Warehouse for the formation of electrochemical cells

Abstract

A warehouse (10) for the formation of electrochemical cells, comprising a containment structure (12) having an inner volume (14) wherein they are housed: a plurality of formation stations (15); a plurality of formation modules (16) each of which is configured to be coupled to a cell tray (11) to implement an at least partial formation cycle of electrochemical cells (100) contained in the cell tray (11); at least one transfer station (20) configured to interface between the inner volume (14) of the containment structure (12) and an environment external to the inner volume (14) of the containment structure (12) and to receive cell trays (11) from the external environment and to deliver cell trays (11) from the inner volume (14) to the external environment; a transport system (22) for transferring cell trays (11) containing electrochemical cells (100) between the transfer station (20) and each formation station (15) or in combination between each formation station (15) and the transfer station (20); wherein at least one formation module (16) of the plurality of formation modules (16) is placed in each formation station (15).

Description

[0001] "Warehouse for the formation of electrochemical cells"

[0002] DESCRIPTION

[0003] The present invention relates to a warehouse for the formation of electrochemical cells.

[0004] The present invention finds particular application in the production of secondary batteries, preferably rechargeable lithium batteries. Although in the course of this description, reference will be made specifically to lithium electrochemical cells, the teachings of the present invention also apply to the case of other secondary electrochemical cells wherein one of the cell construction processes comprises the formation of the electrode through the passage of current therethrough.

[0005] In the production of lithium electrochemical cells, after mechanical assembly operations of the electrochemical cells, the electrochemical cells have to undergo electrical operations that lead to electrochemical phenomena within the electrochemical cells such that the anodes are covered by the so-called "Solid Electrolyte Interphase" (SEI). These operations are known in the technical sector by the term "formation" of the electrochemical cells.

[0006] The electrochemical cell formation operations typically involve a succession of charge / discharge cycles of the electrochemical cells applying currents of 0.1 -0.2 C for predetermined times (on the order of 10-24 hours). The magnitude "C" indicates a current value expressed in amperes numerically equal to the cell capacity in Ah (e.g. for a cell capacity of 2 Ah, the magnitude C is 2 A). The currents actually applied, the charge / discharge times and the number of repetitions of the various charge / discharge cycles depend on the type of battery and each battery manufacturer has developed its own "recipe" that allows to best form the electrode surface layer SEI to maximise battery performance. In fact, only if the formation process is performed properly will the electrode surface layer SEI be deposited on the electrodes of the battery, which optimizes the properties of the battery in terms of charge capacity and uniformity of charge / discharge cycles.

[0007] After the formation operations, the formed electrochemical cells are subjected to electrically passive aging operations, carried out in special resting stations (aging stations) for times in the order of tens or hundreds of hours, in which the cells are allowed "to rest" to allow them to stabilise at specially controlled temperatures. In the Applicant's experience, the formation of the electrochemical cells is performed in a formation plant in which cell trays, each containing a plurality of electrochemical cells arranged in a matrix pattern, are positioned in respective formation chambers.

[0008] In the Applicant's experience, in the formation plants the formation chambers are arranged in cabinets, known by the term "rack". Inside each formation chamber a contacting assembly is placed, configured to enter into electrical contact with each electrochemical cell of the cell tray. A plurality of contacting assemblies, typically the contacting assemblies of the formation chambers of a shelf of the rack, is connected via a plurality of electrical cables to the electrical and electronic components necessary to provide electrical power to the contacting assembly to implement the charge / discharge cycles of the electrochemical cells.

[0009] In a modern formation plant there are dozens of formation racks.

[0010] In fact, by virtue of the ever-increasing demand for secondary batteries, battery production plants have reached very large sizes. Suffice it to say that these plants are commonly called Gigafactories and that their sizes are expressed in GWh to indicate the electricity storage capacity expressed in GWh of the batteries produced there in a year. By way of example, a 1 GWh Gigafactory is able to produce enough batteries capable of powering around 15,000 electric vehicles in a single year. There are 50 GWh operating gigafactories.

[0011] Modern formation plants are highly automated so that the trays containing the electrochemical cells are supplied to the racks and positioned inside the respective formation chambers automatically.

[0012] The Applicant has found that a careful design of the layout of the formation plant is required, necessary to ensure that each formation rack can be served by one or more lifting devices that lift the trays at the formation chambers, to ensure that each lifting device has the necessary manoeuvring space, to ensure that each lifting device can actually reach all the formation chambers it must serve and to ensure that the formation racks can still be safely inspected by specialised personnel to carry out maintenance operations.

[0013] In the Applicant's experience, any expansion or reconfiguration of the plant requires expensive, both in economic terms and in terms of time, redesigns of the layout of the plant to meet the above requirements. The Applicant has therefore felt the need to make any expansion or reconfiguration of a formation plant less onerous.

[0014] The Applicant has perceived that if formation racks were arranged as integrating devices with all the functionalities necessary to manage the transfer and the positioning of the trays of electrochemical cells inside the formation chambers and if such a type of formation rack were arranged in the form of a substantially independent structure that can be interfaced with other parts of the formation plant, any expansion or reconfiguration of the plant would "simply" require the positioning of new formation racks or the repositioning of already existing formation racks, greatly reducing the time and costs necessary to expand or reconfigure a formation plant.

[0015] The Applicant has therefore found that a formation rack could be made from a warehouse equipped with the electrical and electronic components to form electrochemical cells, having a containment structure inside which a plurality of formation chambers are arranged, wherein said warehouse comprises a transfer station that acts as an interface between the warehouse itself and the rest of the plant to receive trays with electrochemical cells to be formed and deliver trays with formed electrochemical cells, and a transport system inside the warehouse capable of transporting trays between the transfer station and the formation chambers and between the formation chambers and the transfer station.

[0016] In this way, the warehouse would be a physically and functionally autonomous "entity", with known sizes and requiring only access to the transfer station and connection to a source of electrical energy in order to be able to be substantially immediately used or integrated into a formation plant.

[0017] The present invention therefore concerns an automatic warehouse for the formation of electrochemical cells.

[0018] Preferably, there is provided a containment structure having an inner volume.

[0019] Preferably, a plurality of formation stations are housed in the inner volume.

[0020] Preferably, a plurality of formation modules are housed in the inner volume, each of which is configured to be coupled to a cell tray to implement an at least partial formation cycle of electrochemical cells contained in said cell tray.

[0021] Preferably, in the inner volume is housed at least one transfer station configured to interface between said inner volume of said containment structure and an environment external to said inner volume of said containment structure and to receive cell trays from said external environment or, or in combination, to deliver cell trays from said inner volume to said external environment.

[0022] Preferably, in the inner volume is housed a transport system for transferring cell trays containing electrochemical cells between the transfer station and each formation station and between each formation station and said transfer station.

[0023] Preferably, at least one formation module of that plurality of formation modules is placed in each formation station.

[0024] The Applicant has found that the containment structure defines predefined and certain overall sizes for the warehouse, making it easier to design a plant layout. The transfer station inside the containment structure acts as an interface with feeding and pick-up systems to the cell tray warehouse and the transport system allows to manage the logistics of transporting the cell trays inside the warehouse to place the trays in the formation stations. The formation modules present in each formation station allow performing the at least partial formation of the electrochemical cells contained in the cell trays. In this way, the warehouse is configured as a physically and functionally autonomous "entity" and can be easily integrated into a new formation plant or into an already existing formation plant.

[0025] By "electrochemical cell" is meant an assembly consisting of at least one anode, one cathode, a possible separator made of dielectric material interposed between the anode and cathode, and an electrolyte. A battery comprises at least one electrochemical cell.

[0026] By "formation" is meant a process in which an electrochemical cell is subjected to charge / discharge / recharge cycles. The currents applied during charge / discharge / recharge cycles, measured in Amperes, are numerically of a lower order of magnitude than the number expressing the total capacity in Ah of the electrochemical cell. For example, when an electrochemical cell has a capacity of 1 Ah, the maximum currents applied are about 0.1 - 0.2 amperes. The charge / discharge / recharge cycles are implemented for such a time (e.g. 12-24 hours) to reach maximum voltage, minimum voltage, and then return the electrochemical cell to a known state of charge, typically 80%.

[0027] By "bi-directional converter" is meant a power supply device capable of supplying electrical energy to a user device and extracting energy from it, enabling a bi- directional exchange of energy between the user device and the power supply device. In a bi-directional converter the direction of the electrical energy flow is directed in a controlled manner either from the power supply device towards the user device or from the user device towards the power supply device; there is never a possibility that the energy flow is simultaneously directed from the power supply device towards the user device and from the user device towards the power supply device.

[0028] By "drawer" is meant any supporting structure capable of supporting a body and inserted into a housing compartment, not necessarily closed on the sides and not necessarily slidable on guides or the like to be extracted from a housing compartment. Therefore, a drawer inserted in a station of the warehouse is understood as a supporting structure (configured to support for example a formation module or part of a formation module) inserted in a station of the warehouse.

[0029] By "conditioning" or "thermally conditioning" a physical entity (such as for example a tray, a formation module, a liquid) is meant subjecting that physical entity to a thermal heating or cooling action.

[0030] The present invention may have at least one of the preferred features described below. Such features may be present individually or in combination with each other, unless expressly stated otherwise, in the warehouse of the present invention.

[0031] Preferably, the warehouse is part of a formation plant comprising a plurality of cell trays each containing electrochemical cells.

[0032] Preferably, the containment structure comprises a frame and a plurality of possibly removable walls delimiting the inner volume of the warehouse.

[0033] The formation stations are preferably positions within the warehouse occupied by the formation modules and by the cell trays when the electrochemical cell formation operations are carried out.

[0034] Preferably, a plurality of transfer stations may be provided, wherein some transfer stations are configured to receive cell trays and other transfer stations are configured to extract cell trays from the warehouse.

[0035] In the preferred embodiment of the invention, a single transfer station is used both to receive cell trays and to extract cell trays from the warehouse.

[0036] Preferably, said transport system is completely contained within the inner volume of the supporting structure.

[0037] Preferably, said transport system comprises an elevator configured to receive and transport at least one cell tray in the inner volume of the containment structure.

[0038] Preferably, said transport system comprises vertical guides to which the elevator is slidably connected.

[0039] Preferably, said vertical guides develop vertically inside the containment structure and reach in height all the formation stations.

[0040] Preferably, said transport system comprises a horizontal guide.

[0041] Preferably, the elevator is horizontally movable along the horizontal guide.

[0042] Preferably, the horizontal guide slides vertically along the vertical guides.

[0043] When a cell tray is placed in the transfer station, the elevator is positioned at the transfer station to receive the cell tray.

[0044] The elevator, possibly moving along the horizontal guide, is lifted along the vertical guides to reach the level of the formation station. The elevator, possibly moving along the horizontal guide, inserts the cell tray into the formation station placing it in contact relationship with a contacting assembly of a formation module.

[0045] The vertical guides, the horizontal guide and the elevator can be chosen as a function of the required movement and positioning precision.

[0046] Preferably, said formation stations are arranged one on top of the other in at least one column of formation stations.

[0047] Preferably, said transfer station is located below said formation stations.

[0048] In this way, the transfer station is easily reachable by an automated cell tray movement system within the plant or by operators in charge of movement the cell trays within the plant. In addition, in this way it is possible to develop the warehouse in height up to levels substantially bound only by the height available within the plant. In fact, it is only necessary to be able to access the transfer station to insert and extract cell trays from the warehouse and the transport system inside the warehouse is left with the task of lifting the cell trays up to the formation stations regardless of their vertical distance from the transfer station.

[0049] Preferably, the transport system is placed between columns of formation stations.

[0050] Preferably, a plurality of formation modules are placed in each formation station.

[0051] Preferably, each formation module comprises a contacting assembly configured to provide an electrical contact for each of said electrochemical cells housed in a cell tray.

[0052] Preferably, said contacting assembly comprises a plurality of electrical contacts configured to enter into electrical contact relationship with poles of the electrochemical cells.

[0053] Preferably, each formation module further comprises at least one bi-directional converter.

[0054] Preferably, said at least one bi-directional converter is in electrical connection with said contacting assembly.

[0055] Preferably, each formation module comprises a bi-directional converter for each electrochemical cell present in a cell tray.

[0056] Each bi-directional converter is configured to directly supply electrical energy to an electrochemical cell, for example at a voltage of 4.2 Volts.

[0057] For supplying the bi-directional converters of the formation modules, a power supply unit comprising a plurality of electrical converters is preferably provided.

[0058] Preferably, such electrical converters are configured to change input voltage values from an electrical power source external to the containment structure to usable input voltage values to the bi-directional converters of the formation modules.

[0059] The electrical converters can be AC / DC or DC / DC converters or both types depending on the electrical conversion diagram to be implemented. Preferably, each formation station comprises at least one electrical connector electrically connectable to said electrical power source external to said containment structure.

[0060] Preferably, each bi-directional converter of each formation module placed in a formation station is electrically connected to said electrical connector.

[0061] Said electrical converters may be placed upstream of said electrical connectors of the formation stations at a position located between said external electrical power source and said electrical connectors of the formation stations or in combination they may be placed downstream of said electrical connectors of the formation stations at a position located between said electrical connectors and said bi-directional converters of the formation modules.

[0062] The Applicant has observed that the maintenance of the formation modules is particularly expensive, since the formation modules consist of complex components subject to high wear due to the electrical powers transmitted to the electrochemical cells to be formed. It is therefore necessary to provide for frequent maintenance interventions of the formation modules.

[0063] The Applicant has found that by mounting the formation modules on drawers placed in the formation stations it is possible to directly access the formation modules for their maintenance.

[0064] For this purpose, preferably a plurality of drawers are housed in said inner volume, wherein at least one of said drawers is inserted in each formation station.

[0065] Preferably, a plurality of formation modules are mounted on each drawer.

[0066] The Applicant has noted that these drawers can also be used to simultaneously connect all the formation modules to the electrical connector present in the formation station. In this way it is possible to reduce the number of electrical connectors present in each formation station up to even one single electrical connector.

[0067] For this purpose, preferably each drawer comprises at least one electrical plug configured to connect electrically with the electrical connector of a respective formation station.

[0068] Preferably, said electrical plug electrically connects, preferably permanently, the electrical connector with the bi-directional converters of the formation modules mounted in the drawer.

[0069] The Applicant has perceived that if the components subject to maintenance and whose access is particularly expensive, such as for example the formation modules, were made movable within the warehouse, these components could be brought if necessary into easily accessible positions in order to be able to perform the relative maintenance operations without the need to have to interrupt the functionality of the entire warehouse so that these components to be maintained can be accessed.

[0070] The Applicant has found that by making the drawers movable with the formation modules mounted on them, it would be possible to move the only drawer bearing the formation modules to be maintained in a position of easy access without necessarily having to interrupt all the formation processes taking place in the warehouse to allow safe access to the components subject to maintenance.

[0071] For this purpose, preferably at least one service station is located in said inner volume.

[0072] Preferably, each drawer is movable within said containment structure, together with the formation modules mounted thereon, between the respective formation station and said at least one service station.

[0073] Preferably, said service station comprises an opening to expose a drawer, when placed in the service station, to an environment external to the inner volume of said containment structure.

[0074] Preferably, the formation stations of said plurality of formation stations are placed above said service station.

[0075] Preferably, said service station is placed along a wall of said warehouse other than a wall along which said transfer station is placed.

[0076] Preferably, the service station is configured to receive only one drawer at a time.

[0077] Preferably, when a drawer is placed in the service station, the formation modules of other drawers placed in respective formation stations can perform formation operations on electrochemical cells.

[0078] Preferably, the service station is located, within the containment structure, at an elevation with respect to a baseplate of the warehouse, directly reachable by an operator.

[0079] The Applicant has noted that during the formation process it may be necessary to actively control the temperature of the electrochemical cells. This, for example, in order to prevent the temperature of the electrochemical cells from rising too high, leading for example to a thermal runaway.

[0080] The Applicant has also noted that, depending on the formation "recipe" to be implemented, it may be necessary to ensure that the electrochemical cells remain at predetermined temperatures or predetermined temperature intervals at predetermined steps of the formation process.

[0081] For this purpose, the Applicant has perceived that the formation warehouse could be used as an incubator for the electrochemical cells being formed.

[0082] Therefore, preferably the warehouse comprises a thermal conditioning system configured to thermally condition cell trays placed in the formation stations.

[0083] Preferably, said thermal conditioning system is configured to thermally condition at least at a first formation temperature the cell trays placed in the formation station.

[0084] Preferably, said thermal conditioning system comprising a fluid conditioner.

[0085] Preferably, the fluid conditioner is configured to heat and / or cool a conditioning liquid.

[0086] Preferably, said thermal conditioning system comprising a warehouse conditioning circuit placed in hydraulic connection with said fluid conditioner and configured to supply conditioned fluid to said formation station.

[0087] The fluid conditioner may be internal to the warehouse containment structure or external to the warehouse containment structure.

[0088] Preferably, said conditioning liquid circulates within the warehouse conditioning circuit.

[0089] Preferably, the conditioning liquid is optionally demineralised, osmotised or distilled water.

[0090] Preferably, said conditioning system is configured to thermally and selectively associate said fluid conditioner with said cell trays. Preferably, said warehouse conditioning circuit does not act on said transfer station.

[0091] Preferably, when a cell tray is inserted in a respective formation station, it is provided to hydraulically connect said warehouse conditioning circuit with a cell tray conditioning circuit.

[0092] Preferably, during the movement of a cell tray operated by the transport system, the cell tray conditioning circuit is not hydraulically connected with said warehouse conditioning circuit.

[0093] The Applicant has rushed that the conditioning system could also be used to cool (or if necessary heat) the formation modules.

[0094] In this regard, preferably said conditioning system further comprises a formation module conditioning circuit for each formation module.

[0095] Preferably, said formation module conditioning circuit is placed in fluid connection with said warehouse conditioning circuit at least when said formation module is in use to implement a formation process.

[0096] Preferably, at each formation station there is placed at least one quick-coupling hydraulic connector for hydraulically connecting said warehouse conditioning circuit with said formation module conditioning circuit and with said cell tray conditioning hydraulic circuit and for disconnecting said warehouse conditioning circuit from said formation module conditioning circuit and from said cell tray conditioning hydraulic circuit.

[0097] Preferably, during the movement of a drawer from the formation station to the service station and from the service station to the formation station, the formation module conditioning circuit is not hydraulically connected with said warehouse conditioning circuit.

[0098] The Applicant considers that hydraulically connecting the formation module conditioning circuit to the warehouse conditioning circuit only when the drawer is in a formation station confers high flexibility and high ease of use of the warehouse in performing the formation operations. In fact, each drawer can be moved within the warehouse without being hydraulically connected to the warehouse conditioning circuit, thus avoiding having to have to provide for complicated and expensive hydraulic connections between the warehouse conditioning circuit and the formation module conditioning circuit.

[0099] Further characteristics and advantages of the present invention will become clearer from the following detailed description of some preferred embodiments, with reference to the appended drawings and provided by way of indicative and non-limiting example, in which:

[0100] Figures 1 and 2 are schematic perspective views of a warehouse for the process of formation of electrochemical cells in accordance with the present invention;

[0101] Figure 3 is a first schematic representation of the interior of the warehouse of Figure 1 ;

[0102] Figure 4 is a second schematic representation of the interior of the warehouse of Figure 1 ;

[0103] Figure 5 is a schematic perspective view of a drawer used in the warehouse of Figure 1 ;

[0104] Figure 6 is a schematic perspective view of a formation module placed in a drawer;

[0105] Figure 7 is a schematic representation of some components of the drawer of Figure 6;

[0106] Figure 8 is a schematic representation of some internal components of the warehouse of Figure 1 ;

[0107] Figures 9 and 10 are schematic representations of a thermal conditioning system, and some of its components, of the warehouse of Figure 1 .

[0108] The representations in the appended figures must not be understood in scale, do not necessarily respect the proportions between the various parts and must be understood as diagrams.

[0109] With initial reference to Figure 1 , 10 indicates as a whole an automatic warehouse for the formation of electrochemical cells in accordance with the present invention.

[0110] The warehouse 10 is arranged to receive trays 1 1 containing electrochemical cells 100 (schematized in Figure 10), for example coming from an upstream packaging plant, not represented, and to subject the electrochemical cells 100 to a formation process. The electrochemical cells 100 are lithium ions secondary electrochemical cells.

[0111] Each cell tray 1 1 has a generally box-like shape, and comprises a plurality of housings for containing, preferably separated from each other, a plurality of electrochemical cells 100.

[0112] The warehouse 10 comprises a containment structure 12 having a plurality of walls 13 that are fixed, preferably removably, to a frame. The containment structure 12 is substantially box-like and encloses an inner volume 14 of the warehouse 10. In Figures 1 and 2, parts of the walls 13 placed in the front and rear position have been removed to show part of the inner volume 14 of the warehouse 10. In Figure 3 and 4 the walls 13 have not been represented.

[0113] The warehouse 10 is a structurally independent structure located within a formation plant. In other words, the warehouse 10 is a cabinet. A plurality of warehouses 10 may be provided within a formation plant.

[0114] The containment structure 12 is arranged to be mounted or rested on a floor of a warehouse or the like of an electrochemical cell formation plant.

[0115] The warehouse 10 comprises at least one formation station 15. In the preferred embodiment of the invention, the warehouse 10 comprises a plurality of formation stations 15. The formation stations 15 are physical positions within the warehouse 10 at which the electrochemical cells 100 are subjected to the formation process. The formation stations 15 are arranged one on top of the other to form columns of formation stations 15. By way of example, four columns of formation stations 15 may be provided. Each formation station 15 is closed to the outside of the warehouse 10 by the walls 13. Each formation station 15 is open towards the inner volume 14. Between the columns of formation stations 15, in the inner volume 14, there is provided a space not occupied by the formation stations 15.

[0116] The warehouse 10 comprises a plurality of formation modules 16. Figure 6 schematically represents a formation module 16.

[0117] Each formation module 16 has the function of at least partially forming the electrochemical cells 100 present in a cell tray 1 1. For this purpose, each formation module 16 is configured to supply electrical energy and preferably receive electrical energy from the electrochemical cells 100 in accordance with a formation recipe that establishes times, voltages, current intensities that the formation module 16 must supply and receive from the electrochemical cells 100.

[0118] Each formation module 16 comprises a contacting assembly 17 (schematized in Figures 6 and 7) configured to contact electrical poles of the electrochemical cells 100 placed in a cell tray 1 1 . The contacting assembly 17 comprises a plurality of electrical contacts 17a configured to enter into electrical contact relationship with poles of the electrochemical cells 100.

[0119] Each formation module 16 further comprises at least one bi-directional converter 18 (schematized in Figure 7) which is electrically connected to the contacting assembly 17. Each bi-directional converter 18 is configured to deliver in output the voltage and current necessary to implement the formation recipe. Preferably, the bi-directional converter 18 is the last stage of a current conversion which, starting from a current, for example alternating, supplied at the plant level, supplies a current with voltage and intensity directly deliverable to the electrochemical cells. By way of example, the bi-directional converter 18 can be a bi-directional DC / DC power supply, which for example receives an input current with a voltage comprised between 12 Volts and 48 Volts and delivers a current with a voltage comprised between 2 and 8 Volts, for example of about 4.2 Volts. By way of example, each bi-directional converter 18 may be sized to deliver a maximum current substantially comprised between 0.05 C and 0.4 C, where C indicates a current value expressed in Amperes numerically equal to the capacity in Ah of an electrochemical cell 100. The number of bi-directional converters 18 of each formation module 16 depends on the number of electrochemical cells 100 which must be formed by the formation module 16 and on the electrical sizing of the bi-directional converter 18. Preferably a plurality of bi-directional converters 18 is provided for each formation module 16. For example, a bi-directional converter 18 may be provided for each electrochemical cell 100 of a cell tray 1 1 .

[0120] Each formation module 16 may further comprise at least one control unit 19 (only schematized in Figure 7), for example a microprocessor unit, configured to command the operation of the plurality of bi-directional converters 18 so as to generate for each electrochemical cell a respective voltage or modulated current, suitable for operating the formation process.

[0121] Each formation module 16 comprises a containment frame 16a containing and integrating the bi-directional converters 18, the contacting assembly 17 and possibly the control unit 19. The contacting assembly 17 is not movable with respect to the bi-directional converters 18.

[0122] As schematically illustrated in Figure 1 , the warehouse 10 comprises a transfer station 20 to which the cell trays 1 1 containing the electrochemical cells 100 that must be subjected to the formation process are conferred, preferably one at a time. The transfer station 20 is intended to allow the entry and exit of cell trays 1 1 from the warehouse 10. The transfer station 20, when the warehouse is in use to perform formation processes, is preferably the only access through which the cell trays 1 1 can be introduced and extracted from the warehouse 10.

[0123] The transfer station 20 comprises an opening 21 to allow the cell trays 1 1 to enter the inner volume 14 of the containment structure 12 and to exit the inner volume 14 of the containment structure 12. The transfer station 20 is located in a lower portion of the warehouse 10 at a transport level that is elevated with respect to the floor level (i.e. the level at which the floor of a plant in which the warehouse 10 is mounted is located). As schematically illustrated in Figure 1 , the warehouse 10 comprises a single transfer station 20.

[0124] To allow the transport of trays 1 1 inside the warehouse 10 and their positioning in the formation stations 15, the warehouse 10 comprises a transport system 22 configured to transport the cell trays 1 1 inside warehouse 10 between the formation stations 15 and the transfer station 20. The transport system 22 is placed inside the warehouse 10, in the inner volume 14. Preferably, the transport system 22 is placed in a space between the columns of formation stations 15.

[0125] The transport system 22 comprises an elevator 23 schematized in Figure 3. The elevator 23 comprises a platform 36 on which a cell tray 1 1 is rested and retained during its movement within the warehouse 10. The elevator 23 is connected to vertical guides 24 that develop vertically inside the warehouse 10 and reach in height all the formation stations 15. The platform 36 is slidable in a horizontal direction along the elevator 23. In the preferred embodiment of the invention, the platform 36 has sizes substantially equal to the sizes of a cell tray 11 . The vertical guides 24 develop starting from the transfer station 20. The vertical guides 24 define a vertical transport path for the elevator 23 and are placed in the space between the columns of formation stations 15, so that the elevator 23 transporting a respective cell tray 1 1 can move within the warehouse 10 without interfering with the formation stations 15. In some embodiments where there is a plurality of columns of formation stations 15 arranged side by side between them within the warehouse 10, the elevator 23 may slide horizontally along a horizontal guide 25. The horizontal guide 25 develops between the vertical guides 24. The elevator 23 can reach any formation station 15. When placed in the transfer station 20, the elevator 23 is directly reachable by an operator through the opening 21 in order to be able to load and unload a cell tray 1 1 from the elevator 23.

[0126] A plurality of drawers 26 are also provided within the warehouse 10. Each drawer 26 defines a supporting structure or frame 27 (schematized in Figure 5). The drawers 26 are substantially identical to each other and may have a box-like shape, a substantially planar shape or any other shape. Each drawer 26 is sized to engage and occupy a formation station 15. As schematically illustrated in Figure 5, a plurality of formation modules 16 are mounted on each drawer 26, preferably arranged one next to the other to define a row of formation modules 16. Also shown in Figure 5 are cell trays 1 1 associated with the contacting assemblies 17 of the formation modules 16. Each drawer 26 thus defines a supporting structure or frame 27 for the formation modules 16 mounted thereon. Each drawer 26 with the relative formation modules 16 mounted thereon is placed inside a respective formation station 15, as schematically illustrated in Figure 3.

[0127] To supply with electrical power the formation modules 16, and in particular the bidirectional converters 18, the warehouse 10 comprises a power supply unit 28. The power supply unit 28 comprises a plurality of electrical converters 29, preferably of the bi-directional type, each configured to change input voltage values from an electrical power source 30 external to the warehouse 10 to usable input voltage values to the bi-directional converters 18 of the formation modules 16. The electrical converters 30 can be AC / DC or DC / DC converters or both types depending on the electrical conversion diagram to be implemented. The electrical converters 30 can be placed, alternatively or in combination, in appropriate electrical cabinets of the warehouse 10, in each drawer 26, in each formation module 16. In Figure 7 an electrical converter 30 placed in a drawer 26 has been schematized.

[0128] In any case, in each formation station 15 there is provided at least one electrical quick-coupling connector 31 electrically connected to the external electrical power source 30. Each drawer 26 comprises at least one electrical plug 32 configured to connect electrically with the electrical quick-coupling connector 31 . The electrical plug 32 electrically connects the electrical quick-coupling connector 31 with the bi-directional converters 18 of the formation modules 16 placed on the drawer 26. The electrical converters 29, depending on the placement position chosen, can be placed upstream of the electrical plug 32 or downstream of the electrical plug 32 (as in the example illustrated in Figure 7).

[0129] As schematically illustrated in Figure 2, the warehouse 10 comprises at least one service station 33 located at a maintenance level below the formation stations 15. The service station 33 is placed at a maintenance level that is directly reachable by maintenance operators. The service station 33 is open both towards the inner volume 14 of the warehouse 10 and towards the external environment. On the side facing the external environment, the service station 33 comprises an opening 34 directly accessible from the external environment. At the opening 34 there is provided a gate 35 configured to close in a controlled manner the opening 34 and inhibit access to the service station 33. Figure 2 schematically shows the gate 35 in open condition.

[0130] The transfer station 20 is located on a side wall of the warehouse other than the side wall on which the service station 33 is placed. Preferably, the transfer station 20 and the service station 33 are placed on mutually opposite side walls of the warehouse 10.

[0131] The drawers 26 are movable within the warehouse 10 to be able to be moved between the respective formation stations 15 and the service station 33, so that each drawer 26 can carry the formation modules 16 mounted thereon in the service station 33 to be able to perform maintenance operations on the formation modules 16.

[0132] In this regard, the transport system 22 of the warehouse 10 is also configured to transport one drawer 26 at a time between the respective formation station 15 and the service station 33 and between the service station 33 and the respective formation station 15.

[0133] The transport system 22 is configured to pick up each drawer 26 from the respective formation station 15 and to insert the drawer 26 into the service station 33 and to pick up a drawer 26 from the service station 33 and insert it into the respective formation station 15.

[0134] In this regard, the elevator 23 (schematized in Figure 4) comprises a resting structure 37 that picks up and supports a drawer 26 during its movement inside the warehouse 10. The elevator 23 is selectively configurable between a drawer 26 transport condition and a tray 1 1 transport condition. The platform 36 is slidably mounted in a horizontal direction on the resting structure 37. The platform 36 can be lifted in height with respect to the resting structure 37 and can be inserted into the resting structure 37. When the platform 36 is inserted into the resting structure 37, the elevator 23 is in a drawer 26 transport condition. When the platform 36 is placed elevated with respect to the resting structure 37, the elevator is in a tray 1 1 transport condition. Figure 4 schematically illustrates the elevator 23 in the drawer 26 transport condition which has just brought a drawer 26 from a formation station 15 (illustrated empty in Figure 4) to the service station 33.

[0135] As schematized in Figure 9, the warehouse 10 comprises a thermal conditioning system 40. The thermal conditioning system 40 is preferably a liquid conditioning system, wherein a conditioning liquid is heated or cooled to act as a heating or cooling agent. Such conditioning liquid may for example be demineralised, osmotised or distilled water. The thermal conditioning system 40 has the function of thermally conditioning at least the electrochemical cells 100 during the formation process, in such a way as to place the electrochemical cells 100 at predetermined and controlled temperatures.

[0136] The thermal conditioning system 40 comprises a warehouse conditioning circuit 41 . The thermal conditioning system 40 further comprises a fluid conditioner 42.

[0137] In the embodiment illustrated in Figure 9, the fluid conditioner 42 has been illustrated positioned within the warehouse 10. In other embodiments, the fluid conditioner 42 may be external to the warehouse 10. The fluid conditioner 42 may be any device capable of bringing the conditioning liquid of the thermal conditioning system 40 to a predetermined temperature, for example capable of cooling the conditioning liquid.

[0138] The warehouse conditioning circuit 41 has the function of bringing conditioning liquid at each formation station 15. For this purpose, the warehouse conditioning circuit 41 comprises a group of delivery hydraulic pipings 43 connecting the fluid conditioner 42 with each formation station 15 and a group of return hydraulic pipings 44 connecting each formation station 15 with the fluid conditioner 42, as schematized in Figure 9.

[0139] The warehouse conditioning circuit 41 further comprises delivery hydraulic connectors 45 and return hydraulic connectors 46 placed at each formation station 15. The delivery hydraulic connectors 45 and the return hydraulic connectors 46 are placed respectively on the group of delivery hydraulic pipings 43 and on the group of return hydraulic pipings 44. The delivery hydraulic connectors 45 and the return hydraulic connectors 46 are quick-coupling connectors, i.e. hydraulic connectors that can be connected to further hydraulic connectors and disconnected from said further hydraulic connectors without the need to use clamping tools. In each formation station 15 a plurality of delivery hydraulic connectors 45 and return hydraulic connectors 46 are provided, preferably in number equal to the number of formation modules 16 present in a drawer 26. Note that the transfer station 20 is not served by the thermal conditioning system 40. The service station 33 may, in some embodiments, be served by the thermal conditioning system 40 and comprise respective delivery hydraulic connectors 45 and return hydraulic connectors 46.

[0140] As schematized in Figure 10, each cell tray 1 1 comprises a tray conditioning circuit 47. The tray conditioning circuit 47 is preferably integrated into the cell tray 11 . The tray conditioning circuit 47 may for example comprise a heat exchanger. The tray conditioning circuit 47 comprises a delivery hydraulic connector 48 and a return hydraulic connector 49. The delivery hydraulic connector 48 is configured to hydraulically connect with one of the delivery hydraulic connectors 45 of the group of delivery hydraulic pipings 43. The delivery hydraulic connectors 48 and the return hydraulic connectors 49 are quick-coupling connectors.

[0141] The thermal conditioning system 40 may also be active on the formation modules 16 placed in the drawers 26 to thermally condition (usually to cool) the formation modules 16 when in use.

[0142] In this regard, as schematically illustrated in Figure 6, each formation module 16 comprises a formation module conditioning circuit 50. The formation module conditioning circuit 50 is preferably integrated into the formation module 16. The formation module conditioning circuit 50 may for example comprise a heat exchanger. The formation module conditioning circuit 50 comprises a delivery hydraulic connector 51 and a return hydraulic connector 52. The delivery hydraulic connector 51 is configured to connect hydraulically with the return hydraulic connector of the tray conditioning circuit 47. The return hydraulic connector 52 is configured to hydraulically connect with one of the return hydraulic connectors 46 of the group of return hydraulic pipings 44. The delivery hydraulic connectors 51 and the return hydraulic connectors 52 are quickcoupling connectors.

[0143] In use, to implement a method for at least partial forming electrochemical cells, a cell tray 1 1 reaches the transfer station 20 where it is picked up by the transport system 22. During this operation, the elevator 23 is configured in the cell tray 1 1 transport condition. The cell tray 1 1 is brought at a formation station 15 by moving inside the warehouse 10, in particular by moving in the inner volume 14 transported by the platform 36 of the elevator 23. When the cell tray 1 1 reaches the pre-chosen formation station 15, the cell tray 11 is inserted into the respective drawer 26. In the preferred embodiment of the invention, the cell tray 1 1 is inserted into the formation station 15 directly from the platform 36. During this operation, the cell tray 1 1 is coupled to a formation module 16 present in the drawer 20. As schematically depicted in Figure 4, each formation module 16 is configured to couple with a respective cell tray 1 1 . In particular, the electrochemical cells contained in the cell tray 1 1 are contacted by the contacting assembly 17 of the formation module 16. In this way the bi-directional converters 18 are in electrical contact with the electrochemical cells 100 to be formed. In each formation station 15 only one drawer 26 is provided.

[0144] In this condition, the formation modules 16 are electrically connected to the external electrical power source 30. In particular, the electrical plug 32 of the drawer 26 is connected to the electrical quick-coupling connector 31 of the formation station 15.

[0145] When the cell tray 1 1 is coupled to the formation module 16, the tray conditioning circuit 47 is hydraulically connected to the warehouse conditioning circuit 41 through one of the delivery hydraulic connectors 45 of the group of delivery hydraulic pipings 43. The tray conditioning circuit 47 is also connected to the formation module conditioning circuit 50.

[0146] The formation module 16 is then activated and the electrochemical cells 100 are subjected to the formation process. During the formation process, conditioning liquid is sent to the tray conditioning circuit 47 and therefrom to the formation module conditioning circuit 50.

[0147] At the end of the formation process, or in any case upon partial completion of the formation process (if necessary to implement a particular formation recipe), the cell tray 1 1 is extracted from the formation station 15. During this operation, the cell tray 1 1 is decoupled from the formation module 16 present in the drawer 20. The contacting assembly 17 of the formation module 16 is disconnected from the electrochemical cells 100 of the cell tray 1 1 . This operation is preferably carried out by the platform 36 of the elevator 23. During the extraction of the cell tray 1 1 from the formation station 15, the tray conditioning circuit 47 is hydraulically disconnected from the warehouse conditioning circuit 41 and the formation module conditioning circuit 50.

[0148] The transport system 22 carries the cell tray 1 1 at the transfer station 20. This operation is carried out by the platform 36 of the elevator 23 which supports and transports the cell tray 1 1 in the inner volume 14. When the cell tray 1 1 reaches the transfer station 20, the cell tray 1 1 is picked up by the elevator 23 and extracted from the warehouse 10.

[0149] In the event that it is necessary to carry out maintenance operations on a formation module 16 or on all the formation modules 16 of the same drawer 26, it is provided to bring the drawer 26 containing the formation module 16 to be maintained in the service station 33.

[0150] This operation can be carried out both in the event that some or all of the formation modules 16 of the drawer 27 are associated with cell trays 1 1 , and in the event that no formation module 16 of the drawer is associated with a cell tray 11 . The first case may for example happen when an unexpected event occurs, such as for example a thermal runaway of the electrochemical cells 100 of a cell tray 1 1 being formed. The second case may for example occur during a scheduled maintenance of the formation modules 16.

[0151] In the first case, it is provided to hydraulically disconnect the tray conditioning circuit 47 of each cell tray 1 1 present in the drawer 26 from the warehouse conditioning circuit 41. It is also provided to hydraulically disconnect all the formation module conditioning circuits 50 of the formation modules 16 placed in the drawer 26 from the warehouse conditioning circuit 41 .

[0152] In the second case it is provided to hydraulically disconnect all the formation module conditioning circuits 50 of the formation modules 16 placed in the drawer 26 from the warehouse conditioning circuit 41 .

[0153] In both cases it is also provided to electrically disconnect the formation modules 16 of the drawer 26 from the external electrical power source 30. This operation is carried out by disconnecting the electrical plug 32 from the electrical quickcoupling connector 31 of the formation station 15. Note that no formation module 16 of a further drawer 26 needs to be electrically disconnected from the external electrical power source 30. Thus, any formation process being executed by any formation module 16 placed on a different drawer 26 may continue without being interrupted. At this point, the transport system 22 positions the elevator 23 at the formation station 15 and picks up the drawer 26 with the relative formation modules 16 mounted thereon. This operation is carried out with the elevator 23 in the drawer 26 transport condition. The transport system 22 moves the elevator 23 with the drawer 26 at the service station 33. At this point, the transport system 22 positions the drawer in the service station 33. An electrical quick-coupling connector 31 identical to those provided in the formation stations 15 is provided in the service station 33. If necessary, the electrical plug 32 can be connected to the electrical quick-coupling connector 31 of the service station 33.

[0154] The formation modules 16 mounted on the drawer 26 can be subjected to maintenance operations. This operation can be carried out without interrupting any formation process being executed by any formation module 16 placed on a drawer 26 inserted in any formation station 15.

[0155] At the end of the maintenance, the transport system 22 picks up, through the elevator 23, the drawer 26 and the formation modules 16 mounted therein from the service station 33. At this point, the transport system 22 positions the elevator 23 at the formation station 15 from which the drawer 26 had been picked up. The transport system 22 then positions the drawer 26 in the formation station 15. During the positioning of the drawer 26 in the formation station 15 it is provided to electrically connect the formation modules 16 of the drawer 26 to the external electrical power source 30. This operation is carried out by connecting the electrical plug 32 to the electrical quick-coupling connector 31 of the formation station 15. During the positioning of the drawer 26 in the formation station 15 it is provided to hydraulically connect all the formation module conditioning circuits 50 of the formation modules 16 placed in the drawer 20 to the warehouse conditioning circuit 41 .

[0156] The formation modules 16 are thus ready to receive tray drawers 1 1 and implement formation processes on the electrochemical cells 100.

Claims

CLAIMS1. Warehouse (10) for the formation of electrochemical cells, comprising a containment structure (12) with an inner volume (14) wherein they are housed: a plurality of formation stations (15); a plurality of formation modules (16) each of which is configured to be coupled to a cell tray (1 1 ) to implement an at least partial formation cycle of electrochemical cells (100) contained in said cell tray (1 1 ); at least one transfer station (20) configured to interface between said inner volume (14) of said containment structure (12) and an environment external to said inner volume (14) of said containment structure (12) and to receive cell trays(1 1 ) from said external environment or, or in combination, to deliver cell trays (1 1 ) from said inner volume (14) to said external environment; a transport system (22) configured to transfer cell trays (1 1 ) containing electrochemical cells (100) between the transfer station (20) and each formation station (15) and between each formation station (15) and said transfer station (20); wherein at least one formation module (16) of that plurality of formation modules (16) is placed in each formation station (15).

2. Warehouse (10) according to claim 1 , wherein said transport system (22) comprises a elevator (23) configured to receive and transport at least one tray of cells (1 1 ) and vertical guides (24) to which the elevator (23) is slidably connected; said vertical guides (24) developing vertically within the containment structure(12) and reaching in height all the formation stations (15).

3. Warehouse (10) according to any one of the preceding claims, wherein said formation stations (15) are arranged one on top of the other in at least one column of formation stations (15); said transfer station (20) being located below said formation stations (15).

4. Warehouse (10) according to any one of the preceding claims, wherein a plurality of formation modules (16) are placed at each formation station (15).

5. Warehouse (10) according to any one of the preceding claims, wherein each formation module (16) comprises a contacting assembly (17) configured to provide an electrical contact for each of said electrochemical cells (100) housed in a cell tray (1 1 ) and at least one bi-directional converter (18) in electricalconnection with said contacting assembly (17).

6. Warehouse (10) according to claim 5, comprising an electrical power supply unit (28) comprising a plurality of electrical converters (29) for changing input voltage values from an electrical power source (30) external to the containment structure (12) to usable input voltage values to the bi-directional converters (18) of the formation modules (16).

7. Warehouse (10) according to claim 6, wherein each formation station (15) comprises at least one electrical connector (31 ) electrically connectable to said electrical power source (30) external to said containment structure (12); each bidirectional converter (18) of each formation module (16) placed in a formation station (15) being electrically connected to said electrical connector (31 ).

8. Warehouse (10) according to any one of the preceding claims, wherein a plurality of drawers (26) are housed in said inner volume (14), wherein at least one of said drawers (26) is inserted in each formation station (15); a plurality of formation modules (16) being mounted on each drawer (26).

9. Warehouse (10) according to claims 7 and 8, wherein each drawer (26) comprises at least one electrical plug (32) configured to connect electrically with the electrical connector (31 ) of a respective formation station (15); said electrical plug (32) electrically connecting the electrical connector (31 ) with the bidirectional converters (18) of the formation modules (16) mounted in the drawer (26).

10. Warehouse (10) according to any one of the preceding claims, comprising a thermal conditioning system (40) configured to thermally condition cell trays (1 1 ) placed in the formation stations (15).

11. Warehouse (10) according to claim 10, wherein said thermal conditioning system (40) comprises a fluid conditioner (42) and a warehouse conditioning circuit (41 ) placed in hydraulic connection with said fluid conditioner (42) and configured to supply conditioned fluid to said formation station (15).

12. Warehouse (10) according to claim 16, wherein said thermal conditioning system (40) further comprises a formation module conditioning circuit (50) foreach formation module (16) configured to thermally condition the formation module (16); each formation module conditioning circuit (50) being hydraulically connectable with said warehouse conditioning circuit (41 ).

13. Warehouse (10) according to claim 8, wherein at least one service station (33) is placed in said inner volume (14); each drawer (26) being movable within said containment structure (12), together with the formation modules (16) mounted thereon, between the respective formation station (15) and said at least one service station (33).

14. Warehouse (10) according to claim 13, wherein said service station (33) comprises an opening (34) to expose a drawer (26), when placed in the service station (33), to an environment external to the inner volume (14) of said containment structure (12).

15. Warehouse (10) according to claim 13, wherein the formation stations (15) of said plurality of formation stations are placed above said service station (33).

16. Warehouse (10) according to claim 14, wherein said service station (33) is placed along a wall of said warehouse other than a wall along which said transfer station (20) is placed.

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