area, are bent (folded over) such that, after bending, the cell cover covers the end face of the electrode stack in the longitudinal direction. In summary, the cell cover is folded in. Therefore, the cell cover is particularly preferably positioned on the first end face of the electrode stack.

[0025] Bending (folding) is conveniently performed using two blades extending transversely and spaced apart longitudinally, with one of the blades pressing against the arrester from above, and the other from below, relative to the vertical stacking direction. In summary, the flat side surface forming the inside of the contact element—that is, the side of the contact element to which the contact plate is welded—is adjusted toward the first end face due to the bending.

[0026] Preferably, the cell cover is pushed onto the electrode stack, in particular counter to the longitudinal direction, expediently after aligning the cell cover parallel to the first end faces.

[0027] In summary, a method for producing a battery cell is advantageously realized, the conductors of which are arranged on opposite end faces of the electrode stack.

[0028] The cell cover comprises, for example, a stopper frame, in particular an electrically insulating one, and an outer wall. The outer wall is arranged on the outside of the cell in the assembled state, and the stopper frame is arranged on the side of the outer wall facing the cell interior of the battery cell. The contact element forming the terminal expediently extends through both the stopper frame and the outer wall.

[0029] The stopper frame of the cell cover preferably has an extension that extends perpendicular to the side surface of the contact element, in particular protrudes upwards therefrom. Preferably, when the cell cover is pushed onto the electrode stack, the extension is pressed into the electrode stack. For example, one such extension is provided on the stopper frame in the transverse direction. Thus, the extensions on both sides of the conductors are pressed into the electrode stack, i.e., penetrate into it. The maximum penetration depth of the extension into the electrode stack is preferably 1 mm or less. The electrode stack is therefore at least slightly deformed. In this way, the cell cover is held to the electrode stack.

[0030] The height of the extension, i.e., its extension in a direction perpendicular to the side surface of the contact element, is preferably greater than the maximum penetration depth. For example, the height of the extension is between 2.5 mm and 5 mm. This creates a space between the electrode stack and the cell lid in the assembled state (next to the extension), in which the conductors, especially curved ones, can be accommodated. The extensions thus also form a type of spacer.

[0031] According to an advantageous embodiment, to form the electrode stack (before its provision, thus before the first electrodes of the arresters are welded), two separate individual stacks (individual electrode stacks) are stacked on top of one another. Each of the individual stacks comprises first electrodes and second electrodes stacked one above the other, and expediently separators arranged between them. The first and second electrodes are fixed to one another, for example, using an adhesive tape (fixing tape). For example, each of the individual stacks comprises between 50 and 200, in particular 100, first electrodes and between 50 and 200, in particular 100, second electrodes.

[0032] The two individual stacks are stacked on top of each other to form the electrode stack such that the conductors of the first electrodes and those of the second electrodes are arranged one above the other in the stacking direction. The conductors of the first electrodes are then compacted and welded together. Advantageously, any deviation in the positioning of the electrodes relative to each other is smaller when forming the electrode stack from individual stacks than when forming a (single) electrode stack with a correspondingly larger number of electrodes.

[0033] As an alternative to forming the electrode stack by stacking the two individual stacks on top of each other, it can be produced using what is known as butterfly welding. Here, the individual stacks are first arranged next to one another in such a way that their end faces with the arresters of the first electrodes lie opposite one another, i.e. face one another, with the individual stacks being inclined towards one another. In particular, the arresters of the two individual stacks are arranged in such a way that the uppermost arrester of the first individual stack, i.e. the arrester facing the second individual stack, is arranged on the uppermost arrester of the second individual stack, i.e. the arrester facing the first individual stack. The arresters of the first electrodes are then welded together, expediently ultrasonically welded. Subsequently, one of the individual stacks is folded onto the other individual stack to form the electrode stack.

[0034] According to an advantageous embodiment, the upper and / or the lower arrester with respect to the vertical direction of the stack is provided with, in particular glued, a protective film, in particular an electrically insulating one. This is expediently carried out after the arresters have been welded to one another and preferably after the arresters have been welded to the contact element, and expediently before the cell cover is arranged on the electrode stack so that the side surface is parallel to the first end face, in particular before the arresters are bent for this purpose. In this way, damage to the arresters during assembly of the battery cell, in particular when bending the arresters, is advantageously avoided or the risk of this is at least reduced. Furthermore, contact of the bent arresters with the edges of the second electrodes on the first end face is avoided.

[0035] The respective protective film preferably projects beyond the arresters in a transverse direction oriented transversely to the longitudinal direction and the stacking direction. In other words, the protective films project laterally beyond the arresters, i.e. along the short edge of the first sections of the substrates. For a comparatively secure hold, the protective films are preferably also attached, in particular glued, in sections, in particular at the ends with respect to the longitudinal direction, to the top side of the electrode stack or to the underside of the electrode stack. The top side is understood to be the upper side of the electrode stack with respect to the stacking direction, and the underside is understood to be the lower side of the electrode stack with respect to the stacking direction. The top side and the underside are oriented perpendicular to the stacking direction.

[0036] A sweatband is used in particular as a protective film.

[0037] According to a preferred embodiment of the method, the weld seam resulting from the welding of the contact plate to the contact element is covered with an additional protective film, preferably before the cell cover is arranged by bending the arresters on the first end face, i.e. before the side surface is arranged parallel to the end face on the electrode stack. For this purpose, the additional protective film is glued to the contact plate, for example. This at least covers the weld seam, for example additionally the area of ​​the arresters and / or the contact element in the area of ​​the weld seam. Due to the additional protective film, damage to the arresters when arranging the cell cover due to welding residues, a sharp edge, or a burr in the weld seam is avoided.

[0038] The cell lid and the electrode stack are expediently secured to each other using a fixing film. For example, the fixing film is wrapped around the electrode stack and the cell lid, particularly on the side surfaces of its stopper frame oriented parallel to the longitudinal direction, and then glued, for example, to the electrode stack and / or the cell lid. The fixing film is then expediently joined to the cell lid, particularly its stopper frame, for example by hot-staking or welding. The fixing film is suitably electrically insulating.

[0039] According to an advantageous embodiment of the method, a housing shell (housing frame, cell shell) is pushed in the longitudinal direction, i.e. from the second end face to the first end face of the electrode stack, over the electrode stack, which is fixed in particular to the cell lid by means of the fixing film, and / or over the stopper frame of the cell lid.

[0040] The housing shell is made, for example, from a sheet metal, in particular from aluminum. The housing shell collectively forms the side walls of the battery cell housing, which are oriented parallel to the longitudinal direction. Together with the cell cover, the housing shell forms a so-called cell cup. The housing shell is therefore hollow-cylindrical in shape, with the cylinder having a rectangle as its base. According to an expedient embodiment, the cell cover, in particular its outer wall, is arranged on the free end side of the housing shell, in particular rests against it. Expediently, the stopper frame is arranged in the spatial area enclosed by the housing shell. The outer wall is therefore larger than the stopper frame and larger than the opening in the housing shell in a direction perpendicular to the longitudinal direction, i.e. to the direction of extension of the housing shell.The cell cover thus covers the housing shell in the longitudinal direction; in particular, the cell cover is aligned with the housing shell in the longitudinal direction when assembled. The free end side of the housing shell is the side oriented perpendicular to the longitudinal direction, i.e., the direction of extension of the housing shell.

[0041] In summary, the cell cover closes the opening of the housing shell.

[0042] A further aspect of the invention relates to a prismatic battery cell produced according to the method in one of the variants described above. The battery cell thus comprises an electrode stack with, expediently alternating, stacked first and second electrodes. The conductors of the first electrodes are arranged on a (first) end face of the electrode stack. The conductors are compacted and welded to one another, in particular ultrasonically welded. In addition, the conductors are welded, in particular laser welded, to the flat side surface of the contact element, in particular in the ultrasonically welded region, wherein the contact element forms one of the cell terminals of the prismatic battery cell. In the assembled state of the battery cell, the cell cover, in particular the flat side surface of its contact element, is parallel to the first end face.

[0043] Preferably, the electrode stack is again formed by two individual stacks stacked on top of each other.

[0044] Preferably, the upper and / or the lower arrester with respect to the stack vertical direction is provided with a protective film, in particular an electrically insulating one.

[0045] Preferably, the electrode stack and the cell cover are secured to each other using a fixing film. The weld seam resulting from the welding of the contact plate to the contact element is preferably covered, in particular taped, with an additional protective film.

[0046] Preferably, a housing shell of a cell housing is pushed over the electrode stack (and, if present, over the stopper frame of the cell lid). In the assembled state, the electrode stack and / or the stopper frame of the cell lid are arranged in the housing interior, thus in the space enclosed by the housing shell. Particularly preferably, the cell lid, in particular its outer wall, is arranged on the free end side of the housing shell, thus covering it in a direction parallel to a central axis of the housing shell.

[0047] Preferably, the stopper frame of the cell lid is pushed onto the electrode stack. In particular, the extension of the stopper frame penetrates into the electrode stack.

[0048] A further aspect of the invention relates to an electrically driven motor vehicle having a prismatic battery cell formed in one of the variants described above and / or manufactured according to the method in one of the variants described above.

[0049] In particular, the motor vehicle comprises a traction battery (HV battery) designed and configured to provide electrical energy for a traction drive. The prismatic battery cell is part of the traction battery.

[0050] In the following, exemplary embodiments of the invention are explained in more detail with reference to a drawing. In the drawings:

[0051] Fig. 1 is a flow chart representing a process sequence for producing a battery cell,

[0052] Fig. 2 shows a schematic perspective view of two individual stacks which are stacked on top of each other to form an electrode stack,

[0053] Fig. 3 shows a schematic perspective view of the electrode stack, wherein the first conductors are arranged on a first end face of the electrode stack and the second conductors are arranged on a second end face of the electrode stack, wherein the first conductors are ultrasonically welded to one another at the free end. Fig. 4 shows a schematic perspective view of the electrode stack, wherein the first conductors are laser-welded to a contact element of a cell lid.

[0054] Fig. 5 shows a schematic perspective view of the electrode stack, with the conductors covered with a protective film and the laser weld seam covered with another protective film,

[0055] Fig. 6 shows a schematic perspective view of the electrode stack and the cell cover, wherein the cell cover is arranged parallel to the first end face,

[0056] Fig. 7 shows schematically and in sections the electrode stack in a plan view, with the cell cover pushed onto the electrode stack,

[0057] Fig. 8 shows a schematic perspective view of the electrode stack, wherein the second conductors are joined to a contact plate which projects through a stopper frame arranged on the second end face, and wherein the electrode stack, the stopper frame and the cell base are fixed to one another by means of a fixing film,

[0058] Fig.9 shows a schematic perspective view of the electrode stack fixed to the stopper frame and the cell lid using the fixing foil, with a housing jacket being pushed over the stopper frame and the electrode stack,

[0059] Fig. 10 schematically shows a perspective view of a cell base joined to the contact sheet,

[0060] Fig. 11 shows a schematic and perspective view of the battery cell, with the cell lid and the cell bottom closing the housing shell, and

[0061] Fig. 12 a sectional view through the cell lid.

[0062] Corresponding parts and sizes are always provided with the same reference symbols in all figures.

[0063] Figure 1 illustrates a method for producing a prismatic battery cell 2, particularly a lithium-ion battery cell, using a flowchart. In the method, in a first step I, two separate individual stacks 4 (individual electrode stacks 4) are stacked one above the other. This is represented by an arrow in Figure 2.

[0064] Each of the individual stacks 4 comprises a plurality of first electrodes 6 and second electrodes 8, which are stacked alternately one above the other in a stacking direction S, wherein a separator (not further shown) is arranged between the first and the second electrodes.

[0065] The first and second electrodes 6, 8 of each individual stack 4 are sheet-like. Each comprises a foil-like substrate with a rectangular section coated with active material and with a conductor. For the purpose of better differentiation, the conductors of the first electrodes 6 are referred to below as first conductors 10 and the conductors of the second electrodes 8 as second conductors 12. The first and second conductors 10, 12 protrude from the shorter side of the rectangular coated section. In each of the individual stacks 4, the first conductors 10 are arranged one above the other and the second conductors 12 are arranged one above the other, with the first conductors 10 protruding in a longitudinal direction L towards the first section and the second conductors 12 protruding opposite to the longitudinal direction L towards the first section of the respective substrate.

[0066] For each of the individual stacks 4, a fixing band 14 is used, by means of which the electrodes 6, 8 of the respective individual stack 4 are fixed. The fixing band 14 is glued to an upper (top) side of the respective individual stack 4 with respect to the stacking direction S and to the lower (bottom) side of the respective individual stack 4 with respect to the stacking direction S, and overlaps a side of the respective individual stack 4 oriented parallel to the stacking direction S.

[0067] In the first step I, the two individual stacks 4 are arranged on top of one another such that the conductors 10 of the first electrodes 6 of both individual stacks 4 are arranged one above the other in the stacking direction S. Accordingly, the conductors 12 of the second electrodes 8 of both individual stacks 4 are arranged one above the other in the stacking direction S.

[0068] The first arresters 10 are arranged on one side of the formed electrode stack 16, referred to as the first end face 18, by stacking the two individual stacks 4. The second arresters 12 are arranged on the second end face 20 of the electrode stack 16, which is opposite the first end face 18, i.e., oriented parallel to it and perpendicular to the stacking direction S. The longitudinal direction L is thus directed from the second end face 20 to the first end face 18.

[0069] The two individual stacks 4 stacked one above the other are expediently fixed to one another by means of a fixing band 14.

[0070] In summary, stacking the two individual stacks 4 on top of each other results in the electrode stack 16, which is provided for the further production of the battery cell 2, wherein the conductors 10 of the first electrodes 6 of the first end face 18 of the electrode arrangement 16 protrude in the longitudinal direction L and the conductors 12 of the second electrodes 8 of the second end face 20 protrude opposite to the longitudinal direction L.

[0071] In a subsequent second step II, the conductors 10 of the first electrodes 6 are compacted and welded together. For this purpose, the first conductors 10 are ultrasonically welded together using ultrasonic welding tools 22. This is shown in Fig. 3, with the ultrasonic tools 22 only schematically indicated as rectangles. During ultrasonic welding, the first conductors 10 are both compacted and joined together. The first conductors 10 are then expediently cut to size, in other words, trimmed, so that their free ends, i.e., the ends facing away from the first end face 18, are aligned with one another.

[0072] In a subsequent third step III, the compacted first arresters 10 are arranged on a flat side surface 24 of a contact element 26 of a cell cover 28 of a cell housing 30. In particular, the compacted region of the first arresters 10 rests directly, i.e., immediately, on the flat side surface 24. Subsequently, the compacted first arresters 10 are welded to the side surface 24, in particular by laser welding, see Fig. 4. For this purpose, a laser is applied to the ultrasonically welded region of the first arresters 10, so that the first arresters 10 are laser-welded to the contact element 26.

[0073] The structure of the cell cover 28 is comparatively clearly visible, in particular, in Figures 4 to 6 and in the sectional view of Figure 12. This comprises a suitably flat (cell) outer wall 32. On the (inner) side of the outer wall facing the electrode stack 16, i.e., on the side facing the cell interior of the battery cell 2, there is arranged a stopper frame 34, in particular an electrically insulating one. The stopper frame 30 of the cell cover 28 preferably has at least one extension 36, which extends perpendicular to the side surface 24 of the contact element 26 toward the inside of the cell; in the assembled state of the battery cell 2, the extension 36 therefore extends counter to the longitudinal direction L. According to the exemplary embodiment shown here, the stopper frame 34 has two such extensions 36, which are arranged at a distance from one another in the transverse direction Q, each end of the stopper frame 34.

[0074] The contact element 26 extends through both the stopper frame 34 and the outer wall 32, so that it is electrically connected to the first conductors 10 on the inside of the cell and can also be electrically and mechanically contacted on the outside of the cell. The contact element 26 thus forms a terminal of the battery cell 2. The contact element 26 is formed as a single piece (monolithic), in particular as a metal part. The contact element 26 comprises a plate-shaped section 38, the side of which facing the electrode stack 16 forms the flat side surface 24. A pin-shaped extension 40 is formed integrally on the plate-shaped section 38, protrudes upwards therefrom and extends through the cell lid 28.

[0075] Furthermore, the cell cover 28 is designed as an assembly, so it is pre-assembled.

[0076] In a subsequent fourth step IV, the first conductor 10 which is upper with respect to a stack vertical direction S and / or the first conductor 10 which is lower with respect to the stack vertical direction S is provided with an electrically insulating protective film 42.

[0077] Optionally, the protective film 42 projects beyond the first arresters 10 in a transverse direction Q oriented transversely to the longitudinal direction L and the stacking direction S. The respective protective film 42 thus projects laterally beyond the arresters 10. For a comparatively secure hold, the protective films 42 are also attached, in particular glued, in sections, in particular at the ends with respect to the longitudinal direction, to the top side 44 of the electrode stack or to the bottom side 46 of the electrode stack 16. In other words, the protective film 42 extends on the top side 44 or the bottom side 46 of the electrode stack 4, respectively, over the region of the edge of the electrode stack 16 on which the respective arrester 10 is arranged.

[0078] The top side 44 is understood to be the upper side of the electrode stack 16 with respect to the stacking direction S, and the bottom side 46 is understood to be the lower side of the electrode stack 16 with respect to the stacking direction S. The top side 44 and the bottom side 46 are oriented perpendicular to the stacking direction S.

[0079] A sweatband is used, in particular, as the protective film 42. The attached protective films 42 can be seen, for example, in Fig. 5.

[0080] Furthermore, in the fourth step IV, the (laser) weld seam 48 resulting from the laser welding of the first arrester 10 to the contact element 26 is covered with a further protective film 50, see also Fig. 5. The further protective film 50 completely covers the weld seam 48. In this way, damage to the first arrester 10, in particular due to welding residues or due to the weld seam 48 itself, is avoided. For a comparatively secure hold, the area of ​​the side surface 24 not covered by the first arresters 10 is expediently covered by the further protective film 50, and this is adhered in this area.

[0081] In a subsequent fifth step V, the cell cover 28 is arranged on the electrode stack 16 such that the cell cover 50, in particular the side surface 24 and / or the outer wall 32, is parallel to the first end face 18. For this purpose, the first conductors 10 are bent in the area not welded to the contact element 26. In this process, the free end of the first conductors 10 is adjusted, i.e., toward the first end face 18.

[0082] Subsequently, in the fifth step V, the cell cover 28 is pushed onto the electrode stack 16. In the process, the extensions 36 are pressed into the electrode stack 16, which is represented in Fig. 6 by an arrow. In the assembled state, the extensions 36 are pressed into the electrode stack 16 on both sides of the first conductor 10 with respect to the transverse direction Q, i.e. they penetrate into it. The cell cover 28 arranged on the first end face 18 is shown in particular in Figs. 6 and 7. As can be seen in particular in Fig. 7, a maximum penetration depth w of the respective extension 36 into the electrode stack 16 is 1 mm or less. The electrode stack 16 is therefore at least slightly deformed, so that the cell cover 28 is held on the electrode stack 16.

[0083] In a subsequent sixth step VI, the second arresters 12 are compacted and preferably welded together and expediently subsequently trimmed. For example, the second arresters 12 are ultrasonically welded to one another at least locally, for example point-by-point or section-by-section, so that they are pre-fixed to one another. The compacted second arresters 12 are then placed between a contact plate 52 and a sacrificial plate 54 and ultrasonically welded to them. Optionally, the upper second arrester 10 with respect to the vertical stack direction S and / or the lower second arrester 10 with respect to the vertical stack direction S are provided with a protective film 42, in particular an electrically insulating one. In a subsequent seventh step VII, a further stopper frame 56 (second stopper frame 56) is arranged on the second end face 20.In this case, the contact plate 52 welded to the second arresters 12 is guided through a passage 58 of the second stopper frame 56 extending in the longitudinal direction L. In other words, the stopper frame 56 is pushed over the contact plate 52 and the second arresters 12, so that the contact plate 52 and the second arresters 12 extend through the passage 58 of the second stopper frame 56. This is illustrated in Fig. 8.

[0084] For example, the second stopper frame 56 is pushed onto the second end face 18 in a manner analogous to the (first) stopper frame 34, so that its extensions penetrate into the electrode stack 16 (not shown further).

[0085] In a subsequent eighth step VIII, the electrode stack 16, the cell lid 28, and the second stopper frame 56 are fixed to one another using a, in particular electrically insulating, fixing film 60. For this purpose, the fixing film 60 is wound around the electrode stack 16 and around the side surfaces 72 of the stopper frame 34 of the cell lid 28, which are oriented parallel to the longitudinal direction L, and around the side surfaces 72 of the second stopper frame 34, which are oriented parallel to the longitudinal direction L, as represented by arrows in Fig. 8. For example, the fixing film 60 is fixed using an adhesive tape 52 after the winding process. In addition, the fixing film 60 is welded to the stopper frame 34 and to the second stopper frame 56 at their side surfaces 72 oriented parallel to the longitudinal direction L, or joined by hot caulking.

[0086] In a subsequent ninth step IX, a housing shell 62 of the cell housing 30 is pushed over the contact plate 52, over the second stopper frame 56 and over the electrode stack 16, see also Fig. 9. The housing shell 62 encompasses the cell interior, thus forming the side walls of the cell housing 30 oriented parallel to the longitudinal direction L. The housing shell 62 is thus designed as a hollow prism (hollow cylinder with a rectangular base area).

[0087] The electrode stack 4 and the stopper frame 34 are arranged in the housing shell 62, i.e., are accommodated within the space area encompassed by the housing shell 62.

[0088] In a subsequent tenth step X, the contact plate 52 is laser-welded to a contact element 26 of a cell base 66 of the cell housing 30, see also Fig. 10. The contact element 26 forms a further terminal of the battery cell 2, i.e., the contact element 26 can be electrically and / or mechanically contacted from outside the battery cell 2, see Fig. 11. The welding of the contact plate 52 thus takes place on a cell inner side of the contact element 26. In summary, the contact element 26 is electrically conductively connected to the second conductors 12 by means of the contact plate 52. Optionally, the (laser) weld seam 48 resulting from the welding of the contact plate 52 to the contact element 26 is covered with a further protective film 50.

[0089] In a subsequent eleventh step XI, the cell cover 28 is arranged on the free end side 64 of the housing shell 62, see also Fig. 12. Consequently, the cell cover 28 rests on the free end side 64. The free end side 64 is understood to mean the side surface of the housing shell 62 oriented perpendicular to the longitudinal direction L, thus perpendicular to the direction of extension or the central axis of the housing shell 62.

[0090] In addition, the cell bottom 66 is arranged on the other free end side 64 of the housing shell 62, see also Fig. 11. For this purpose, the second conductors 12 are bent accordingly, in particular in their non-compacted area, in particular folded and / or folded in. Consequently, the cell bottom 66 rests on this free end side 64. The cell bottom 66 is thus arranged such that it conceals the second stopper frame 56 and the second end face 20 of the electrode stack 16.

[0091] The cell lid 28 and the cell bottom 66 each close an opening 68 of the housing shell 62. The cell bottom 66 and the cell lid 28 are expediently welded to the housing shell 62, in particular by laser welding in a fluid-tight manner, so that a cuboid-shaped cell housing is formed.

[0092] Conveniently, the battery cell 2 is then filled with an electrolyte through a filling opening 70 arranged in the cell base 66. The filling opening 70 is then closed, for example, with a pin, in particular made of an elastomer. The filling opening 70 and the pin received therein are then covered, for example, by a cover, in particular made of metal, and welded to an outer side of the cell base 66. The filling opening 70 is thus sealed.

[0093] In a manner not shown in detail, an electrically powered motor vehicle, in particular its traction battery, has a prismatic battery cell 2 manufactured according to the method described above. The invention is not limited to the exemplary embodiment described above. Rather, other variants of the invention can be derived therefrom by a person skilled in the art within the scope of the claims without departing from the subject matter of the invention. In particular, all individual features described in connection with the exemplary embodiment and / or in the claims can also be combined with one another in other ways without departing from the subject matter of the invention.

[0094] List of reference symbols

[0095] Battery cell

[0096] Single stack first electrode second electrode

[0097] Arrester of a first electrode

[0098] Arrester of a second electrode

[0099] Fixing tape

[0100] Electrode stack first end face second end face

[0101] Ultrasonic tool

[0102] Side surface of the contact element

[0103] Contact element / T erminal

[0104] cell lid

[0105] Cell housing

[0106] exterior wall

[0107] (first) stopper frame

[0108] Process plate-like section pin-like process

[0109] protective film

[0110] Top of the electrode stack

[0111] Bottom of the electrode stack

[0112] Weld seam 50 additional protective film

[0113] 52 contact plate

[0114] 54 sacrificial plate

[0115] 56 (second) stopper frame

[0116] 58 Implementation

[0117] 60 fixing film

[0118] 62 Housing shell

[0119] 64 Free end side

[0120] 66 cell floor

[0121] 68 Opening

[0122] 70 Filling opening

[0123] 72 side surface

[0124] L longitudinal direction

[0125] Q transverse direction

[0126] S Stacking direction / stacking direction w Penetration depth

[0127] I Forming the electrode stack

[0128] II Ultrasonic welding of the first arresters together

[0129] III Laser welding of the welded arresters at the contact element

[0130] IV Applying protective films

[0131] V Slide the cell lid onto the electrode stack

[0132] VI Joining the second arrester with a contact plate

[0133] VII Slide on the second stopper frame

[0134] VIII Fixing the cell lid to the electrode stack

[0135] IX Sliding on a housing shell X Welding the contact plate with the contact element of the cell base

[0136] XI Closing the housing shell

Claims

Patent claims 1. A method for producing a prismatic battery cell (2), wherein an electrode stack (16) with stacked first electrodes (6) and second electrodes (8), wherein conductors (10) of the first electrodes (6) protrude from an end face (18) of the electrode arrangement (16) in the longitudinal direction (L), wherein conductors (10) of the first electrodes (6) are compacted and welded to one another, in particular ultrasonically welded, wherein the compacted conductors (10) are arranged on a flat side surface (24) of a contact element (26) of a cell cover (28) of a cell housing (30), forming a cell terminal, and are welded to the contact element (26), in particular laser welded, and wherein the cell cover (28) is arranged on the electrode stack (16), in particular pushed onto it, in such a way that the cell cover (50), in particular the side surface (24), is parallel to the end face (18).

2. Method according to claim 1, characterized in that, to form the electrode stack (16), two separate individual stacks (4) are stacked on top of one another, each of which has first electrodes (6) and second electrodes (8) stacked one above the other and fixed to one another.

3. Method according to claim 1 or 2, characterized in that the upper conductor (10) with respect to a stack vertical direction (S) and / or the lower conductor (10) with respect to the stack vertical direction (S) are provided with a protective film (42), in particular an electrically insulating one.

4. Method according to one of claims 1 to 3, characterized in that the weld seam (48) resulting from the welding of the arrester (10) to the contact element (26) is covered with a further protective film (50).

5. Method according to one of claims 1 to 4, characterized in that the electrode stack (16) and the cell cover (28) are fixed to one another by means of a fixing film (60).

6. Method according to one of claims 1 to 5, characterized in that the cell cover (28) has a stopper frame (SR) with an extension (36) extending perpendicular to the side surface (24), and / or wherein when the cell cover (28) is pushed onto the electrode stack (16), the extension (36) is pressed into the electrode stack (16).

7. Method according to one of claims 1 to 6, characterized in that a housing shell (62) of the cell housing (30) is pushed in the longitudinal direction (L) over the electrode stack (16), which is fixed to the cell cover (28) in particular by means of the fixing film (60).

8. The method according to claim 7, characterized in that the cell cover (28) is arranged on the free end side (64) of the housing shell (62).

9. Prismatic battery cell (2) produced by the method according to one of claims 1 to 8.

10. Motor vehicle with a battery cell (2) according to claim 9.

Images