Method and apparatus for forming electrochemical cells for battery production

Abstract

A method for forming electrochemical cells (1) for battery production comprises the steps of housing a plurality of electrochemical cells (1) in a container (3), and arranging a power device (5) comprising a compacting assembly of electrochemical cells and an electronic control unit (8) configured to activate at least partially the electrochemical cells. The method further involves coupling the power device (5) to the container (3) in a first coupling station (20), electrically powering the power device (5) in an activation station (36) to activate the electrochemical cells, decoupling the container (3) coupled to the power device (5) in a first decoupling station (40) spaced out from said first coupling station (20).

Description

[0001] Method and apparatus for forming electrochemical cells for battery production

[0002] The present invention relates to a method for carrying out the process of forming electrochemical cells within a battery production process.

[0003] The present invention also relates to an apparatus particularly configured to effectively implement the aforesaid method.

[0004] The present invention applies preferably, though not exclusively, to the production of secondary batteries, e.g. lithium-ion batteries, which will be referred to hereinafter without losing generality.

[0005] As known, the production of electrochemical cells involves, in wider terms:

[0006] - a step of mechanically building the electrochemical cell, wherein a winding of electrodes of a predefined shape and size is made, and wherein this winding is inserted into a specific protective outer casing,

[0007] - a step of filling the electrochemical cell with an electrolyte solution, and finally,

[0008] - a step of forming the electrochemical cell to make it suitable for delivering and / or storing electrical energy.

[0009] In particular, this last step involves one or more electrochemical cell charge and discharge operations by supplying modulated voltages or currents, thanks to which electrochemical phenomena are induced within the electrochemical cell, leading to the formation of a solid electrolyte interface at the electrodes.

[0010] The formation of this interface is essential to define and optimise the properties of the electrochemical cell in terms of both charge capacity and uniformity of successive charge and discharge cycles.

[0011] In a known process, the electrochemical cells to be subjected to the formation process are inserted into a container provided with special housing seats that allows to transport them all together with a predefined orientation and position. The container generally has no lid so that the electrochemical cells are freely accessible from above.

[0012] The container with the electrochemical cells is then taken to an activation station where it is engaged by special equipment that supplies (or draws from) each electrochemical cell with a voltage or current modulated according to a predefined charge and discharge pattern.

[0013] For this purpose, the equipment comprises a contacting assembly, configured to make electrical contact with each electrochemical cell, a power supply group and a control unit that defines the timing and modes of the charge and discharge steps of the electrochemical cells.

[0014] Typically, the equipment contacting assembly is mounted on a frame and can move vertically so that it can be lowered onto the container, suitably placed underneath it, and come into contact with the electrochemical cells housed in the container.

[0015] Thus, charge and discharge cycles of the electrochemical cells can be carried out, upon completion of which the contacting assembly is lifted from the electrochemical cells, allowing the entire container containing them to be moved to a subsequent work station, typically an aging station, as better explained below.

[0016] In this description as well as in the accompanying claims, some terms and expressions are deemed to assume, unless otherwise expressly indicated, the meaning set forth in the following definitions.

[0017] Two components, such as a container and a power device or a control device, are "coupled" to each other when they are held in a fixed proximity condition. These components are preferably, but not necessarily, kept in contact with each other.

[0018] These components can be provided with elements that can maintain this proximity condition, such as mechanical hooking elements, or they can be maintained in a proximity condition by an external element.

[0019] A "shelf" of a cabinet refers to a location within a cabinet arranged to house an object, e.g. a container or drawer.

[0020] A shelf can be a ledge on which this object can be placed, or a supporting element, such as guides that can engage and hold a container or drawer within the cabinet in a certain position.

[0021] A "drawer" of a cabinet refers to an element arranged to be placed in a cabinet shelf and movable in relation to that shelf. The drawer is further configured to support or engage one or more containers so as to move them from and to a shelf and hold them in place on that shelf.

[0022] An electrochemical cell "formation" process or step refers to the set of operations to which an electrochemical cell is subjected in order to form a solid electrolyte interface in correspondence of at least one of its electrodes.

[0023] These operations generally comprise one or more steps for electrically charging and subsequently discharging the electrochemical cell, followed or alternated with a maturing or consolidation step during which the electrochemical cell is left to rest for an appropriate amount of time so as to allow the completion of the aforesaid solid electrolyte interface.

[0024] The first step of the formation process, wherein electrical energy is delivered to the electrochemical cells by means of successive charge and discharge cycles, is referred to hereinafter as "activation".

[0025] It should be noted that in the relevant technical field, the term "formation" is also sometimes used to indicate only this first step of the process, but for the sake of clarity, it is preferred herein to use separate terms to indicate the step of applying the charge / discharge cycles and to indicate the entire process for forming the solid electrolyte interface within the electrochemical cell.

[0026] The subsequent maturing or consolidation step is identified hereinafter by the term "aging", more commonly used in the relevant technical field.

[0027] The formation process is thus formed by the activation step and the ageing step. These steps may be distinct and separate, scheduled one after the other, but in some types of formation processes it is envisaged that they may be interspersed with each other, e.g. by providing a first activation step followed by a first aging step followed by a second activation step and a second aging step.

[0028] The Applicant preliminarily noted that the electrochemical cell formation process represents a particularly critical step within the battery production cycle, due to the very long times required in both the activation step and the subsequent aging step. The activation step can, in fact, last as long as 10 - 12 hours while the aging step normally lasts several days, e.g. 10 - 12 days.

[0029] The Applicant thus ascertained that in an industrial battery production process, wherein several thousands of electrochemical cells per hour can be packed, enormous space is required to store the electrochemical cells for the time necessary for their formation process.

[0030] The Applicant therefore realised that improving the formation process in terms of time and layout would have a major positive impact on the entire production cycle.

[0031] In this perspective, the Applicant noted that, in the known process outlined above, the activation step of the electrochemical cells appears to be particularly cumbersome.

[0032] In particular, the Applicant observed that several operations are carried out in the activation station: the lowering of the contacting assembly onto the electrochemical cells housed in the container, the charge and discharge cycles of the electrochemical cells and the subsequent lifting of the contacting assembly away from the electrochemical cells.

[0033] Based on these observations, the Applicant realised that by carrying out the step of coupling the contacting assembly with the electrochemical cells, or the step of separating the contacting assembly from the electrochemical cells, at a position in the plant other than the activation station where the cells are subjected to charge and discharge cycles, the activation station would be occupied by a single container for a shorter time, increasing the production capacity of the activation station.

[0034] The Applicant, on the basis of this intuition, has therefore developed a power device provided with a contacting assembly and the necessary electronic components to control the activation step of the electrochemical cells, but separate and independent from the power supply system, so that it can be coupled and decoupled from the container in any position of the plant without necessarily having to be positioned in the activation station, leaving the latter available for the activation step of the electrochemical cells.

[0035] The Applicant has finally found that a process of coupling a container housing the electrochemical cells to be activated with a power device in a coupling station as described above, then electrically powering the power device in an activation station to at least partially activate the electrochemical cells, and finally decoupling the container from the power device in a decoupling station spaced out from the coupling station, allows to leave the activation station available for the activation step of the electrochemical cells.

[0036] Therefore, the present invention, in a first aspect thereof, relates to a method for forming electrochemical cells for battery production.

[0037] Preferably, this method comprises the step of housing a plurality of electrochemical cells in a container.

[0038] Preferably, this method comprises the step of arranging a power device comprising a contacting assembly, which is preferably configured to provide an electrical contact for each electrochemical cell of said plurality of electrochemical cells housed in said container.

[0039] Preferably, the power device comprises an electronic control unit configured to apply a modulated voltage or current to said electrochemical cells such that said electrochemical cells are at least partially activated. More preferably, said modulated voltage or current is applied by means of said contacting assembly and at least one bidirectional power supply.

[0040] Preferably, this method comprises the step of coupling said power device to said container in a first coupling station.

[0041] Preferably, this method comprises the step of electrically powering said power device within an activation station so as to subject said electrochemical cells to said modulated voltage or current and at least partially form said electrochemical cells.

[0042] Preferably, this method comprises the step of decoupling said container from said power device in a first decoupling station.

[0043] Preferably, said first decoupling station is spaced out from said first coupling station.

[0044] Thanks to these characteristics, the method proposed by the present solution allows to manage the two steps of coupling and decoupling the container and the power device in separate positions, so as to take advantage of the time during which the container and the power device occupy the activation station. Furthermore, on the other hand, this method allows to manage individual power devices without affecting the entire activation step. For example, individual power devices can be subjected to maintenance without necessarily having to intervene in the activation station, thus limiting downtime.

[0045] The present invention, in a second aspect thereof, relates to an apparatus for forming electrochemical cells for battery production.

[0046] Preferably, the apparatus comprises a plurality of containers each configured to house a respective plurality of electrochemical cells to be formed.

[0047] Preferably, the apparatus comprises a first coupling station, arranged to couple a power device to each container containing said plurality of electrochemical cells.

[0048] Preferably, said power device is provided with a contacting assembly configured to provide an electrical contact for each electrochemical cell of said plurality of electrochemical cells housed in said container.

[0049] Preferably, said power device is provided with an electronic control unit configured to apply to said electrochemical cells, by means of said contacting assembly and at least one bidirectional power supply, a modulated voltage or current so as to allow the at least partial activation of said electrochemical cells. Preferably, the apparatus comprises at least one activation station arranged to house at least one of said containers coupled to said power devices.

[0050] Preferably, said activation station is arranged to electrically power said power device so that it can at least partially activate the electrochemical cells housed in said at least one container.

[0051] Preferably, the apparatus comprises a first decoupling station arranged to decouple each container from its respective power device.

[0052] Preferably, said first decoupling station is spaced out from said first coupling station.

[0053] Preferably, the apparatus comprises a transport system arranged to move said containers successively from said first coupling station to said decoupling station.

[0054] Thanks to these features, the apparatus of the present invention allows to effectively implement the method described above, thereby benefiting from its advantages.

[0055] A further advantage, also substantially resulting from the separation of the two steps, is greater flexibility in the design of the plant layout.

[0056] The present solution, in at least one of the aforementioned aspects, may have at least one of the further preferred features set forth below.

[0057] In some embodiments, said power device, once decoupled from said container, is returned to said first coupling station to be coupled to another container.

[0058] Thus, the power device is put back into circulation ensuring the operational continuity of the production plant.

[0059] At the same time, the power device, once decoupled from the container, can be easily removed from the production cycle, e.g. for a maintenance operation, and replaced by another power device without negatively affecting the activation process of the electrochemical cells.

[0060] It will be noted that the container and the power device, when coupled together, form an individually manipulable unit, in other words they are integrally constrained to each other so that they can be transported, held, supported as if they were a single component.

[0061] In some embodiments, said first coupling station is spaced out from said activation station.

[0062] Preferably, said method comprises the step of moving said container coupled to said power device from said first coupling station to said activation station. Thus, the coupling operation between the power device and the container and the activation operation of the electrochemical cells are carried out at separate points in the system.

[0063] In some embodiments, said first decoupling station is spaced out from said activation station.

[0064] Preferably, said method comprises the step of moving said container coupled to said power device from said activation station to said first decoupling station. Thus, the decoupling operation between the power device and the container and the electrochemical cell activation operation are carried out at separate points in the system.

[0065] In a preferred embodiment, the activation station is spaced out from both the first coupling station and the first decoupling station.

[0066] In some embodiments, said activation station is defined within an activation cabinet.

[0067] In some embodiments, said activation cabinet is closed by external walls and comprises an opening for the inlet and / or outlet of said container.

[0068] Thus, the activation station is better protected and the internal environment easier to control.

[0069] Preferably, said activation cabinet is provided with shelves and said activation station is defined in one of said shelves.

[0070] Preferably, said power device coupled to said container is connected to a power supply group when housed on one of said shelves.

[0071] Preferably, the electrical connection between said power device and said power supply group is of a removable type, e.g. plug-in or swipe.

[0072] Preferably, said activation cabinet is provided with one or more power supply groups associated with said shelves and arranged to electrically power said power devices when housed in said shelves.

[0073] In some embodiments, at least 80% of the shelves of said activation cabinet, more preferably all the shelves of said activation cabinet, represent activation stations for containers coupled to respective power devices.

[0074] It will be appreciated that, at least when the coupling and decoupling stations are spaced out from the activation station, the shelves can be sized so as to house the containers coupled to the respective power devices with no need for additional space (e.g. in height) to allow for the movement of the power device from and to the container being coupled. Preferably, said activation cabinet comprises a transport member arranged to carry said container from and to said shelves.

[0075] For example, said transport member may comprise a lift capable of engaging and / or supporting the container coupled to the power device, lifting it to the designated shelf, and eventually inserting it within the shelf.

[0076] In some embodiments, at least one of said shelves is sized to house a single container coupled to said power device.

[0077] Thus, each container can be placed directly on the respective shelf defining the activation station.

[0078] Preferably, each shelf of said cabinet is sized to house a single container coupled to said power device.

[0079] In some embodiments, a respective drawer is housed in each of said shelves. Preferably, said drawer is sized to support a predefined number of said containers coupled to said power devices.

[0080] In these embodiments, each shelf is sized to house several containers coupled to their respective power devices, and the provision of a drawer associated with the shelf facilitates the handling and positioning of individual containers from and to the shelf.

[0081] In some embodiments, said drawer can be pulled out of and inserted into said activation cabinet.

[0082] Preferably, said method comprises the step of placing a predefined number of said containers coupled to said power devices in said drawer outside said activation cabinet.

[0083] Preferably, said method comprises the step of moving said drawer with said containers coupled to said power devices to a shelf of said activation cabinet.

[0084] Thus, the correct positioning of the containers coupled to the respective power devices can be done outside the activation cabinet, thus reducing the handling of components within the activation cabinet.

[0085] In some embodiments, said containers coupled to said power devices are positioned in said drawer at said first coupling station.

[0086] Thus, the plant layout required for the coupling of power devices and their respective containers and their positioning on the drawers is minimised.

[0087] In an alternative embodiment, said containers coupled to said power devices are placed in said drawer downstream of said first coupling station.

[0088] In some embodiments, said containers coupled to said power devices are removed from said drawer outside said activation cabinet.

[0089] In some embodiments, said first coupling station is defined within said activation cabinet.

[0090] In some embodiments, said first coupling station is defined at the inlet of said activation cabinet.

[0091] Thus, the path required to move the containers coupled to the respective power devices is minimised.

[0092] Thus, furthermore, both the coupling operation between the container and the power device and the subsequent activation operation can take place within the activation cabinet, even if in separate positions thereof.

[0093] For example, it can be provided that the coupling takes place at the base level of the activation cabinet and then the container and power device are lifted to one of the upper shelves for the activation operation.

[0094] Therefore, in this case, the container is transported to the activation cabinet where it is coupled to the power device and where it is subsequently moved, remaining inside the activation cabinet, to its own activation station.

[0095] In some embodiments, said first decoupling station is defined within said activation cabinet.

[0096] In some embodiments, said first decoupling station is defined at the outlet of said activation cabinet.

[0097] Thus, the return path of power devices from the first decoupling station to the first coupling station is minimised.

[0098] In some embodiments, said power device is mechanically connected to a drawer of said activation cabinet.

[0099] In some embodiments, each drawer is provided with several power devices.

[0100] In some embodiments, said power device is permanently constrained with said drawer.

[0101] In these embodiments, it may be preferred that said container be coupled to said power device by moving said container towards said drawer.

[0102] In other embodiments, said power device is constrained to the drawer by means of a mechanical connection that allows a relative movement between said power device and said drawer.

[0103] In these embodiments, it may be preferred that said container be coupled to said power device by moving said power device from said drawer towards said container. In other embodiments, said power device is movable in relation to said drawer between an open position in which the power device (or power devices) is spaced out from the drawer to allow placing containers on the drawer, and a closed position in which the power device (or power devices) is coupled to the containers placed on the drawer.

[0104] Thus, the drawer, containers and power device (or power devices) form an individually manipulable unit.

[0105] The type of mechanical constraint between the drawer and the power device can consist, for example, of a hinge joint or a coupling which can slide linearly. In some embodiments, said container, once decoupled from said power device, is moved to an aging station.

[0106] Preferably, the electrochemical cells are left to rest for a predetermined aging time in said aging station in order to continue and / or complete their formation process.

[0107] In some embodiments, said container, before being moved to said aging station, is coupled to a control device of said electrochemical cells.

[0108] Preferably, said control device comprises at least one temperature sensor, configured to detect the temperature of at least one of said electrochemical cells, more preferably of each electrochemical cell housed in said container.

[0109] Thus, the temperature of at least one or each of the electrochemical cells is detected without having to move the entire container from the aging station.

[0110] This makes it possible to control this parameter with a very high measuring frequency, even continuously, so as to act promptly in the event of unwanted overheating of one or more electrochemical cells during this step.

[0111] Preferably, said control device comprises at least one circuit measuring the open circuit voltage (OCV) of at least one of said electrochemical cells, more preferably of each electrochemical cell housed in said container.

[0112] Thus, the open circuit voltage of at least one or each of the electrochemical cells is detected without having to move the entire container from the aging station. As in the previous case, this makes it possible to control this parameter with a very high measuring frequency, even continuously, so as to act promptly in the event of anomalies.

[0113] In some embodiments, said control device is coupled to said container after said container has been decoupled from said power device.

[0114] Thus, the container is firstly coupled to a power device and then, at the end of the activation step and before starting the aging step, it is coupled to a control device.

[0115] Preferably, said control device is coupled to said container in a second coupling station.

[0116] In some embodiments, the second coupling station is provided downstream of the first decoupling station.

[0117] Preferably, the second coupling station is at least partially integrated with the first decoupling station, so that the two operations of decoupling from the power device and the subsequent coupling to the control device, enabling to replace the devices coupled to the container, are carried out at the same location, one after the other.

[0118] In some alternative embodiments, said control device is coupled to said container before said power device is coupled to said container, so as to be interposed between said power device and said container.

[0119] Thus, at the end of the activation step, it is sufficient to decouple the power device, leaving only the control device coupled to the container, so that the container can then be moved directly to the aging station.

[0120] Of course, in this case, the control device will be configured so as to allow the contacting assembly of the power device to make electrical contact with the electrochemical cells housed in the container on the side opposite the control device.

[0121] Furthermore, in this case, the second coupling station is provided upstream of the first coupling station.

[0122] In certain embodiments, at least one of the temperature and open circuit voltage (OCV) of each of said electrochemical cells housed in said container is detected by said control device while said container is held stationary within said aging station.

[0123] In some embodiments, at the end of said aging time, said container is moved from said aging station and said control device is decoupled from said container. Preferably, said control device is decoupled from said container in a second decoupling station.

[0124] Preferably, said control device, once decoupled from said container, has returned to said second coupling station.

[0125] In some embodiments, said aging station is defined within an aging cabinet.

[0126] In some embodiments, said aging cabinet is closed by external walls and comprises an opening for the inlet and / or outlet of said container.

[0127] Thus, the aging station is better protected and the internal environment easier to control.

[0128] Preferably, said aging cabinet is provided with shelves and said aging station is defined in one of said shelves.

[0129] Preferably, said control device coupled to said container is connected to a power supply group when housed on one of said shelves.

[0130] Preferably, the electrical connection between said control device and said power supply group is of a removable type, e.g. plug-in or swipe.

[0131] Preferably, said aging cabinet is provided with one or more power supply groups associated with said shelves and arranged to electrically power said control devices when housed in said shelves.

[0132] In some embodiments, at least 80% of the shelves of said aging cabinet, more preferably all the shelves of said aging cabinet, represent aging stations for containers coupled with respective control devices.

[0133] Preferably, said aging cabinet comprises a transport device arranged to carry said container from and to said shelves.

[0134] In some embodiments, at least one of said shelves is sized to house a single container coupled to said control device.

[0135] Preferably, each shelf of said aging cabinet is sized to house a single container coupled to said control device.

[0136] In some embodiments, a respective drawer is housed in each of said shelves, which is preferably sized to support a predefined number of said containers coupled to said control devices.

[0137] In some embodiments, the drawers of said aging cabinet can be pulled out of and inserted into said aging cabinet.

[0138] Preferably, the drawers of said aging cabinet are interchangeable with the drawers of said activation cabinet.

[0139] Thus, the drawers can be used to support the containers both in the activation station and in the subsequent aging station without having to move the containers from one drawer to another.

[0140] In some embodiments, said second coupling station is defined within said aging cabinet.

[0141] In some embodiments, said second coupling station is defined at the inlet of said aging cabinet. Thus, the path required to move the containers coupled to the respective control devices is minimised.

[0142] In some embodiments, said second decoupling station is defined within said aging cabinet.

[0143] Thus, both the coupling operation between the container and the control device and the subsequent aging operation can take place within the aging cabinet, even if in separate locations therein.

[0144] In some embodiments, the aging cabinet has one or more of the characteristics described above with reference to the cabinet wherein the activation station is defined.

[0145] In some embodiments, the apparatus comprises an insertion station, which is arranged to insert a respective plurality of electrochemical cells into said containers.

[0146] Preferably, said insertion station is positioned downstream of said coupling station.

[0147] In some embodiments, an outlet station is provided downstream of said second decoupling station, wherein the formed electrochemical cells are pulled out of said container.

[0148] Preferably, said container has returned to said insertion station.

[0149] It should be specified that some steps of the method described above may be independent of the order of execution reported. Furthermore, some steps may be optional. Furthermore, some steps of the method may be performed repetitively, or may be performed in series or in parallel with other steps of the method.

[0150] In a further aspect, the present solution relates to a method for forming electrochemical cells for battery production.

[0151] Preferably, this method comprises the step of housing a plurality of electrochemical cells in a container.

[0152] Preferably, this method comprises the step of arranging a power device comprising a contacting assembly, which is preferably configured to provide an electrical contact for each electrochemical cell of said plurality housed in said container.

[0153] Preferably, the power device comprises an electronic control unit configured to apply a modulated voltage or current to said electrochemical cells such that said electrochemical cells are at least partially activated. More preferably, said modulated voltage or current is applied by means of said contacting assembly and at least one bidirectional power supply.

[0154] Preferably, this method comprises the step of coupling said power device to said container in a first coupling station.

[0155] Preferably, this method comprises the step of moving said container coupled to said power device to an activation station.

[0156] Preferably, said method comprises the step of electrically powering said power device within said activation station so as to subject said electrochemical cells to said modulated voltage or current and at least partially form said electrochemical cells.

[0157] Preferably, this method comprises the step of pulling said container coupled to said power device out of said activation station.

[0158] Preferably, this method comprises the step of moving said container coupled to said power device to a first decoupling station.

[0159] Preferably, this method comprises the step of decoupling said container from said power device in said first decoupling station.

[0160] Thanks to these characteristics, the method according to this further aspect of the present solution allows to efficiently and independently manage the two steps of coupling the container (or, more precisely, between the electrochemical cells contained therein) to the power device, and activating the electrochemical cells resulting from the subsequent power supply of the power device.

[0161] This separation of the steps makes it possible, for example, to increase the space available to the containers within the activation station, as their footprint, when already coupled to their respective power devices, is significantly smaller than the footprint of the current equipment, which requires the space and structure necessary for the coupling operation.

[0162] Furthermore, on the other hand, this method allows to manage individual power devices without affecting the entire activation step. For example, individual power devices can be subjected to maintenance without necessarily having to intervene in the activation station, thus limiting downtime.

[0163] In a further aspect, the present solution relates to a method for forming electrochemical cells for battery production.

[0164] Preferably, this method comprises the step of arranging a plurality of containers. Preferably, a plurality of electrochemical cells to be formed are housed in each container. Preferably, this method comprises the step of arranging a plurality of power devices.

[0165] Preferably, each power device comprises a contacting assembly, which is preferably configured to provide an electrical contact for each electrochemical cell of said plurality of electrochemical cells housed in said container.

[0166] Preferably, the power device comprises an electronic control unit configured to apply a modulated voltage or current to said electrochemical cells such that said electrochemical cells are at least partially activated. More preferably, said modulated voltage or current is applied by means of said contacting assembly and at least one bidirectional power supply.

[0167] Preferably, this method comprises the step of moving a first power device of said plurality of power devices to a first coupling station.

[0168] Preferably, this method comprises the step of coupling said first power device to a first container of said plurality of containers in said first coupling station. Preferably, this method comprises the step of moving a second power device of said plurality of power devices to said first coupling station.

[0169] Preferably, this method comprises the step of coupling said second power device to a second container of said plurality of containers in said first coupling station. Thanks to these features, the method according to this further aspect of the present solution allows to manage more efficiently power devices without affecting the entire activation step. For example, individual power devices may be subjected to maintenance without necessarily having to stop the activating station, thus limiting downtime.

[0170] The features and advantages of the present solution will become clearer from the detailed description of an embodiment thereof shown, by way of non-limiting example, with reference to the appended drawings, wherein:

[0171] - Figure 1 is a schematic plan view from above of a first embodiment of an apparatus for forming electrochemical cells for battery production made according to the present invention;

[0172] - Figure 2 is a schematic illustration representing the sequence of operational steps that take place in the apparatus of Figure 1;

[0173] - Figure 3 is a schematic view of some components of the apparatus in Figure 1, namely a container, a power device and a control device, in a coupled and decoupled condition; - Figure 4 is a schematic plan view from above of a second embodiment of an apparatus for forming electrochemical cells for battery production made according to the present invention;

[0174] - Figures 5 and 6 are schematic frontal views of respective components of the apparatus of Figure 4 at specific moments in the formation process;

[0175] - Figure 7 is a schematic plan view from above of a third embodiment of an apparatus for forming electrochemical cells for battery production made according to the present invention;

[0176] - Figure 8 is a schematic plan view from above of a fourth embodiment of an apparatus for forming electrochemical cells for battery production made according to the present invention,

[0177] - Figures 9 and 10 are schematic elevated frontal views of a component of the apparatus in Figure 8, specifically an activation cabinet, at successive moments in the formation process,

[0178] - Figure 11 is a cross-sectional schematic view of the component of Figure 10.

[0179] Referring initially to Figures 1 to 3, a first example of an apparatus for forming electrochemical cells for battery production made according to the present invention is collectively referred to as 100.

[0180] The forming apparatus 100 is arranged to receive electrochemical cells 1, for example coming from an upstream, non-represented packaging plant, and to subject them to a formation process in order to obtain electrochemical cells formed and ready to be used to deliver electrical energy.

[0181] In the preferred example described herein, electrochemical cells 1 are secondary, cylindrical, lithium-ion electrochemical cells.

[0182] The apparatus 100 comprises, in its most general units, an insertion station 10, a first coupling station 20, an activation area 30, a first decoupling station 40, a second coupling station 50, an aging area 60, a second decoupling station 70 and an outlet station 80.

[0183] A transport system comprehensively denoted by 90 leads the electrochemical cells 1 along the aforesaid stations and areas in the terms specified below.

[0184] At the insertion station 10, conveniently arranged at the inlet of the apparatus 100, the electrochemical cells 1 to be formed are placed in special containers 3. The containers 3 are substantially identical to each other and comprise a plurality of seats 4 configured to house and support a respective plurality of electrochemical cells 1 according to a predefined vertical orientation.

[0185] The containers 3 have a generic box shape delimited by a base and side walls and without a cover, so as to leave the upper ends of each electrochemical cell 1 exposed at one of its poles.

[0186] The containers 3 are further preferably provided with a conducting circuit that electrically connects the bottom of each seat 4, at the other pole of the electrochemical cell 1 with the upper edge of the side walls of the container 3.

[0187] The insertion station 10 is preferably served by one or more robots 11, e.g. of the pick-and-place type, configured to pick up the electrochemical cells 1 from a conveyor 12 and place them in the seats 4 of each container 3.

[0188] In the coupling station 20, placed immediately downstream of the insertion station 10, each container 3 is coupled to a power device 5, as schematically represented in Fig. 3 in combination (al).

[0189] The power device 5 comprises a contacting assembly 6 configured to provide an electrical contact for each electrochemical cell 1 housed in the container 3. This electrical contact is provided directly by contact of the contacting assembly 6 with the upper free pole of the electrochemical cell 1 and indirectly by contact between the contacting assembly and the conducting circuit provided on the container 3 in contact with the pole resting on the bottom of the housing 4.

[0190] The power device 5 further comprises an electronic control unit 8 configured to apply a modulated voltage or current to the electrochemical cells 1, by means of the contacting assembly 6 and at least one bidirectional power supply, so as to allow the activation of the electrochemical cells 1.

[0191] The containers 3 coupled to the respective power devices 5 are moved to the activation area 30 by a carrier 91 of the transport system 90.

[0192] The carrier 91 can be represented by a carriage 92 moving on rails 93, as visible in Figures 9 to 11, or by an automatic guided vehicle (AGV) or belt conveyor or any other suitable transport system.

[0193] The activation area 30 comprises a plurality of activation cabinets 31, substantially identical to each other, within which the step of activating the electrochemical cells 1 takes place.

[0194] Each activation cabinet 31 is delimited externally by walls 32 and access to its inner space is provided by an opening 33, obtained at the base of the activation cabinet 31 and sized to allow the inlet and outlet of the containers 3 coupled to the respective power devices 5.

[0195] The activation cabinet 31 comprises therein a plurality of shelves 34, arranged, for example, overlapped in two or more columns, and a lift 35 configured to support a container 3 and carry it to the designated shelf 34.

[0196] In this embodiment, the containers 3 are sized to occupy an entire shelf 34.

[0197] Each activation cabinet 31 is further provided with one or more power supply groups (not shown) arranged to be connected to the power devices 5 when the respective containers 3 are placed on a shelf 34.

[0198] For this purpose, plug-in or sliding contacts are provided on the shelf 34 to allow for the electrical connection between the power supply group and the power device 5.

[0199] The location of the container 3 coupled to the power device 5 connected to the power supply group defines an activation station 36 of the electrochemical cells 1 housed in the container 3 within the activation cabinet 31.

[0200] In this embodiment, all the shelves 34 of the activation cabinet 31 are arranged to house a container 3 and to supply the respective power device 5 coupled to the container 3, so that, as such, each shelf 34 can be identified as an activation station 36.

[0201] The containers 3 coupled to the respective power devices 5 leaving the activation area 30 are moved by the carrier 91 to the first decoupling station 40 where the power devices 5 are decoupled from the respective container 3, e.g. by means of a robotic arm 41.

[0202] The power devices 5 decoupled from the containers 3 are then led back to the first coupling station 20, e.g. by a carrier 94, where it is made available for coupling to a new container 3.

[0203] The containers 3 separated in the first decoupling station 40, on the other hand, are led to the aging area 60, where the electrochemical cells 1, already activated, are left to rest for an appropriate aging time to complete the process for forming the solid electrolyte interface triggered in the previous activation step.

[0204] However, before entering the aging area 60, the containers 3 are coupled to a control device 7, as schematically represented in Fig. 3 in combination (a2), at the second coupling station 50, which is conveniently placed immediately downstream of the first decoupling station 40.

[0205] In practice, the first decoupling station 40 and the second coupling station 50 can have common locations and equipment, so that the power device 5 is immediately replaced in coupling on the container 3 by the control device 7.

[0206] The control device 7 comprises one or more temperature sensors configured to detect the temperature of each electrochemical cell 1 housed in the container 3 and one or more circuits for measuring the open circuit voltage (OCV) of each electrochemical cell 1 housed in the container 3.

[0207] The container 3 is led into the aging area 60 by means of a carrier 95, which may be the same as or different from the carrier 91.

[0208] The aging area 60 comprises a plurality of aging cabinets 61, which are substantially identical to each other, within which the electrochemical cell aging step 1 takes place.

[0209] Each aging cabinet 61 is entirely similar to the activation cabinet 31 and is therefore delimited externally by walls 62 while access to its inner space is ensured by an opening 63, formed at the base of the aging cabinet 61 and sized to allow the inlet and outlet of the containers 3 coupled to the respective control devices 7.

[0210] The aging cabinet 61 also comprises therein a plurality of shelves 64, arranged, for example, overlapped in two or more columns, and a lift configured to support a container 3 and carry it up to the designated shelf 64.

[0211] The aging cabinet 61 is also provided with one or more power supply groups (not shown) arranged to be connected to the control devices 7 when the respective containers 3 are placed on one of its shelves.

[0212] The location of the container 3 coupled to the control device 7 connected to the power supply group defines an aging station 66 of the electrochemical cells 1 housed in container 3, within the aging cabinet 61.

[0213] In this embodiment, all the shelves of the aging cabinet 61 are arranged to house a container 3 and to supply the respective control device 7 coupled to the container 3, so that, as such, each shelf of the cabinets 61 can be identified as an aging station 66.

[0214] The containers 3 coupled to the respective control devices 7 leaving the aging area 60 are moved by the conveyor 95 to the second decoupling station 70 where the control devices 7 are decoupled from the respective container 3, for example by means of a robotic arm 71.

[0215] The control devices 7 decoupled from the containers 3 are then led back to the second coupling station 50, e.g. by a carrier 96, where it is made available for coupling to a new container 3.

[0216] The containers 3 separated in the second decoupling station 70, on the other hand, are led to the outlet station 80 where the electrochemical cells 1, now formed, are pulled out of the container 3 and sent to the following processing steps, e.g. to a wrapping and packaging plant, while the empty containers 3 are taken by a carrier 97 back to the insertion station to be filled with new electrochemical cells 1 to be formed.

[0217] The formation apparatus 100 operates as described below.

[0218] The electrochemical cells 1 to be formed are inserted into the seats 4 of a container 3 at the insertion station 10, then the container 3 is coupled to a power device 5 in the first coupling station 20 to form a first individually manipulatable unit 5a.

[0219] The latter is transported by the carrier 91 into one of the activation cabinets 31, where it is taken over by the lift 35 and positioned in a free shelf 34 so as to establish an electrical connection between the power device 5 and a power supply group associated with the shelf 34.

[0220] The electronic control unit 8 of the power device 5 starts the activation process of the electrochemical cells 1, subjecting the latter to one or more charge and discharge cycles according to predefined times and modes, thanks to the electrical energy supplied to the cells by the contacting assembly 6.

[0221] The residence time of the electrochemical cells 1 in the activation station 36, defined by the shelf 34, depends on the construction specifications of the electrochemical cells and can last between 10 and 15 hours.

[0222] At the end of the period set for the activation step, the container 3 with the power device 5 coupled thereto is pulled out of the activation cabinet 31, still using the lift 35, and is taken by means of the carrier 91 to the first decoupling station 40, where the container 3 and the power device 5 are separated.

[0223] The first decoupling station 40 is partially corresponding to the second coupling station 50, so that the container 3 just released from the power device 5 is coupled to a control device 7 forming a second individually manipulatable unit 7a.

[0224] The latter is taken to one of the aging cabinets 61 and similarly to the activation cabinet 31 is picked up by a lift and taken to a shelf within the aging cabinet 61 where the control device 7 is connected to a power supply group.

[0225] In this location, which becomes the aging station 66 for electrochemical cell 1, the container 3 is kept for the maturation period necessary to complete the formation process.

[0226] The aging period can be between 10 and 12 days and, during this time, the container 3 can conveniently be kept stationary in the aging station.

[0227] During the aging period, the temperature and open circuit voltage of each electrochemical cell 1 can be detected by the control device 7 at the desired time frequency with no need to move the container 3.

[0228] The detected values can be processed by the control device 7 itself i.e. transmitted to an external control unit which, if necessary, can signal an anomaly and issue an alarm.

[0229] It is further provided that the container 3, while in its own aging station 66, is kept under predefined temperature conditions.

[0230] At the end of the aging period, the container 3 with the control device 7 coupled thereto is pulled out of the aging cabinet 61 and taken to the second decoupling station 70, where container 3 and control device 7 are separated.

[0231] While the control device 7 is returned to the second coupling station 50 by the carrier 96, the electrochemical cells 1 are pulled out of the container 3 in the outlet station 80 to be led to the next processing units, thus releasing the container 3 which is returned to insertion station 10 by the carrier 97.

[0232] In a variant of the process described above, it is provided that the control device 7 is coupled to the container 3 before the power device 5 so that it is interposed between the power device 5 and the container 3, as schematically represented in Fig. 3 in combination (b).

[0233] In this case, the second coupling station 50 is positioned upstream of the first coupling station 20, and is preferably at least partially integrated thereto.

[0234] The control device 7 is then kept coupled with the container 3 even during the activation step, at the end of which the power device 5 is decoupled and the container 3 and the control device 7 coupled thereto are then transferred to the aging area 60.

[0235] This variant of the formation process can be provided both in the embodiment described above with reference to the diagram in Figure 1 and in the embodiment described hereinafter.

[0236] Figure 4 describes a second example of an apparatus for forming electrochemical cells for battery production, collectively designated by 200, and made according to the present invention. In Figure 4, components equal or similar to those of the apparatus 100 are denoted by the same numerical references.

[0237] The apparatus 200 differs from the apparatus 100 in that the containers 3, before being taken into the activation cabinets 31 and the aging cabinets 61, are placed in special drawers of those cabinets, denoted respectively by 37 for the activation cabinets 31 and by 67 for the aging cabinets 61.

[0238] This allows for more flexibility in the sizing of the containers 3, as they are less limited by the size of the shelves 34 and 64.

[0239] In particular, the containers 3 can be considerably smaller than the shelves of the activation cabinets and aging cabinets, and consequently also the power devices 5 and control devices 7 that are to be coupled to the containers 3, so that they are less bulky and less heavy, facilitating their transport between the different stations of the apparatus 200.

[0240] On the other hand, the drawers 37 are sized to be properly positioned on the shelves 34 and the drawers 67 are sized to be properly positioned on the shelves 64. If the shelves 34 and shelves 64 have the same dimensions, it is preferred that also the drawers 37 and 67 also have substantially the same dimensions, so that they can support an equal number of containers 3.

[0241] In the embodiment described herein, the drawers 37 of each activation cabinet 31 are movable, by means of the lift 35, between the respective shelf 34 and the inlet opening 33, where they can receive and deliver the containers 3 coupled to the respective power devices 5.

[0242] Similarly, the drawers 67 of each activation cabinet 61 are movable, by means of the lift, between the respective shelf 64 and the inlet opening 63, where they can receive and deliver the containers 3 coupled to the respective control devices 7.

[0243] Outside the activation area 30 and the aging area 60, the apparatus 200 therefore operates in a completely similar way to the apparatus 100.

[0244] Conversely, in the activation area 30, it is provided that the containers 3 coupled to the respective power devices 5 are taken into the activation cabinet 31 after being placed on a drawer 37 positioned at the opening 33. The drawer 37, once filled with a predefined number of containers 3, e.g. 6, is taken to the shelf 34 for the step of activating the electrochemical cells 1. At the end of this step, the drawer 37 is returned to the outlet 33 so as to allow picking up the containers 3 and moving them to the first decoupling station 40. Similarly, in the aging area 60 it is provided that the containers 3 coupled to their respective control devices 7 are taken into the aging cabinet 61 after being placed on a drawer 67 positioned at the opening 63. The drawer 67, once filled with a predefined number of containers 3, e.g. 6, is taken to the shelf 64 for the ageing step of electrochemical cells 1. At the end of this step, the drawer 67 is returned to the opening 63 so as to allow to pick up the containers 3 and move them to the second decoupling station 70.

[0245] The remaining parts of the apparatus 200 are substantially the same or similar to those of the apparatus 100 described above, to which reference is made for structural and functional details.

[0246] In Figure 7 a third example of an apparatus for forming electrochemical cells for battery production, collectively designated by 300, and made according to the present invention, is described.

[0247] In Figure 7, components equal or similar to those of the apparatus 100 or apparatus 200 are denoted by the same numerical references.

[0248] The apparatus 300 differs from the apparatus 200 in that the drawers 37 can be completely pulled out of the activation cabinets 31 and the positioning of the containers 3 coupled to the respective power devices 5 on the drawers 37 takes place at an appropriate distance from the activation cabinets 31, for example in a positioning station 301 provided between the first coupling station and the activation area 30.

[0249] In the apparatus 300, the drawers 37 are further compatible with the aging cabinets 67, so that the same drawer 37, once left the activation area 30 and passed the first decoupling station 40 and the second coupling station 50, can be conveniently used to bring the containers 3 coupled to the control devices 7 within the aging cabinets 61 for the aging step.

[0250] At the end of the aging step, the containers 3 are removed from the drawers 37 in a separation station 302 provided between the aging area 60 and the second decoupling station 70. While the containers 3 are sent to the second decoupling station 70, the drawers 37 are returned to the positioning station 301.

[0251] The remaining parts of the apparatus 300 are substantially the same or similar to those of the apparatus 100 and 200 described above, to which reference is made for structural and functional details.

[0252] In a variant embodiment of the apparatus 300, not shown in the enclosed figures, the positioning station 301 coincides at least partially with the first coupling station 20.

[0253] In particular, it may be provided that each drawer 37 is provided with one or more power devices 5, which are mechanically constrained to the drawer 37 so that they can be moved between an open position, in which the power devices 5 are spaced out from the drawer 37 to allow the containers 3 to be placed on it, and a closed position, in which the power devices 5 are coupled to the containers 3 placed on the drawer 37.

[0254] In Figure 8 a fourth example of an apparatus for forming electrochemical cells for battery production, collectively designated by 400, and made according to the present invention, is described.

[0255] In Figure 8, components equal or similar to those of the apparatus 100 or apparatus 200 or apparatus 300 are denoted by the same numerical references. The apparatus 400 differs from the apparatuses of the previous examples in that the containers are coupled to and decoupled from the respective power devices 5 or the respective control devices 7 at the activation cabinets 31 i.e. the aging cabinets 61.

[0256] In other words, at each activation cabinet 31 there is provided a first coupling station 20 and a first decoupling station 40, while in each aging cabinet 61 there is provided a second coupling station 50 and a second decoupling station 70.

[0257] Thus, the containers 3, filled only with the electrochemical cells 1 and without the power devices 5 or control devices 7 are moved more easily between the various areas and stations of the apparatus 400.

[0258] More specifically, the apparatus 400 comprises an insertion station 10 wherein the electrochemical cells 1 are inserted into the seats 4 of the containers 3. The latter are directly moved by the carrier 91 to an activation cabinet 31 where, at its opening 33, there is provided the first coupling station 20 wherein the containers 3 are coupled to a respective power device 5.

[0259] The first coupling station 20 can be made as a body protruding from the activation cabinet 31, as visible in Figure 8 and Figure 11, or it can be made completely within the activation cabinet 31.

[0260] In a particular embodiment, it is provided that the power devices 5 are fixedly constrained underneath the drawer 37, so that the individual containers 3, in the first coupling station 20, can be coupled to the respective power devices 5 by lifting the container 3 directly from the carriage 92, as shown in Figures 9 and 10. In alternative embodiments, it is provided that the power devices 5 are constrained to the drawer 37 and can move, so that, for example, they can descend from the drawer 37 to couple with the container 3 carried by the carriage 92.

[0261] Once all the power devices 5 have been coupled to their respective containers 3, the drawer 37 is taken by the lift 35 into the activation cabinet 31 at a housing provided with the connection to the power supply group, so as to define the activation station 36 and proceed to the activation step of the electrochemical cells 1 as described above.

[0262] At the end of the activation, the drawer is lowered to be taken to the first decoupling station 40 where the containers 3, separated from the power devices 5, are handed over to respective carriages 92 which transport them directly to the aging area 60.

[0263] The first decoupling station 40 is preferably separated from the first coupling station 20, as shown with a dotted line in Figure 11.

[0264] In one embodiment, not in accordance with the present invention, the first decoupling station 40 may substantially coincide with the first coupling station 20.

[0265] The containers 3 taken to the aging area 60 are led to an aging cabinet 61 where, at its opening 63, a second coupling station 50 is provided, wherein the containers 3 are coupled to a respective control device 7.

[0266] The second coupling station 50 can be made as a body protruding from the ageing cabinet 61 or can be made completely within the ageing cabinet 61.

[0267] In a special embodiment, it is provided that the control devices 7 are fixedly constrained underneath the drawer 67, so that the individual containers 3, in the second coupling station 50, can be coupled to the respective control devices 7 by lifting the container 3 directly from the carriage 92.

[0268] In alternative embodiments, it is provided that the control devices 7 are constrained to the drawer 67 and can move, so that, for example, they can descend from the drawer 67 to couple with the container 3.

[0269] Once all the control devices 7 have been coupled to their respective containers 3, the drawer 67 is taken by the lift to a shelf 64 to proceed to the aging step of the electrochemical cell 1.

[0270] At the end of the ageing step, the drawer 67 is lowered to the second decoupling station 70 where the containers 3, separated by the control devices 7, are transported directly to outlet station 90.

[0271] This solution thus allows to solve the technical problem identified above, while at the same time achieving additional benefits also deriving from the specific embodiments described above. Obviously, in order to meet specific and contingent application needs, a person skilled in the art will be able to make further modifications and variants to the solution described above that are nevertheless within the scope of protection as defined by the following claims.

Claims

CLAIMS1. Method for forming electrochemical cells (1) for battery production, comprising:- housing a plurality of electrochemical cells (1) in a container (3),- arranging a power device (5) comprising: i. a contacting assembly (6) configured to provide an electrical contact for each electrochemical cell of said plurality of electrochemical cells (1) housed in said container (3), and ii. an electronic control unit (8) configured to apply to said electrochemical cells (1), by means of said contacting assembly (6) and at least one bidirectional power supply, a modulated voltage or current so as to allow the at least partial activation of said electrochemical cells (1),- coupling said power device (5) to said container (3) in a first coupling station (20),- electrically powering said power device (5) within an activation station (36) so as to subject said electrochemical cells (1) to said modulated voltage or current and at least partially activate said electrochemical cells,- decoupling said container (3) from said power device (5) in a first decoupling station (40) spaced out from said first coupling station (20).

2. Method according to claim 1, wherein said power device (5), once decoupled from said container (3), is returned to said first coupling station (20) to be coupled to another container (3).

3. Method according to claim 1 or 2, wherein said first coupling station (20) is spaced out from said activation station (36) and said method comprises moving said container (3) coupled to said power device (5) from said first coupling station (20) to said activation station (36).

4. Method according to any one of the preceding claims, wherein said first decoupling station (40) is spaced out from said activation station (36) and said method comprises moving said container (3) coupled to said power device (5) from said activation station (36) to said first decoupling station (40).

5. Method according to any one of the preceding claims, wherein saidactivation station (36) is defined within an activation cabinet (31).

6. Method according to claim 5, wherein said first coupling station (20) is defined within or at the inlet to said activation cabinet (31).

7. Method according to claim 5 or 6, wherein said first decoupling station (40) is defined within or at the outlet of said activation cabinet (31).

8. Method according to any one of the preceding claims, wherein said container (3), once decoupled from said power device (5), is moved to an aging station (66) wherein said electrochemical cells (1) are left to rest for a predetermined aging time, so as to continue and / or complete the formation process, and, prior to being moved to said aging station (66), is coupled to a control device (7) of said electrochemical cells (1) comprising at least one from a temperature sensor, configured to detect the temperature of at least one of said electrochemical cells and an open circuit voltage measurement circuit of at least one of said electrochemical cells.

9. Apparatus (100, 200, 300, 400) for forming electrochemical cells (1) comprising:- a plurality of containers (3) each configured to house a respective plurality of electrochemical cells (1) to be formed,- a first coupling station (20), arranged to couple to each container (3), containing said plurality of electrochemical cells (1), a power device (5) provided with: i. a contacting assembly (6) configured to provide an electrical contact for each electrochemical cell of said plurality of electrochemical cells (1) housed in said container (3), and ii. an electronic control unit (8) configured to apply to said electrochemical cells (1), by means of said contacting assembly (6) and at least one bidirectional power supply, a modulated voltage or current so as to allow the at least partial activation of said electrochemical cells (1),- at least one activation station (36) arranged to house at least one of said containers (3) coupled to said power devices (5) and to electrically power said power device (5) so that it can at least partially activate the electrochemical cells (1) housed in said at least one container (3),- a first decoupling station (40) spaced out from said first coupling station and arranged to decouple each container (3) from the respective power device (5),- a transport system (90) arranged to move said containers (3) successively from said first coupling station (20) to said first uncoupling station (40).

10. Apparatus according to claim 9, wherein said activation station (36) is defined within an activation cabinet (31), said activation cabinet (31) being provided with at least one power supply group arranged to electrically power said power device (5).

11. Apparatus according to claim 10, wherein said first coupling station (20) is defined at said activation cabinet (31).

12. Apparatus according to claim 10 or 11, wherein said first decoupling station (40) is defined at said activation cabinet (31).

13. Apparatus according to any one of claims 9 to 12, wherein said first coupling station (20) is spaced out from said activation station (36).

14. Apparatus according to any one of claims 9 to 13, wherein said first decoupling station (40) is spaced out from said activation station (36).

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