Preparation process for large-capacity battery, and large-capacity battery

Abstract

The present invention relates to the field of batteries, and specifically relates to a preparation process for a large-capacity battery, and a large-capacity battery, overcoming the problem of shared manifold assemblies for existing large-capacity batteries being difficult to assemble. The process comprises the steps of: placing, in an inverted orientation, a battery cell provided with a through-hole into a housing; and inserting two spacer plates into a gap between a bottom of the battery cell and a bottom of the housing, the two spacer plates being located at two sides of the through-hole. The method enables fluid communication among electrolyte regions of inner cavities of battery cells, ensuring cell-to-cell consistency by means of electrolyte sharing, and improving large-capacity battery cycle life to a certain extent.

Description

A fabrication process for a high-capacity battery and the high-capacity battery itself. Technical Field

[0001] This invention relates to the field of batteries, specifically to a manufacturing process for a high-capacity battery and a high-capacity battery itself. Background Technology

[0002] Currently, many batteries on the market are made into large-capacity batteries by connecting multiple individual cells in parallel or series (also known as battery modules or battery packs).

[0003] An existing high-capacity battery, as shown in Figure 1, includes a battery pack body formed by several individual cells connected in parallel and a shared piping assembly located at the bottom of the battery pack body. The shared piping assembly connects all the internal cavities of the individual cells, ensuring that all cells in the battery pack are within a single electrolyte system. This shared piping assembly enhances the uniformity of the electrolyte in each individual cell, improving cycle life. It also allows for the replenishment of electrolyte to the battery pack, extending its lifespan and improving its safety during use.

[0004] However, this type of shared pipeline assembly is formed by directly sealing and plugging together multiple sub-pipes 01 and intermediate connecting pipes 02 with an interference fit; at this time, the multiple sub-pipes 01 are set one by one on the lower cover plate 03 of the single cell, the sub-pipes extend along the arrangement direction of the single cell 3, and are integrally extruded with the lower cover plate 03, and communicate with the opening of the lower cover plate 03.

[0005] During assembly, the two ends of the sub-pipe 01 are used as the connection ends with the intermediate connecting pipe 02. When the two individual cells are connected, one end of the sub-pipe on each of the two individual cells is squeezed into the two ends of the intermediate connecting pipe 02.

[0006] The shared piping assembly requires all sub-pipes 01 and the intermediate connecting pipe 02 to be coaxial during the insertion process in order to achieve an effective connection. However, the coaxiality of the sub-pipes and the intermediate connecting pipe 02 is difficult to guarantee due to the following reasons:

[0007] 1) The sub-pipes and the lower cover plate are a single piece. If the position of the sub-pipes on the lower cover plate is slightly off, or the dimensions of the sub-pipes themselves are slightly off, it will cause the coaxiality of the sub-pipes to be off when they are plugged in.

[0008] 2) When welding the above-mentioned integral component to the cylinder, due to differences in the welding process, the position of the sub-pipes relative to the cylinder may be inconsistent, which may lead to deviations in the coaxiality of each sub-pipe during insertion.

[0009] 3) This solution requires the use of special tooling during the connection process. If the tooling is not used properly or if the construction personnel are not careful, the coaxiality of each sub-pipeline may be deviated.

[0010] In addition, during the insertion process, the deviation between the various sub-pipes will increase with the number of insertions, making it more difficult to ensure the coaxiality between the various sub-pipes as the number of insertions increases; thus, the yield rate decreases during the assembly process as the number of insertions increases.

[0011] In summary, this solution may cause the sub-pipes to shift relative to the lower cover plate or the lower cover plate to shift relative to the cylinder during insertion because the sub-pipes of two adjacent individual cells are difficult to be coaxial, which may lead to battery damage. Summary of the Invention

[0012] The purpose of this invention is to provide a manufacturing process for a large-capacity battery and a large-capacity battery in general, overcoming the problem that existing large-capacity batteries are difficult to assemble using shared pipeline components.

[0013] The first aspect of this invention provides a process for manufacturing a high-capacity battery, comprising the following steps:

[0014] Step 1: Make a through hole at the bottom of the single cell, at which point the single cell is in an inverted position;

[0015] Step 2: Place the individual battery with through holes into the cylinder with at least one open end in an inverted position, ensuring that the terminal of each individual battery extends out of its corresponding clearance hole, and the cylinder is in an inverted position.

[0016] Step 3: Insert two pads into the gap between the bottom of the individual battery and the bottom of the cylinder, with the two pads located on both sides of the through hole;

[0017] Step 4: Repeat steps 1 to 3 to install at least two individual cells with through holes at the bottom along the length of the cylinder.

[0018] Step 5: Secure the end cap to the open end of the cylinder and seal it to each clearance hole and the top cover of the individual battery.

[0019] This invention involves installing multiple individual battery cells with through holes at their bottoms into a cylindrical body with one open end. The cylindrical body is then sealed with an end cap, placing the multiple individual battery cells within a closed space. This allows the electrolyte zones within each individual battery cell to be interconnected. By sharing the electrolyte among the individual cells, consistency is ensured. In other words, by connecting the electrolyte chambers of each individual battery cell, the electrolytes of all individual cells are placed in the same system, reducing differences between the electrolytes of each individual cell and improving consistency to a certain extent. This, in turn, improves the cycle life of large-capacity batteries to a certain extent.

[0020] This invention features two pads between the bottom of each individual battery cell and the bottom of the casing. The gap between the two pads at the bottom of all individual batteries allows the electrolyte zones within each individual battery cell to be interconnected without the need for insertion. In the direction of the individual battery cell arrangement, there is no need to consider the coaxiality of insertion, resulting in lower requirements for processing and assembly precision. At the same time, no special tooling is required, and the assembly process is relatively simple, greatly reducing the processing difficulty and cost of this type of large-capacity battery with a shared system, enabling mass production.

[0021] In this invention, each individual battery cell has its terminals extending beyond the top of the casing. Compared to structures where the terminals are located inside the casing, the terminals provide better heat dissipation. Furthermore, once the terminals extend beyond the casing, if the battery temperature becomes too high, it is easier to use heat exchange equipment to remove the heat from the terminals in a timely manner, ensuring that this type of high-capacity battery operates at its optimal temperature.

[0022] Furthermore, in order to improve the sealing between the clearance hole and the top cover of the individual battery, while ensuring the insulation between the terminal post and the top of the cylinder, the above method also includes step 6: setting an insulating seal in the gap between each clearance hole and the terminal post.

[0023] Furthermore, the above method also includes step 7: placing a terminal adapter on each individual battery terminal, pressing the terminal adapter tightly against the insulating seal, and then welding the terminal adapter to the individual battery terminal.

[0024] In this invention, by setting up an electrode adapter, the insulating seal can be pressed tightly to prevent the insulating seal from falling off in the event of thermal runaway, thus preventing thermal runaway flue gas from leaking out from this point. At the same time, by setting up an electrode adapter, heat exchange devices can be conveniently used to exchange heat on the electrode of the individual battery.

[0025] Furthermore, since the end cap and the open end of the cylinder need to be connected by welding, to prevent potential hazards caused by the electrolyte overflowing from the bottom of the individual cell through the clearance hole encountering open flames or high temperatures during welding, the method also includes a step of cleaning the electrolyte overflowing from the bottom of the individual cell through the clearance hole after step 1 and before starting step 2.

[0026] Furthermore, to prevent the individual battery terminals from being scratched or damaged when placed in the cylinder in an inverted position, in step 2 of this invention: when the individual battery is placed in the cylinder, it is necessary to ensure that there is a safe distance between the individual battery terminals and the inner wall of the top of the cylinder.

[0027] Furthermore, in step 5 above, the end cap is fixed and sealed to the open end of the cylinder by welding while inverted. Then, after the whole structure is flipped over, each clearance hole and the top cover of the individual battery are sealed and connected by welding.

[0028] Furthermore, in order to ensure that the pole adapter can uniformly apply clamping force to the insulating seal to ensure the insulating seal's insulation performance, the insulating seal includes a flexible insulating sealing ring and a pressure ring; first, the flexible insulating sealing ring is placed in the clearance hole; then, the pressure ring is placed on the flexible insulating sealing ring.

[0029] The flexible insulating sealing ring has a flexible stepped structure. The small-diameter section of the stepped structure extends into the clearance hole and contacts the top cover of the single battery cell, while the large-diameter section of the stepped structure is located outside the cylinder and contacts the top of the cylinder.

[0030] The pressure ring is a metal part.

[0031] Furthermore, step 5 above specifically involves welding the edge of the clearance hole near the individual battery to the top cover of the individual battery to achieve a sealed connection.

[0032] Furthermore, the edge of the aforementioned clearance hole near the individual battery is sealed to the top cover of the individual battery using a filler wire welding method.

[0033] Furthermore, the above method also includes steps of vacuuming, liquid injection, formation, and aging.

[0034] A second aspect of the present invention also provides a high-capacity battery manufactured by the above-described process.

[0035] The third aspect of this invention also provides another high-capacity battery manufacturing process, which differs from the above method in that multiple individual batteries are strung together and then placed into the cylinder at once, specifically including the following steps:

[0036] Step 1: Assemble multiple individual cells with through holes at the bottom into a battery string. At this time, each individual cell in the battery string is in an inverted position.

[0037] Step 2: Place the battery pack string into a cylinder with at least one open end in an inverted position;

[0038] Step 3: Insert a pad into the gap between the bottom of the battery string and the bottom of the cylinder;

[0039] Step 4: Secure the end cap to the open end of the cylinder and seal it to each clearance hole and the top cover of the individual battery.

[0040] The fourth aspect of this invention also provides another process for manufacturing a high-capacity battery, comprising the following steps:

[0041] Step 1: Place the top plate with 2n clearance holes on top of n individual cells, so that the terminals of each individual cell pass through the corresponding clearance holes, where n is an integer greater than 1; seal the connection between each clearance hole and the top cover of the individual cell.

[0042] Step 2: Invert the cells so that the bottom of each cell faces upwards, and make through holes at the bottom of each cell.

[0043] Step 3: Install pads at the non-through-hole areas at the bottom of each individual cell;

[0044] Step 4: Fasten the box with one open end, press the bottom plate of the box against the pad, and seal and fix the open end of the box to the top plate.

[0045] This invention places a single battery cell with a through-hole at the bottom inside a sealed casing (consisting of a top plate and a box with an open end), so that multiple single batteries are in a sealed space. This allows the electrolyte zones inside each single battery cell to be interconnected. By sharing the electrolyte among the single batteries, the consistency of each single battery cell is ensured. That is, by connecting the electrolyte cavities of each single battery cell, the electrolyte of all single batteries cells is in the same system, reducing the differences between the electrolytes of each single battery cell and improving the consistency between the single batteries to a certain extent, thereby improving the cycle life of large-capacity batteries to a certain extent.

[0046] This invention places a pad between the non-through-hole portion of the bottom of each individual battery and the bottom of the casing. By utilizing the gap between the through-holes on the bottom of all individual batteries and the bottom plate of the casing, the electrolyte areas inside each individual battery can be interconnected without insertion. In the arrangement direction of the individual batteries, there is no need to consider the coaxiality of insertion, and the requirements for processing and assembly accuracy are lower. At the same time, no special tooling is required, and the assembly process is relatively simple, which greatly reduces the processing difficulty and processing cost of this type of large-capacity battery with a shared system, and enables mass production.

[0047] In this invention, each individual battery terminal extends beyond the top of the casing (i.e., each individual battery terminal passes through a corresponding clearance hole on the top plate). Compared to a structure where the terminals are located inside the casing, the terminals provide better heat dissipation. Furthermore, when the terminals extend beyond the casing, if the battery temperature becomes too high, it is easier to use heat exchange equipment to promptly remove the heat from the terminals, ensuring that this type of high-capacity battery operates at its optimal temperature.

[0048] Furthermore, in order to improve the sealing between the clearance hole and the top cover of the single cell, while ensuring the insulation between the terminal post and the top plate, the above-mentioned manufacturing process also includes step 5: setting an insulating sealant in the gap between each clearance hole and the terminal post.

[0049] Furthermore, the above-mentioned preparation process also includes step 6: placing a terminal adapter on each individual battery terminal, pressing the terminal adapter tightly against the insulating seal, and then welding the terminal adapter to the individual battery terminal. In this invention, by setting the terminal adapter, the insulating seal can be pressed tightly, preventing it from falling off in the event of thermal runaway and causing leakage of thermal runaway gas. Simultaneously, by setting the terminal adapter, heat exchange devices can be conveniently used to exchange heat between the individual battery terminals.

[0050] Furthermore, since the top plate and the open end of the casing need to be connected by welding, to avoid potential hazards caused by electrolyte overflowing from the individual cells through the through holes encountering open flames or high temperatures during welding, the method also includes a step of cleaning the electrolyte overflowing from the individual cells through the through holes after opening them at the bottom of each individual cell, before sealing and fixing the open end of the casing to the top plate.

[0051] Further, in step 1, n individual cells are first arranged into a battery pack in the same direction. Then, two end fixing plates are placed against both ends of the battery pack, and a fixing strap is fitted over the two end fixing plates and the outer periphery of the battery pack to fix the battery pack between the two end fixing plates. Finally, a top plate with 2n clearance holes is placed on top of the n individual cells. The battery pack is secured using the fixing strap and the two end fixing plates, improving the overall structural stability. This stable structure prevents the individual cells from easily shifting or shaking during subsequent operations, thus facilitating a sealed connection between each clearance hole and the top cover of each individual cell.

[0052] Furthermore, in step 1, before fixing the battery pack to the two end fixing plates, a step of setting a separator between adjacent individual cells is also included; fixing ribs perpendicular to the plane of the separator are set on opposite sides of the separator, and the two sides of the fixing ribs abut against the sides of the individual cells on both sides of the separator.

[0053] In high-capacity batteries, multiple individual cells generate heat during operation. Separators, placed between adjacent cells, effectively increase the heat dissipation area within the battery pack. When heat is generated, the separators act as a heat conduction medium, rapidly transferring heat from individual cells to all parts of the battery pack, accelerating heat dissipation. This effectively reduces the overall temperature of the battery pack, preventing performance degradation or shortened lifespan due to overheating, and ensuring the stability and reliability of the battery under high load operation.

[0054] In addition, as the battery charges and discharges, chemical reactions occur inside the individual cells, causing the battery volume to expand to a certain extent. When the individual cells expand, the separator can deform within a certain range to buffer this expansion force, preventing the individual cells from being damaged by mutual compression, thus improving the safety and durability of the battery pack.

[0055] Meanwhile, the fixing ribs extend out from both sides of the partition and abut against the sides of the individual cells, playing a limiting role to prevent the individual cells from shaking or shifting within the battery pack, avoiding mutual collisions, and ensuring that the battery pack can operate stably even under vibration and bumpy conditions.

[0056] Furthermore, step 4 also includes a step of welding the box body with one open end to the fixed stiffening plate using a through-welding method.

[0057] By tightly connecting the fixing ribs with the separator and the shell, the rigidity of the entire large-capacity battery is strengthened to a certain extent, the strength of the shell structure is improved in all aspects, and the safe operation of the battery is effectively guaranteed.

[0058] In addition, the fixing ribs are in close contact with the individual cells, which can efficiently conduct the heat generated by the charging and discharging of the battery, and dissipate the heat through the connection with the casing, maintain the internal temperature balance of the battery pack, extend the battery life, and improve the battery performance in all aspects.

[0059] Furthermore, in order to ensure that the pole adapter can uniformly provide clamping force to the insulating seal to ensure the insulating seal's insulation performance, the insulating seal includes a flexible insulating sealing ring and a pressure ring; the specific operation process of step 6 above is: first, place the flexible insulating sealing ring in the clearance hole; then place the pressure ring on the flexible insulating sealing ring;

[0060] The aforementioned flexible insulating sealing ring has a flexible stepped structure. The small-diameter section of the stepped structure extends into the clearance hole and contacts the top cover of the single battery cell, while the large-diameter section of the stepped structure is located outside the top plate and contacts the top plate.

[0061] The aforementioned pressure ring is a metal part.

[0062] Furthermore, step 1 above specifically involves welding the edge of the clearance hole near the individual battery to the top cover of the individual battery to achieve a sealed connection.

[0063] Furthermore, step 4 is followed by steps of liquid injection, formation, and aging.

[0064] The fifth aspect of this invention provides another process for manufacturing a high-capacity battery, comprising the following steps:

[0065] Step 1: Invert n individual cells so that the bottom of the cells is facing up, and make through holes in the bottom of each individual cell; where n is an integer greater than 1.

[0066] Step 2: Invert the box with the bottom opening facing upwards, and put the n individual batteries with through holes into the box from the opening end in an inverted position, ensuring that the terminals of each individual battery extend out of the corresponding clearance holes opened on the top plate of the box.

[0067] Step 3: With the box in an inverted position, place pads on the non-through-hole areas at the bottom of each individual battery cell;

[0068] The base plate is fixed and sealed to the open end of the box;

[0069] Step 4: Flip over and seal the connection between each clearance hole and the top cover of the individual battery.

[0070] This invention places a single battery cell with a through hole at the bottom inside a sealed casing (consisting of a bottom plate and a box with an open end), so that multiple single batteries are in a closed space and the electrolyte areas inside each single battery cell are interconnected. By sharing the electrolyte among the single batteries, the consistency of each single battery cell is ensured. That is, by connecting the electrolyte chambers of each single battery cell, the electrolyte of all single batteries cells is in the same system, reducing the differences between the electrolytes of each single battery cell and improving the consistency between the single batteries to a certain extent, thereby improving the cycle life of large-capacity batteries to a certain extent.

[0071] This invention places a pad between the non-through-hole portion of the bottom of each individual battery and the bottom plate of the casing. By utilizing the gap between the through-holes at the bottom of all individual batteries and the bottom plate of the casing, the electrolyte areas inside each individual battery can be interconnected without insertion. In the arrangement direction of the individual batteries, there is no need to consider the coaxiality of insertion, and the requirements for processing and assembly accuracy are lower. At the same time, no special tooling is required, and the assembly process is relatively simple, which greatly reduces the processing difficulty and processing cost of this type of large-capacity battery with a shared system, and enables mass production.

[0072] In this invention, each individual battery terminal extends beyond the top of the casing (i.e., the terminal passes through the clearance hole on the top plate). Compared to a structure where the terminal is inside the casing, the terminal has better heat dissipation. In addition, when the terminal extends beyond the casing, if the battery temperature is too high, it is easier to use a heat exchange device to remove the heat from the terminal in a timely manner, ensuring that this type of high-capacity battery operates at the optimal temperature.

[0073] Furthermore, when the electrolyte is shared among the individual battery cells, there is free electrolyte inside the casing. At this point, the advantages of the extended terminals become apparent. The electrical connection points of the terminals are located outside the casing, a layout that physically avoids direct contact between them and the internal electrolyte. In practical applications, if the electrolyte comes into contact with the electrical connection components, the chemical components in the electrolyte may react with the metal parts, leading to circuit corrosion, increased resistance, and reduced energy transfer efficiency. More seriously, it may cause a short circuit, generating a large amount of heat instantly, or even igniting a fire, severely threatening battery safety. The extended terminals design effectively eliminates these potential hazards. Under complex operating conditions, whether in high-temperature, humid environments, or subjected to external vibration and impact, it ensures the battery's safety and reliability, guaranteeing stable operation and providing a solid safety guarantee for battery applications in various scenarios.

[0074] Furthermore, in order to improve the sealing between the clearance hole and the top cover of the single cell, while ensuring the insulation between the terminal post and the top plate, the above-mentioned manufacturing process also includes step 5: setting an insulating sealant in the gap between each clearance hole and the terminal post.

[0075] Furthermore, the above-mentioned preparation process also includes step 6: placing a terminal adapter on each individual battery terminal, pressing the terminal adapter tightly against the insulating seal, and then welding the terminal adapter to the individual battery terminal. In this invention, by setting the terminal adapter, the insulating seal can be pressed tightly, preventing it from falling off in the event of thermal runaway and causing leakage of thermal runaway gas. Simultaneously, by setting the terminal adapter, heat exchange devices can be conveniently used to exchange heat between the individual battery terminals.

[0076] Furthermore, since the base plate and the open end of the casing need to be connected by welding, to avoid potential hazards caused by electrolyte overflowing from the individual cells through the through holes encountering open flames or high temperatures during welding, the method also includes a step of cleaning the electrolyte overflowing from the individual cells through the through holes before fixing and sealing the base plate to the open end of the casing, after creating through holes at the bottom of each individual cell.

[0077] Further, in step 2, n individual batteries with through holes are first arranged in the same direction to form a battery pack. Then, two end fixing plates are placed against the two ends of the battery pack respectively. The fixing strap is sleeved on the two end fixing plates and the outer periphery of the battery pack to fix the battery pack between the two end fixing plates. The battery pack is then placed into the box from the open end of the box in an inverted position.

[0078] The battery pack is secured using a fixing strap and two end fixing plates, which improves the overall stability of the structure. The stable structure prevents individual cells from easily shifting or shaking during subsequent operations, making it easy to place multiple individual cells as a whole inside the box.

[0079] Furthermore, in step 1, before fixing the battery pack to the two end fixing plates, a step of setting a separator between adjacent individual cells is also included; fixing ribs perpendicular to the plane of the separator are set on opposite sides of the separator, and the two sides of the fixing ribs abut against the sides of the individual cells on both sides of the separator.

[0080] In high-capacity batteries, multiple individual cells generate heat during operation. Separators, placed between adjacent cells, effectively increase the heat dissipation area within the battery pack. When heat is generated, the separators act as a heat conduction medium, rapidly transferring heat from individual cells to all parts of the battery pack, accelerating heat dissipation. This effectively reduces the overall temperature of the battery pack, preventing performance degradation or shortened lifespan due to overheating, and ensuring the stability and reliability of the battery under high load operation.

[0081] In addition, as the battery charges and discharges, chemical reactions occur inside the individual cells, causing the battery volume to expand to a certain extent. When the individual cells expand, the separator can deform within a certain range to buffer this expansion force, preventing the individual cells from being damaged by mutual compression, thus improving the safety and durability of the battery pack.

[0082] Meanwhile, the fixing ribs extend out from both sides of the partition and abut against the sides of the individual cells, playing a limiting role to prevent the individual cells from shaking or shifting within the battery pack, avoiding mutual collisions, and ensuring that the battery pack can operate stably even under vibration and bumpy conditions.

[0083] Furthermore, after step 2, there is also a step of welding the box body to the fixed stiffening plate based on the through-welding method.

[0084] By tightly connecting the fixing ribs with the partitions and the shell (box), the rigidity of the entire large-capacity battery is strengthened to a certain extent, the strength of the shell structure is improved in all aspects, and the safe operation of the battery is effectively guaranteed.

[0085] In addition, the fixing ribs are in close contact with the individual cells, which can efficiently conduct the heat generated by the charging and discharging of the battery, and dissipate the heat through the connection with the casing, maintain the internal temperature balance of the battery pack, extend the battery life, and improve the battery performance in all aspects.

[0086] Furthermore, in order to ensure that the pole adapter can uniformly provide clamping force to the insulating seal to ensure the insulating seal's insulation performance, the insulating seal includes a flexible insulating sealing ring and a pressure ring; the specific operation process of step 6 above is: first, place the flexible insulating sealing ring in the clearance hole; then place the pressure ring on the flexible insulating sealing ring;

[0087] The aforementioned flexible insulating sealing ring has a flexible stepped structure. The small-diameter section of the stepped structure extends into the clearance hole and contacts the top cover of the single battery cell, while the large-diameter section of the stepped structure is located outside the top plate and contacts the top plate.

[0088] The aforementioned pressure ring is a metal part.

[0089] Furthermore, step 1 above specifically involves welding the edge of the clearance hole near the individual battery to the top cover of the individual battery to achieve a sealed connection.

[0090] Furthermore, step 4 is followed by steps of liquid injection, formation, and aging.

[0091] The beneficial effects of this invention are:

[0092] This invention places a single battery cell with a through-hole at the bottom inside a sealed casing, allowing multiple single batteries to be in a closed space. This enables the electrolyte zones inside each single battery cell to be interconnected. By sharing the electrolyte among the single batteries, the consistency of each single battery cell is ensured. In other words, by connecting the electrolyte cavities of each single battery cell, the electrolyte of all single batteries cells is in the same system, reducing the differences between the electrolytes of each single battery cell and improving the consistency between the single batteries to a certain extent. This, in turn, improves the cycle life of large-capacity batteries to a certain extent.

[0093] This invention features two pads between the bottom of the individual battery and the bottom of the casing. The gap between the two pads at the bottom of all individual batteries allows the electrolyte zones inside each individual battery to be interconnected without the need for insertion. In the arrangement direction of the individual batteries, there is no need to consider the coaxiality of insertion, resulting in lower requirements for processing and assembly precision. At the same time, no special tooling is required, and the assembly process is relatively simple, greatly reducing the processing difficulty and cost of this type of large-capacity battery with a shared system, enabling mass production.

[0094] In this invention, each individual battery cell has its terminals extending beyond the top of the casing. Compared to structures where the terminals are located inside the casing, the terminals provide better heat dissipation. Furthermore, with the terminals extending beyond the casing, if the battery temperature becomes too high, it is easier to use heat exchange equipment to promptly remove the heat from the terminals, ensuring that this type of high-capacity battery operates at its optimal temperature. Attached Figure Description

[0095] Figure 1 is a schematic diagram of a large-capacity battery structure in the background technology;

[0096] Figure 2 is a schematic diagram of the cylinder structure;

[0097] Figure 3 is a process flow diagram of Example 1;

[0098] Figure 4 is an exploded view of the large-capacity battery in Example 1 in the inverted state;

[0099] Figure 5 is a schematic diagram of the high-capacity battery structure in Example 1;

[0100] Figure 6 is a cross-sectional view of the high-capacity battery in Example 1;

[0101] Figure 7 is a magnified view of a portion of Figure 6;

[0102] Figure 8 is a process flow diagram of Example 2;

[0103] Figure 9 is an exploded view of the large-capacity battery in the inverted state in Example 2;

[0104] Figure 10 is a schematic diagram of the structure of the large-capacity battery in Example 3;

[0105] Figure 11 is a cross-sectional view of the high-capacity battery in Example 3;

[0106] Figure 12 is a partial structural schematic diagram of the large-capacity battery in Example 3;

[0107] Figure 13 is a partial structural schematic diagram of the large-capacity battery in Example 3;

[0108] Figure 14 is a schematic diagram of the partial explosion structure of the large-capacity battery in Example 3;

[0109] Figure 15 is a partial structural schematic diagram of the large-capacity battery in Example 3;

[0110] Figure 16 is a schematic diagram of the structure of the large-capacity battery in Example 3;

[0111] Figure 17 is a partial structural schematic diagram of the high-capacity battery in Example 4;

[0112] Figure 18 is a schematic diagram of the structure of the large-capacity battery in Example 4;

[0113] Figure 19 is a cross-sectional view of the high-capacity battery in Example 4;

[0114] Figure 20 is a schematic diagram of the structure of the large-capacity battery in Example 5;

[0115] Figure 21 is a cross-sectional view of the high-capacity battery in Example 5;

[0116] Figure 22 is a partial structural schematic diagram of the large-capacity battery in Example 5;

[0117] Figure 23 is a schematic diagram of the partial explosion structure of the large-capacity battery in Example 5;

[0118] Figure 24 is a partial structural schematic diagram of the large-capacity battery in Example 5;

[0119] Figure 25 is a partial structural schematic diagram of the large-capacity battery in Example 5;

[0120] Figure 26 is a schematic diagram of the exploded structure of the large-capacity battery in Example 5;

[0121] Figure 27 is a structural schematic diagram of the large-capacity battery in Example 5 from another perspective;

[0122] Figure 28 is a schematic diagram of the structure of the large-capacity battery in Example 5;

[0123] Figure 29 is a partial structural schematic diagram of the high-capacity battery in Example 6;

[0124] Figure 30 is a schematic diagram of the structure of the large-capacity battery in Example 6;

[0125] Figure 31 is a partial enlarged cross-sectional view of the large-capacity battery in Example 6;

[0126] The attached diagram is labeled as follows: 01, Sub-pipeline; 02, Intermediate connecting pipe; 03, Lower cover plate; 1, Cylinder body; 2, Clearance hole; 3, Individual cell; 4, Through hole; 5, Pad plate; 6, End cap; 7, Insulating seal; 71, Flexible insulating sealing ring; 72, Pressure ring; 8, Terminal adapter; 9, Battery string; 10, Electrolyte sharing channel; 21, Shell; 211, Box body; 212, Top plate; 213, Clearance hole; 22, Individual cell; 221, Terminal; 222, Through hole; 223, Insulating seal; 2231, Flexible insulating sealing ring; 2232, Pressure ring; 224, Terminal adapter; 23, Electrolyte sharing channel; 24, Fixing strap; 25, Pad plate; 26, End fixing plate; 28, Partition plate; 29, Fixing rib plate; 31. Shell; 311. Housing; 312. Base plate; 313. Clearance hole; 32. Single cell; 321. Terminal post; 322. Through hole; 323. Insulating seal; 3231. Flexible insulating sealing ring; 3232. Pressure ring; 324. Terminal post adapter; 33. Electrolyte sharing channel; 34. Fixing strap; 35. Pad; 36. End fixing plate; 38. Partition; 39. Fixing rib. Detailed Implementation

[0127] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0128] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0129] In the description of this invention, it should be noted that the terms "top," "bottom," etc., indicating orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0130] The design concept of Examples 1 and 2 is to abandon the scheme of forming a large-capacity battery by sharing electrolyte among multiple individual cells through a combination of interlocking and secondary unpacking. Examples 1 and 2 change the design concept by opening through holes at the bottom of the individual cells and then placing them into a large-capacity battery casing, so that the electrolyte areas in the multiple individual cells are interconnected (under an electrolyte-sharing system formed by the casing). This not only solves the problem that the interlocking process may cause damage to the individual cells, but also reduces the complexity of the large-capacity battery manufacturing process caused by the need for secondary unpacking of individual cells when manufacturing large-capacity batteries by interlocking.

[0131] The general process of repackaging the above-mentioned single battery is as follows: First, a through hole is made on the commercially available square aluminum-cased lithium battery. Then, a sealing mechanism is set on the through hole. Next, when the single batteries are assembled into a large-capacity battery, the sealing mechanism is dislodged or dissolved by external force or electrolyte immersion, thereby forming the through hole again.

[0132] Commercially available square aluminum-cased lithium batteries include a top cover, a bottom cover, an outer casing, and a cell assembly. The cell assembly, also known as an electrode assembly, consists of a positive electrode, a separator, and a negative electrode arranged in sequence, assembled using a stacking or winding process. The top cover, bottom cover, and outer casing form the casing of a single battery cell, and the cell assembly is housed within this casing. This commercially available square aluminum-cased lithium battery has already undergone processes such as electrolyte filling and formation.

[0133] In Examples 1 and 2, the high-capacity battery casing includes a cylindrical body with at least one open end, and an end cap for sealing the open end of the cylindrical body. Both the cylindrical body and the end cap are made of aluminum. As shown in Figure 2, the top of the cylindrical body 1 is provided with multiple clearance holes 2. These clearance holes 2 are used to allow the terminals of individual cells to extend out of the cylindrical body 1 when manufacturing high-capacity batteries. Therefore, the diameter of the clearance holes 2 is larger than the outer diameter of the terminals of individual cells.

[0134] For ease of description, in the following embodiments, the length direction of the cylinder 1 is defined as the x-direction, the width direction of the cylinder 1 is defined as the y-direction, and the height direction of the cylinder 1 is defined as the z-direction.

[0135] Example 1

[0136] As shown in Figures 3 to 7, this embodiment provides a specific method for manufacturing a high-capacity battery. The specific implementation steps of this method are as follows:

[0137] Step 1: Make a through hole 4 at the bottom of the single cell 3, at which point the single cell 3 is in an inverted position;

[0138] In this step, the so-called inverted state actually refers to the way the single cell 3 is placed with its bottom facing up and its top facing down. The purpose is to ensure that when the through hole 4 is opened, the electrolyte inside the single cell 3 will not flow out in large quantities.

[0139] In this embodiment, the single cell 3 is a commercially available square aluminum-cased lithium battery. Therefore, in this step, a through hole can be directly opened at the bottom of the commercially available square aluminum-cased lithium battery using a tool. Compared with the prior art, there is no need to modify the commercially available square aluminum-cased lithium battery (set a sealing mechanism), which greatly reduces the manufacturing difficulty and cost.

[0140] Step 2: Place the single cell 3 with the through hole 4 into the cylindrical body 1 with at least one open end in an inverted position.

[0141] Referring to Figure 4, in this step, the so-called inverted state actually refers to the placement of the cylinder 1 with the bottom facing upwards and the top facing downwards. Specifically, this step involves using a robotic arm to feed the individual battery 3 into the cylinder 1 from the open end along the x-direction, ensuring that the terminal of the individual battery 3 can extend out of its corresponding clearance hole 2 under the action of gravity. At the same time, during the process of transporting the individual battery into the cylinder 1, the robotic arm must always ensure that the end face of the individual battery terminal and the inner wall of the top of the cylinder 1 are kept at a safe distance to avoid the terminal rubbing against the cylinder and causing problems.

[0142] One point that needs to be emphasized here is that the dimensions of the inner wall at the top and bottom of cylinder 1 in the z-direction are slightly larger than the z-direction dimension between the bottom of the individual cell and the top surface of the individual cell terminal.

[0143] Step 3: Insert a pad 5 into the gap between the bottom of the individual battery 3 and the bottom of the cylinder 1;

[0144] The reason why the inner wall of the top and bottom of the cylinder 1 has a slightly larger z-direction dimension than the z-direction dimension between the bottom of the single cell and the top surface of the terminal of the single cell 3 is to allow the single cell 3 to enter the cylinder smoothly. However, after the terminal of the single cell 3 extends out of the clearance hole, a gap will be generated between the bottom of the single cell 3 and the bottom of the cylinder 1. In order to fill the gap, this embodiment needs to insert two pads 5 along the x-direction into the gap (in this embodiment, the dimension of the pad along the x-direction is basically the same as the dimension of the thickness direction of the single cell, and the pad is preferably made of an insulating material with a certain deformation capability). The two pads 5 are distributed on both sides of the through hole 4 (i.e., distributed along the y-direction on both sides of the through hole). This ensures that the single cell terminal is properly positioned after the large-capacity battery is assembled. Firstly, the corresponding clearance holes at the top of the cylinder can be extended, and machining and assembly errors can be compensated for to ensure that the z-direction dimensions of each individual battery terminal protruding from the clearance holes are basically consistent, thus providing favorable support for the subsequent electrical connection and heat exchange device installation. Secondly, the space between the two pads 5 corresponding to each individual battery 3 can form an electrolyte sharing channel 10 in the x-direction, which not only ensures the continuity of electrolyte communication between individual batteries (i.e., no interruption of electrolyte flow), but also eliminates the need to separately machine the electrolyte sharing channel at the bottom of the cylinder, making the cylinder machining simpler. Thirdly, the pads can ensure the installation stability of the individual batteries in the z-direction within the cylinder (i.e., the individual batteries will not shake in the z-direction during transportation and operation).

[0145] Step 4: Repeat steps 1 to 3 to set at least two individual battery cells 3 with through holes 4 at the bottom along the length of the cylinder 1; in this embodiment, 12 individual battery cells 3 are used to form a large-capacity battery, and 12 pairs of clearance holes 2 for the extension of the terminal posts of the individual battery cells 3 will be pre-processed on the top of the cylinder 1.

[0146] Step 5: Secure the end cap 6 to the open end of the cylinder 1 and seal the connection between each clearance hole 2 and the top cover of the individual battery 3.

[0147] In this embodiment, this step is performed in the following two steps:

[0148] First, after all 12 individual batteries 3 are installed into the cylinder 1, the end cap 6 is welded to the open end of the cylinder 1 by friction stir welding while the cylinder 1 is inverted.

[0149] In this embodiment, the end cap 6 can be provided with a liquid injection port and a venting port separately, or a liquid injection and venting port can be provided together. In some other embodiments, the liquid injection port and the venting port can also be provided at the top or bottom of the cylinder.

[0150] Next, the entire assembly is rotated 180° to seal each clearance hole 2 and the top cover of the individual battery 3. Since the diameter of the clearance hole 2 is larger than the outer diameter of the terminal post of the individual battery 3 (there is a gap here, as shown by mark A in Figure 7), and there may still be a small gap between the top cover of the individual battery 3 and the inner wall of the top of the cylinder 1 (as shown by mark B in Figure 7), in order to ensure sealing, this embodiment adopts a method of welding the edge of the clearance hole 2 near the individual battery 3 to the top cover of the individual battery 3 to achieve a sealed connection, thus preventing the external environment from interfering with the internal environment of the large-capacity battery through gaps A and B;

[0151] It should be emphasized that the size of the minute gap between the top cover of each individual battery 3 and the inner wall of the top of the cylinder 1 is different (mainly the size of the top cover of each individual battery and the inner wall of the top of the cylinder 1 differs in the Z direction). Therefore, in this embodiment, it is preferable to use filler wire welding to seal the edge of the clearance hole 2 near the individual battery to the top cover of the individual battery 3. This can meet the sealing reliability and weld strength of different minute gaps. Compared with the method of using non-filler wire welding, filler wire welding also has the advantages of higher welding efficiency and smaller welding defects.

[0152] In addition to the welding method used in this embodiment, in some other embodiments, laser welding can also be used to weld the area around each clearance hole on the top of the cylinder and the area around the corresponding electrode post on the top cover of the individual battery. However, this welding method requires a high cylinder wall thickness (setting a thicker cylinder wall thickness may result in poor welding effect, while setting a thinner cylinder wall thickness may result in high temperature damage to the inside of the individual battery).

[0153] In other embodiments, step 5 can also be performed using the following procedure:

[0154] In the inverted state, the steps of fixing and sealing the end cap 6 to the open end of the cylinder 1 and sealing the top cover of each clearance hole 2 and the individual battery 3 are completed respectively. These two steps can be performed in any order, as long as the internal environment and external environment of the final large-capacity battery are sealed and isolated.

[0155] In this embodiment, the step of opening the through hole 4 is completed before the individual battery 3 is installed into the cylinder 1. Compared with the method of opening the through hole 4 of the individual battery 3 after all the individual batteries 3 are installed into the cylinder, the space required for the tool to enter the cylinder 1 to perform the opening operation can be eliminated, thereby reducing the size of the cylinder, improving the energy density of the large-capacity battery to a certain extent, and reducing the difficulty of opening the through hole in the individual battery.

[0156] When performing step 1, opening the through hole 4 in the single cell 3, due to the pressure difference, some free electrolyte in the single cell 3 may still overflow from the single cell 3 after overcoming gravity and onto the single cell 3. If it is not cleaned in time, the excessively high temperature or open flame may pose a risk when performing the welding work in step 5. Therefore, step 1 of this embodiment also includes a step of cleaning the single cell 3 with electrolyte after waiting for a period of time to allow the electrolyte in the single cell 3 to completely overflow after completing the step of opening the through hole 4 at the bottom of the single cell 3.

[0157] In this embodiment, in order to compensate for the loss of electrolyte in each individual cell when the through hole is opened, and also to ensure that there is enough electrolyte in the large-capacity battery to realize the shared electrolyte system of each individual cell, the process also includes an electrolyte injection operation after step 5. Specifically, electrolyte is injected into the large-capacity battery casing using the injection port on the end cap or the cylinder.

[0158] As a large-capacity battery composed of multiple individual cells, in order to ensure its excellent performance, formation and aging steps can also be performed on the large-capacity battery after liquid injection.

[0159] In this embodiment, based on the above manufacturing process, the following two optimization designs were also made:

[0160] Optimized Design 1: Since the gap between the terminal post of the individual battery 3 and the clearance hole 2 is small, the insulation between the terminal post of the individual battery 3 and the cylinder 1 may be difficult to ensure. In addition, if a large-capacity battery experiences thermal runaway, cracks will appear at the welded position between the clearance hole 2 and the top cover of the individual battery 3, causing thermal runaway fumes to leak out from that position. Therefore, this embodiment also includes step 6, which is to set an insulating seal 7 in the gap between each clearance hole 2 and the terminal post. The insulating seal 7 can ensure the insulation between the terminal post and the cylinder. At the same time, even if leakage occurs at the welded position, the insulating seal can also serve as a second barrier to prevent the leakage of thermal runaway fumes.

[0161] Optimized Design 2: A terminal adapter 8 is placed on each of the three terminals of a single cell, tightly pressing the terminal adapter 8 against the insulating seal 7. The terminal adapter 8 is then welded to the terminal of the single cell. By setting the terminal adapter 8, the insulating seal 7 is pressed tightly, preventing it from detaching in the event of thermal runaway and causing leakage of thermal runaway gas. Therefore, the design of the terminal adapter 8 pressing the insulating seal 7 acts as a third barrier to prevent leakage of thermal runaway gas. Simultaneously, the terminal adapter 8 facilitates heat exchange between the three terminals of the single cell using a heat exchange device.

[0162] To ensure that the terminal adapter 8 can uniformly apply clamping force to the insulating seal and thus guarantee the insulation seal 7, in this embodiment, the insulating seal 7 includes a flexible insulating sealing ring 71 and a pressure ring 72. During assembly, the flexible insulating sealing ring 71 is first placed in the clearance hole 2, and then the pressure ring 72 is placed on the flexible insulating sealing ring 71. The flexible insulating sealing ring 71 has a flexible stepped structure, with the small-diameter section of the stepped structure extending into the clearance hole and contacting the top cover of the single battery cell, and the large-diameter section of the stepped structure located outside the cylinder and contacting the top of the cylinder. The pressure ring 72 is a metal part.

[0163] In some other embodiments, the insulating seal 7 may also be an insulating seal layer disposed at the clearance hole and the pole post gap by a casting process.

[0164] Example 2

[0165] As shown in Figures 8 and 9, this embodiment provides another specific method for manufacturing a high-capacity battery. The specific implementation steps of this method are as follows:

[0166] Step 1: Arrange multiple individual cells 3 with through holes 4 at the bottom into a battery string 9 along the x direction. At this time, each individual cell 3 in the battery string 9 is in an inverted position.

[0167] In this step, the so-called inverted state actually refers to the way the single cell 3 is placed with its bottom facing up and its top facing down. The purpose is to ensure that the electrolyte inside the single cell 3 will not flow out in large quantities when the through hole is opened.

[0168] In this embodiment, a commercially available square aluminum-cased lithium battery is selected as the single cell. Therefore, in this step, a through hole can be directly opened at the bottom of the commercially available square aluminum-cased lithium battery using a tool. Compared with the prior art, there is no need to modify the commercially available square aluminum-cased lithium battery (set a sealing mechanism), which greatly reduces the manufacturing difficulty and cost.

[0169] In this embodiment, multiple individual batteries 3 can be connected into a battery string 9 by means of a strip or a connecting strip. The purpose is to improve the relative displacement between individual batteries 3 when the battery string 9 is placed into the cylinder 1.

[0170] In this embodiment, multiple individual batteries 3 are used to form a battery string 9, and then the battery string 9 is inverted. Then, a through hole 4 is opened at the bottom of each individual battery 3. In some other embodiments, multiple individual batteries can be inverted first, and then the through holes are opened at the bottom of the individual batteries before the multiple individual batteries are formed into a battery string.

[0171] Step 2: Place the battery pack string 9 into the cylindrical body 1, which is open at least one end, in an inverted position.

[0172] Referring to Figure 9, in this step, the so-called inverted state actually refers to the placement of the cylinder 1 with the bottom facing upwards and the top facing downwards. The specific steps of this step are as follows: the robotic arm is used to feed the battery string 9 into the cylinder 1 from the open end along the x-direction, and ensures that under the action of gravity, the terminal of each individual battery 3 can extend out of its corresponding clearance hole 2. At the same time, the robotic arm needs to always ensure that the end face of the terminal of the individual battery 3 and the inner wall of the top of the cylinder 1 are kept at a safe distance during the process of conveying the battery string 9 into the cylinder 1, so as to avoid the terminal rubbing against the cylinder and causing problems.

[0173] One point that needs to be emphasized here is that the z-axis dimension of the inner wall at the top and bottom of the cylinder is slightly larger than the z-axis dimension between the bottom of the individual cell and the top surface of the individual cell terminal.

[0174] Step 3: Insert a pad into the gap between the bottom of the battery string 9 and the bottom of the cylinder 1;

[0175] The reason why the dimensions of the inner walls at the top and bottom of the cylinder 1 in the z-direction are slightly larger than the z-direction dimension between the bottom of the individual battery 3 and the top surface of the terminal of the individual battery 3 is to ensure that the battery string 9 can smoothly enter the cylinder. However, after the terminal of the individual battery 3 extends out of the clearance hole, a gap will be generated between the bottom of the battery string 9 and the bottom of the cylinder 1. In order to fill the gap, this embodiment needs to insert two pads 5 along the x-direction into the gap (in this embodiment, the dimensions of the pads along the x-direction are basically the same as the dimensions of the battery string along the x-direction, and the pads are preferably made of insulating materials with a certain deformation capacity). The two pads 5 are distributed on both sides of the through hole 4 (i.e., distributed along the y-direction on both sides of the through hole). Firstly, it can compensate for processing and assembly errors. After the large-capacity battery is assembled, the three terminals of each individual cell can still extend out of the corresponding clearance hole 2 at the top of the cylinder 1, thus providing favorable support for the subsequent electrical connection and heat exchange device installation. Secondly, the space between the two pads can form an electrolyte sharing channel 10 in the x direction, which not only ensures the continuity of electrolyte communication between individual cells (i.e., no electrolyte interruption), but also eliminates the need to process the electrolyte sharing channel separately at the bottom of the cylinder, making the cylinder processing simpler. Thirdly, the pads can ensure the installation stability of the battery string in the z direction inside the cylinder (i.e., the battery string will not shake in the z direction during transportation and operation).

[0176] Step 4: Secure the end cap 6 to the open end of the cylinder 1 and seal the connection between each clearance hole 2 and the top cover of the individual battery 3.

[0177] In this embodiment, this step is performed in the following two steps:

[0178] First, after the battery pack string 9 is installed into the cylinder 1, the end cap 6 is welded to the open end of the cylinder 1 by friction stir welding while the cylinder 1 is inverted.

[0179] In this embodiment, the end cap 6 can be provided with a liquid injection port and a venting port separately, or a liquid injection and venting port can be provided together. In some other embodiments, the liquid injection port and the venting port can also be provided at the top or bottom of the cylinder.

[0180] Next, the entire structure is rotated 180° to seal the connection between each clearance hole 2 and the top cover of the individual battery 3.

[0181] Since the diameter of the clearance hole 2 is larger than the outer diameter of the terminal post of the single cell 3 (there is a gap here, as shown by mark A in Figure 7), and there may still be a small gap between the top cover of the single cell 3 and the inner wall of the top of the cylinder 1 (as shown by mark B in Figure 7), in order to ensure the sealing, this embodiment adopts the method of welding the edge of the clearance hole 2 near the single cell 3 to the top cover of the single cell 3 to achieve a sealed connection, so as to avoid the external environment from interfering with the internal environment of the large-capacity battery through gaps A and B;

[0182] In addition to the welding method used in this embodiment, in some other embodiments, laser welding can also be used to weld the area around each clearance hole 2 on the top of the cylinder 1 and the area around the pole on the top cover of the corresponding single cell 3. However, this welding method requires a high wall thickness of the cylinder 1 (setting a thicker cylinder wall thickness may result in poor welding effect, while setting a thinner cylinder wall thickness may result in high temperature damage inside the single cell).

[0183] In other embodiments, step 4 can also be performed using the following procedure:

[0184] In the inverted state, the steps of fixing and sealing the end cap 6 to the open end of the cylinder and sealing the top cover of each clearance hole 2 and the individual battery 3 are completed respectively. These two steps can be performed in any order, as long as the internal environment and external environment of the final large-capacity battery are sealed and isolated.

[0185] In this embodiment, the battery pack string 9 completes the step of opening through holes before being installed into the cylinder 1. Compared with the method of opening through holes in individual cells after all individual cells are installed into the cylinder 1, the space required for the tool to enter the cylinder 1 to perform the opening operation can be eliminated, thereby reducing the size of the cylinder, improving the energy density of large-capacity batteries to a certain extent, and reducing the difficulty of opening through holes in individual cells.

[0186] When performing step 1, opening the through hole 4 in the single cell 3, due to the existence of pressure difference, some free electrolyte in the single cell may still overcome gravity and overflow from the single cell 3 onto the single cell 3. If it is not cleaned in time, the excessively high temperature or open flame may pose a risk when performing the welding work in step 4. Therefore, step 1 of this embodiment also includes a step of cleaning the single cell 3 with electrolyte after waiting for a period of time to allow the electrolyte in the single cell 3 to completely overflow after completing the step of opening the through hole 4 at the bottom of the single cell 3.

[0187] In this embodiment, in order to compensate for the loss of electrolyte in each individual cell when the through hole 4 is opened, and also to ensure that there is enough electrolyte in the large-capacity battery to realize the shared electrolyte system of each individual cell 3, the process also includes an electrolyte injection operation after step 4. Specifically, electrolyte is injected into the large-capacity battery casing using the injection port on the end cap or the cylinder.

[0188] As a large-capacity battery composed of multiple individual cells, in order to ensure its excellent performance, formation and aging steps can also be performed on the large-capacity battery after liquid injection.

[0189] In this embodiment, based on the above manufacturing process, the following two optimization designs were also made:

[0190] Optimized Design 1: Since the gap between the terminal of the single cell 3 and the clearance hole 2 is small, the insulation between the terminal of the single cell 3 and the cylinder 1 may be difficult to ensure. In addition, if a large-capacity battery experiences thermal runaway, cracks will appear at the welded position between the clearance hole 2 and the top cover of the single cell 3, causing thermal runaway fumes to leak out from that position. Therefore, this embodiment also includes step 5, which is to set an insulating seal 7 in the gap between each clearance hole 2 and the terminal. The insulating seal 7 can ensure the insulation between the terminal and the cylinder. At the same time, even if leakage occurs at the welded position, the insulating seal 7 can also serve as a second barrier to prevent the leakage of thermal runaway fumes.

[0191] Optimized Design Two: This also includes step 6, where a terminal adapter 8 is placed on each individual cell's three-terminal, tightly pressing the terminal adapter against the insulating seal 7. The terminal adapter 8 is then welded to the individual cell's three-terminal. By setting the terminal adapter 8, the insulating seal 7 can be pressed tightly, preventing it from detaching in the event of thermal runaway and causing leakage of thermal runaway gas. Therefore, the design of the terminal adapter 8 pressing the insulating seal 7 can act as a third barrier to prevent leakage of thermal runaway gas. Simultaneously, the terminal adapter facilitates heat exchange between the individual cell terminals using a heat exchange device.

[0192] To ensure that the terminal adapter 8 can uniformly apply pressure to the insulating seal 7 and guarantee its insulation seal performance, in this embodiment, the insulating seal 7 includes a flexible insulating sealing ring 71 and a pressure ring 72. During assembly, the flexible insulating sealing ring 71 is first placed in the clearance hole 2, and then the pressure ring 72 is placed on the flexible insulating sealing ring 71. The flexible insulating sealing ring 71 has a flexible stepped structure, with the small-diameter section of the stepped structure extending into the clearance hole and contacting the top cover of the single battery cell, and the large-diameter section of the stepped structure located outside the cylinder and contacting the top of the cylinder. The pressure ring 72 is a metal part.

[0193] In some other embodiments, the insulating seal 7 may also be an insulating seal layer disposed at the gap between the clearance hole 2 and the pole post by a casting process.

[0194] When implementing the high-capacity battery manufacturing process in the above two embodiments, it must be carried out under specific conditions. At least the following points must be ensured under these specific conditions:

[0195] Fully enclosed cleanroom: In order to maintain the cleanliness of production and avoid contamination by dust and other impurities, lithium battery production workshops are usually designed as fully enclosed cleanroom environments.

[0196] Temperature and humidity control: Extremely low relative humidity and dew point temperature must be maintained to prevent moisture from entering the battery and causing quality problems. Critical processes require even more stringent standards, with the dew point controlled below -40°C and the relative humidity below 0.5%.

[0197] Dust control: Dust is one of the most critical factors to control throughout the manufacturing process because it can affect the electrical performance of batteries and may pose safety hazards.

[0198] Examples 3 and 4 disclose a method for preparing a high-capacity battery. First, a top plate with 2n clearance holes is placed on top of n individual cells, so that the terminals of each individual cell pass through the corresponding clearance holes, where n is an integer greater than 1. Each clearance hole and the top cover of the individual cell are sealed together. Then, all the individual cells with the top plate fixed are inverted so that the bottom of each individual cell faces upward, and through holes are made at the bottom of each individual cell. Next, a pad is placed at the non-through hole part of the bottom of each individual cell. Finally, a box with one open end is fastened, so that the bottom plate of the box presses the pad, and the open end of the box is sealed and fixed to the top plate.

[0199] The core of Examples 3 and 4 lies in placing the individual cells with through holes at the bottom directly into a sealed housing consisting of a top plate and an open-end casing. This allows multiple individual cells to be in a closed space, thereby enabling the electrolyte zones within each individual cell to be interconnected. Compared to the fabrication of large-capacity batteries in the background art, Examples 3 and 4 eliminate the process of connecting sub-pipes to form a shared channel, greatly reducing production difficulty and enabling mass production.

[0200] In addition, in the fabrication of large-capacity batteries in the background technology, after the various sub-pipes are connected to form a shared pipeline, a secondary unpacking operation is required for each individual cell to enable the electrolyte regions of each individual cell to be connected through the shared pipeline.

[0201] The process of repackaging is relatively complicated. The general process is as follows: First, a through hole is made on the commercially available square aluminum-cased lithium battery. Then, a sealing mechanism is set on the through hole. Next, after all the sub-pipes are connected and a shared pipeline is formed, electrolyte is introduced into the shared pipeline to dissolve and detach the sealing mechanism, thus forming a through hole again. Alternatively, external force (such as using a packing tool) can be used to insert into the shared pipeline, open the sealing mechanism, and form a through hole again.

[0202] Unlike the above process, in Examples 3 and 4, after the through hole is made in the single cell, it can be placed directly into the casing without performing the above complicated secondary unpacking process. This not only avoids additional sealing treatment of the through hole, but also saves the complicated operation of opening the sealing mechanism later, and the overall preparation process is greatly simplified.

[0203] In terms of space utilization, the above-mentioned secondary unpacking method using unpacking tools requires the unpacking tools to be inserted into the shared pipeline for operation. This necessitates reserving sufficient space inside the shared pipeline for the unpacking tools to operate, which makes the overall battery size larger in the height direction.

[0204] In Examples 3 and 4, electrolyte sharing is achieved simply by placing a gasket between the individual battery cell and the casing to leave a gap. This method has smaller dimensional requirements in the height direction, effectively improving space utilization efficiency and making the overall battery structure more compact. In practical applications, it can better adapt to equipment or environments with strict space requirements.

[0205] Other high-capacity battery manufacturing processes are also disclosed in the prior art. For example, the high-capacity battery manufacturing process disclosed in Chinese Patent CN119092774A also employs a secondary unpacking process. During unpacking, external force or the electrolyte itself is needed to create through holes in the individual battery casing, enabling the electrolyte to share a channel and connect with the electrolyte area of ​​the individual battery. In contrast, Examples 3 and 4 do not require additional sealing treatment or complex post-opening operations, demonstrating significant advantages. Furthermore, the dimensional advantage of Examples 3 and 4 in the height direction further highlights their advantages in space utilization and structural compactness.

[0206] Example 3

[0207] The structure of the large-capacity battery to be prepared in this embodiment is shown in Figures 10 and 11, including a housing 21 and 12 individual cells 22 arranged in the housing 21. In some other embodiments, the number of individual cells 22 can be adjusted according to actual needs.

[0208] As can be seen from the figure, this embodiment is a rectangular shell 21. For ease of description, the length direction of the shell 21 is defined as the x-direction, the width direction of the shell 21 is defined as the y-direction, and the height direction of the shell 21 is defined as the z-direction.

[0209] In this embodiment, the shell 21 can be made of steel or aluminum.

[0210] The steel casing 21 has relatively high strength, providing robust physical protection for the battery pack. However, under certain circumstances, it may chemically react with the electrolyte, negatively impacting battery performance. To overcome this problem, this embodiment incorporates an electrolyte-repellent film on the inner wall of the steel casing 21, acting as a barrier to effectively isolate the steel casing 21 from the electrolyte and prevent direct contact and reaction between the two.

[0211] The electrolyte-repellent membrane should have at least two characteristics: firstly, it should not react with the electrolyte; secondly, it should have good mechanical properties and be able to firmly adhere to the inner wall of the steel shell 21, thus playing a stable role in isolation over a long period of time. In this embodiment, the electrolyte-repellent membrane can be a metallic nickel layer coated on the inner wall of the steel shell 21, or it can be a polytetrafluoroethylene (PTFE) coating, etc.

[0212] The aluminum casing 21 has a low density, making it significantly lighter than traditional steel. Furthermore, unlike steel, aluminum does not react with the electrolyte, ensuring the battery's long-term stability and reliability. In addition, aluminum has high thermal conductivity, enabling it to quickly dissipate heat generated inside the battery.

[0213] In this embodiment, the housing 21 consists of a box 211 with one open end and a top plate 212 (parallel to the xy plane) for sealing the open end. On the top plate 212, there are clearance holes 213 corresponding to the polarity terminals of each individual battery 22. The polarity terminals of each individual battery 22 pass through and extend out of the corresponding clearance holes 213. The area of ​​the top plate 212 corresponding to the clearance hole 213 (the area of ​​the top plate 212 around the clearance hole 213 or the wall of the clearance hole 213) is fixedly sealed to the housing of the individual battery 22.

[0214] It should be noted that:

[0215] The polarity terminal of the single cell 22 mentioned here can be the terminal post 221 of the single cell 22. In order to avoid the terminal post 221 of the single cell 22 not being able to extend smoothly out of the clearance hole 213 or the height of extending out of the clearance hole 213 not meeting the set requirements, a terminal post adapter 224 can be connected to the terminal post 221 of the single cell 22, and the overall structure of the terminal post 221 of the single cell 22 and the terminal post adapter 224 can be used as the polarity terminal of the single cell 22.

[0216] A through hole 222 is made in the lower cover of the single cell 22, and a pad 25 is set between the non-through hole 222 area and the bottom plate of the casing 21 to form an electrolyte sharing channel 23.

[0217] Referring to Figures 12 to 14, this embodiment prepares the above-mentioned high-capacity battery through the following process:

[0218] Step 1: As shown in Figure 12, place the top plate 212 with 24 clearance holes 213 on top of the 12 individual cells 22, ensuring that the terminal post 221 of each individual cell 22 passes through the corresponding clearance hole 213; seal the connection between each clearance hole 213 and the top cover of the individual cell 22.

[0219] This step can be implemented in two ways. In the first way, the 12 individual batteries 22 can be arranged into a battery pack along the x direction, and then the top cover of each clearance hole 213 and the individual battery 22 can be sealed and connected.

[0220] The second method involves sequentially sealing the top covers of the 12 individual battery cells 22 to each of the clearance holes 213 on the top plate 212.

[0221] Compared to the second method, the first method is more efficient and can save time costs in large-scale production. This embodiment selects the first method.

[0222] To improve the overall stability of the battery pack, as shown in Figure 12, this embodiment also employs two end fixing plates 26 and fixing straps 24 to securely restrain the battery pack. Specifically, in this embodiment, after arranging 12 individual cells 22 into a battery pack along the x-direction, the two end fixing plates 26 are respectively placed against both ends of the battery pack along the x-direction. The fixing straps 24 are then wrapped around the battery pack and the end fixing plates 26. By tightening the fixing straps 24, the end fixing plates 26 are made to tightly adhere to the individual cells 22 at both ends of the battery pack. In this way, multiple individual cells 22 are firmly restrained between the two end fixing plates 26, which not only effectively prevents the individual cells 22 from shifting in the x-direction but also enhances the overall rigidity of the battery pack.

[0223] This embodiment can employ two fixing straps 24, one near the top of the battery pack and the other near the bottom, forming a symmetrical constraint structure around the battery pack. In practical applications, the number and installation position of the fixing straps 24 can be flexibly adjusted according to the specific dimensions of the battery pack, the usage environment, and the stress conditions. For example, for larger battery packs with complex stress conditions, the number of fixing straps 24 can be appropriately increased to provide stronger fixation and protection.

[0224] In addition, the battery pack is fixed by the fixing strap 24 and the two end fixing plates 26, which improves the stability of the overall structure. The stable structure ensures that the individual battery 22 will not easily shift or shake during subsequent operations, thus facilitating the sealing connection between each clearance hole 213 and the top cover of the individual battery 22.

[0225] To further optimize the performance of the battery pack, this embodiment may also provide a separator 28 between adjacent individual cells 22. The separator 28 has fixing ribs 29 perpendicular to its plane on both sides, with the two sides of the fixing ribs 29 abutting against the sides of the individual cells 22 on both sides of the separator 28. This further improves the structural stability of the battery pack and also optimizes its heat dissipation performance.

[0226] As can be seen from Figure 12, in this embodiment, a separator 28 is provided between every three individual cells 22, and a total of three separators 28 are provided.

[0227] During the operation of a large-capacity battery, as the charging and discharging process proceeds, a chemical reaction occurs inside the individual cell 22, causing a certain degree of volume expansion. In this embodiment, when the individual cell 22 expands, the separator 28 can deform within a certain range to buffer this expansion force, thus maintaining the stability of the overall structure of the battery pack and preventing the application of additional stress to the casing 21 that could potentially damage it.

[0228] Furthermore, when heat is generated, the separator 28 acts as a heat conduction medium, rapidly transferring the heat generated by the individual cells 22 to all parts of the battery pack, accelerating heat dissipation. This effectively reduces the overall temperature of the battery pack, preventing battery performance degradation or shortened lifespan due to overheating, and ensuring the stability and reliability of the battery under high load operation.

[0229] In other embodiments, the number of separators 28 can be flexibly adjusted based on factors such as battery pack capacity, the number of individual cells 22, and the expected usage environment. For example, if the battery pack capacity is large and the individual cells 22 generate a lot of heat, the number of separators 28 can be appropriately increased to enhance heat dissipation; if the number of individual cells 22 is large, the number of separators 28 can also be increased to ensure structural stability.

[0230] In this embodiment, three fixing ribs 29 are provided on each opposite side of each partition 28. The three fixing ribs 29 are evenly distributed along the z-direction, and each fixing rib 29 is parallel to the xz plane. In the thickness direction (x-direction) of the partition 28, the size of the fixing rib 29 is larger than the thickness of the partition 28. It extends out of the partition 28 on both sides and abuts against the sides of the individual cells 22 on both sides of the partition 28, thereby limiting the individual cells 22 on both sides from the y-direction.

[0231] In other embodiments, the number of fixing ribs 29 can be flexibly adjusted according to various factors such as the specific specifications of the battery pack, the expected external forces it will withstand, and the arrangement of the individual cells 22. For example, if the battery pack is used in an environment with frequent vibration, the number of fixing ribs 29 can be appropriately increased, and they can be installed in key parts of the battery pack that are susceptible to vibration.

[0232] Since the diameter of the clearance hole 213 is larger than the outer diameter of the terminal post 221 of the single cell 22, in order to ensure sealing, this embodiment adopts a method of welding the edge of the clearance hole 213 on the side closer to the single cell 22 to the top cover of the single cell 22 to achieve a sealed connection, thus avoiding the gap between the clearance hole 213 and the terminal post 221 from the external environment from interfering with the internal environment of the large-capacity battery.

[0233] In addition to the welding method used in this embodiment, in some other embodiments, laser welding can also be used to weld the area around each clearance hole 213 of the top plate 212 and the area around the corresponding electrode post 221 on the top cover of the single cell 22. However, this welding method requires a high wall thickness of the top plate 212 (a thicker top plate 212 may result in poor welding effect, while a thinner top plate 212 may cause high-temperature damage to the inside of the single cell 22).

[0234] Step 2: As shown in Figure 13, invert the components from Step 1 and open through holes 222 at the bottom of each individual cell 22.

[0235] In this step, "inverted" means that the bottom of the individual cell 22 is facing upwards and the top is facing downwards. The purpose is to ensure that the electrolyte inside the individual cell 22 does not flow out in large quantities when the through hole 222 is opened.

[0236] In this embodiment, the single cell 22 is a commercially available square aluminum-cased lithium battery. Therefore, in this step, a through hole 222 can be directly opened at the bottom of the commercially available square aluminum-cased lithium battery using a tool. Compared with the prior art, there is no need to modify the commercially available square aluminum-cased lithium battery (set a sealing mechanism), which greatly reduces the manufacturing difficulty and cost.

[0237] It should be noted that when the through-hole 222 is opened in the single cell 22 and the subsequent processes after opening the through-hole 222 are carried out under specific conditions, the following points must be ensured at least under these conditions:

[0238] Fully enclosed cleanroom: In order to maintain the cleanliness of production and avoid contamination by dust and other impurities, lithium battery production workshops are usually designed as fully enclosed cleanroom environments.

[0239] Temperature and humidity control: Extremely low relative humidity and dew point temperature must be maintained to prevent moisture from entering the battery and causing quality problems. Critical processes require even more stringent standards, with the dew point controlled below -40°C and the relative humidity below 0.5%.

[0240] Dust control: Dust is one of the most critical factors to control throughout the manufacturing process because it can affect the electrical performance of batteries and may pose safety hazards.

[0241] In addition, during this step, due to the pressure difference, some free electrolyte in the single cell 22 may still overflow from the single cell 22 after overcoming gravity. If it is not cleaned in time, excessively high temperature or open flame may pose a risk when performing subsequent welding work. Therefore, step 2 of this embodiment also includes a step of cleaning the single cell 22 after waiting for a period of time to allow the electrolyte in the single cell 22 to completely overflow after completing the step of opening the through hole 222 at the bottom of the single cell 22.

[0242] Step 3: Install a pad 25 at the non-through hole 222 part at the bottom of each individual cell 22;

[0243] As shown in Figure 14, in this embodiment, an annular pad 25 is provided at the bottom of each individual battery 22. The orthographic projection of the inner hole of the annular pad 25 onto the bottom of each individual battery 22 covers the through hole 222 on the bottom of each individual battery 22. The purpose of adding the pad 25 is mainly to form a gap between the through hole 222 and the bottom plate of the housing 21, which serves as an electrolyte sharing channel 23. There is no need to separately process the electrolyte sharing channel at the bottom of the housing 21, making the processing of the housing 21 simpler.

[0244] In some other embodiments, two rectangular pads 25 may be used, both of which extend along the x-direction and are arranged along the y-direction. In the y-direction, the distance between the two rectangular pads 25 needs to be greater than the size of the through hole 222 of the bottom plate of the single cell 22.

[0245] Step 4: On the product in Step 3, fasten the box body 211 with one open end, press the bottom plate of the box body 211 against the pad 25, and seal and fix the open end of the box body 211 to the top plate 212.

[0246] Referring to Figures 15 and 16, in this embodiment, the box 211, with one open end facing downwards, is fastened onto the product completed in step 3. In the specific operation of sealing and fixing the open end of the box 211 to the top plate 212, considering the actual needs of the welding process, the entire assembly needs to be flipped so that the top plate 212 faces upwards, in order to smoothly perform the sealing welding work between the open end of the box 211 and the top plate 212.

[0247] To effectively prevent the box body 211 from detaching from the top plate 212 during the flipping process, the box body 211 and the top plate 212 can be pre-positioned before flipping. Multiple positioning protrusions can be evenly distributed along the edge of the open end of the box body 211, while corresponding positioning grooves can be formed on the top plate 212. When the box body 211 is fastened onto the product, the positioning protrusions fit precisely into the positioning grooves, achieving initial and accurate positioning of the box body 211 and the top plate 212. Alternatively, a positioning pin and positioning hole combination can be used. Positioning pins and positioning holes are installed at corresponding positions on the open end of the box body 211 and the top plate 212, respectively. When fastening the box body 211, the positioning pins accurately insert into the positioning holes, ensuring the relative position of the box body 211 and the top plate 212 is stable before flipping, greatly reducing the risk of them detaching during the flipping process.

[0248] In addition, during the flipping process, electrolyte leakage is inevitable due to the through-hole 222 already opened at the bottom of the individual cell 22. Therefore, after flipping, the electrolyte needs to be cleaned to ensure the cleanliness of the welding work area and avoid the risks that may arise from excessively high temperatures or open flames during welding.

[0249] In this embodiment, in order to compensate for the loss of electrolyte in each individual cell 22 during the opening of the through hole 222 and this step, and also to ensure that there is enough electrolyte in the large-capacity battery to realize the shared electrolyte system of each individual cell 22, the process also includes an electrolyte injection operation after step 4. Specifically, electrolyte is injected into the large-capacity battery casing 21 through the electrolyte injection port on the casing.

[0250] As a large-capacity battery composed of multiple individual cells 22, in order to ensure its excellent performance, formation and aging steps can also be performed on the large-capacity battery after liquid injection.

[0251] In this embodiment, the one-end open housing 211 can be integrally formed using a stamping process. In terms of manufacturing, integrally forming the one-end open housing 211 using a stamping process has significant advantages. The stamping process enables efficient, mass production, greatly improving production efficiency. Integral forming means reducing complex processes such as splicing and welding, lowering labor and time costs in the production process, and also reducing errors that may arise from assembling multiple parts, improving product consistency and yield. From a structural performance perspective, the integrally formed housing 211 is more robust. Compared to a housing 211 assembled from multiple parts, integral forming eliminates splicing gaps, avoiding the overall structural weakness caused by insufficient strength at gaps. This allows the housing 211 to better maintain structural integrity when subjected to the pressure of the internal battery pack and possible external impacts and compression, further enhancing the structural strength of the battery casing 21 and providing more reliable protection for the battery pack.

[0252] The casing 211, formed by stamping, has an open end and a certain draft angle. In this embodiment, the draft angle can be corrected by using the end fixing plates 26 on both sides, so that the battery pack and the casing 21 can be assembled more precisely. The end fixing plates 26 can be designed as inclined surfaces that complement the draft angle of the casing 211. During assembly, the end fixing plates 26 apply appropriate pressure to make fine adjustments to the sides of the casing 211, compensating for the dimensional deviations caused by the draft angle.

[0253] When there is a separator 28 between each individual cell 22, the fixing stiffener 29 can be welded to the housing 21 by through welding to ensure that a strong and durable connection is formed between the fixing stiffener 29 and the housing 21, so that the two are tightly combined into a whole structure.

[0254] In this embodiment, the fixing rib 29 is tightly connected to the partition 28 and the shell 21, which has at least the following advantages:

[0255] From a structural strength perspective, this design enhances the rigidity of the entire large-capacity battery to a certain extent. The fixing ribs 29, working in conjunction with the separator 28 and the casing 21, comprehensively improve the structural strength of the casing 21. In practical applications, when the battery is subjected to external impact or compression, the fixing ribs 29 effectively disperse the external force, preventing the casing 21 from deforming or cracking due to excessive localized stress, thus strongly ensuring the safe operation of the battery. Furthermore, the fixing ribs 29 extend beyond the sides of the separator 28 and tightly abut against the sides of the individual battery cells 22, thus limiting the movement of the individual battery cells 22. During daily use of the battery pack, especially under complex conditions such as vibration and bumps, this prevents the displacement of the individual battery cells 22.

[0256] In terms of heat dissipation, since the fixing rib 29 is in close contact with the individual battery cell 22, it can effectively conduct the heat generated by the battery during charging and discharging, and dissipate the heat to the outside through the connection with the casing 21. This helps to maintain the temperature balance inside the battery pack, prevent local overheating, thereby extending the battery's lifespan and improving the overall performance of the battery.

[0257] Example 4

[0258] Based on the preparation process of Example 3, this embodiment also makes the following two optimized designs, which can be seen in Figures 17 to 19:

[0259] Optimized Design 1: Due to the small gap size between the terminal post 221 of the individual battery 22 and the clearance hole 213, the insulation between the terminal post 221 of the individual battery 22 and the top plate 212 may be difficult to ensure. In addition, if a large-capacity battery experiences thermal runaway, cracks will appear at the welded position between the clearance hole 213 and the top cover of the individual battery 22, causing thermal runaway fumes to leak out from that position. Therefore, this embodiment also includes step 5, that is, setting an insulating seal 223 in the gap between each clearance hole 213 and the terminal post 221. The insulating seal 223 can ensure the insulation between the terminal post 221 and the top plate 212. At the same time, even if leakage occurs at the welded position, the insulating seal 223 can also serve as a second barrier to prevent the leakage of thermal runaway fumes.

[0260] Optimized Design 2: A terminal adapter 224 is placed on each individual cell 22 terminal 221, pressing the terminal adapter 224 tightly against the insulating seal 223. The terminal adapter 224 is then welded to the individual cell 22 terminal 221. By setting the terminal adapter 224, the insulating seal 223 can be pressed tightly, preventing it from falling off in the event of thermal runaway and causing leakage of thermal runaway gas. Therefore, the design of the terminal adapter 224 pressing the insulating seal 223 can act as a third barrier to prevent leakage of thermal runaway gas. Simultaneously, the terminal adapter 224 facilitates heat exchange between the individual cell 22 terminal 221 using a heat exchange device.

[0261] To ensure that the terminal adapter 224 can uniformly apply clamping force to the insulating seal 223 and thus guarantee the insulation seal 223's sealing performance, in this embodiment, the insulating seal 223 includes a flexible insulating sealing ring 2231 and a pressure ring 2232. During assembly, the flexible insulating sealing ring 2231 is first placed in the clearance hole 213; then, the pressure ring 2232 is placed on the flexible insulating sealing ring 2231. The flexible insulating sealing ring 2231 has a flexible stepped structure, with the smaller diameter section of the stepped structure extending into the clearance hole 213 and contacting the top cover of the single battery 22, and the larger diameter section of the stepped structure located outside the top plate and contacting the top of the top plate. The pressure ring 2232 is a metal part.

[0262] In some other embodiments, the insulating seal 223 may also be an insulating seal layer disposed at the gap between the clearance hole 213 and the pole post 221 by a casting process.

[0263] Examples 5 and 6 disclose a method for preparing a high-capacity battery. First, n individual batteries are inverted with their bottoms facing upwards, and through holes are made in the bottom of each individual battery; where n is an integer greater than 1. Then, the box with its open bottom is inverted with its open end facing upwards, and the n individual batteries with through holes are placed into the box from the open end in an inverted position, ensuring that the terminals of each individual battery pass through the corresponding clearance holes made on the top plate of the box. Next, with the box in the inverted position, a pad is placed at the non-through hole part of the bottom of each individual battery. The bottom plate is fixed and sealed to the open end of the box. Finally, the box is flipped over, and each clearance hole and the top cover of the individual battery are sealed together.

[0264] The core of Examples 5 and 6 lies in placing the individual cells with through holes at the bottom directly into a sealed housing consisting of a base plate and an open-bottom box, thus placing multiple individual cells in a sealed space and enabling the electrolyte zones within each individual cell to be interconnected. Compared to the fabrication of large-capacity batteries in the prior art, Examples 5 and 6 eliminate the process of connecting sub-pipes to form a shared channel, greatly reducing production difficulty and enabling mass production.

[0265] In addition, in the fabrication of large-capacity batteries in the background technology, after the various sub-pipes are connected to form a shared pipeline, a secondary unpacking operation is required for each individual cell to enable the electrolyte regions of each individual cell to be connected through the shared pipeline.

[0266] The process of repackaging is relatively complicated. The general process is as follows: First, a through hole is made on the commercially available square aluminum-cased lithium battery. Then, a sealing mechanism is set on the through hole. Next, after all the sub-pipes are connected and a shared pipeline is formed, electrolyte is introduced into the shared pipeline to dissolve and detach the sealing mechanism, thus forming a through hole again. Alternatively, external force (such as using a packing tool) can be used to insert into the shared pipeline, open the sealing mechanism, and form a through hole again.

[0267] Unlike the above process, in Examples 5 and 6, after the through hole is made in the single cell, it can be placed directly into the casing without performing the above complicated secondary unpacking process. This not only avoids additional sealing treatment of the through hole, but also saves the complicated operation of opening the sealing mechanism later, and the overall preparation process is greatly simplified.

[0268] In terms of space utilization, the above-mentioned secondary unpacking method using unpacking tools requires the unpacking tools to be inserted into the shared pipeline for operation. This necessitates reserving sufficient space inside the shared pipeline for the unpacking tools to operate, which makes the overall battery size larger in the height direction.

[0269] In Examples 5 and 6, electrolyte sharing is achieved simply by placing a gasket between the individual battery cell and the casing, leaving a gap. This method has smaller dimensional requirements in the height direction, effectively improving space utilization efficiency and making the overall battery structure more compact. In practical applications, it can better adapt to equipment or environments with strict space requirements.

[0270] Other high-capacity battery manufacturing processes are also disclosed in the prior art. For example, the high-capacity battery manufacturing process disclosed in Chinese Patent CN119092774A also employs a secondary unpacking process. During unpacking, external force or the electrolyte itself is needed to create through holes in the individual battery casing, enabling the electrolyte to share a channel and connect with the electrolyte area of ​​the individual battery. In contrast, Examples 5 and 6 do not require additional sealing treatment or complex post-opening operations, demonstrating significant advantages. Furthermore, the dimensional advantage of Examples 5 and 6 in the height direction further highlights their advantages in space utilization and structural compactness.

[0271] Example 5

[0272] The structure of the large-capacity battery to be prepared in this embodiment is shown in Figures 20 and 21, including a housing 31 and 12 individual cells 32 arranged in the housing 31. In some other embodiments, the number of individual cells 32 can be adjusted according to actual needs.

[0273] As can be seen from the figure, this embodiment is a rectangular shell 31. For ease of description, the length direction of the shell 31 is defined as the x-direction, the width direction of the shell 31 is defined as the y-direction, and the height direction of the shell 31 is defined as the z-direction.

[0274] In this embodiment, the shell 31 can be made of steel or aluminum.

[0275] The steel casing 31 has relatively high strength, providing robust physical protection for the battery pack. However, under certain circumstances, it may chemically react with the electrolyte, negatively impacting battery performance. To overcome this problem, this embodiment incorporates an electrolyte-repellent film on the inner wall of the steel casing 31, acting as a barrier to effectively isolate the steel casing 31 from the electrolyte and prevent direct contact and reaction between the two.

[0276] The electrolyte-repellent membrane should have at least two characteristics: firstly, it should not react with the electrolyte; secondly, it should have good mechanical properties and be able to firmly adhere to the inner wall of the steel shell 31, thus playing a stable role in isolation over a long period of time. In this embodiment, the electrolyte-repellent membrane can be a metallic nickel layer coated on the inner wall of the steel shell 31, or it can be a polytetrafluoroethylene (PTFE) coating, etc.

[0277] The aluminum casing 31 has a low density, making it significantly lighter than traditional steel. Furthermore, unlike steel, aluminum does not react with the electrolyte, ensuring the battery's long-term stability and reliability. In addition, aluminum has high thermal conductivity, enabling it to quickly dissipate heat generated inside the battery.

[0278] In this embodiment, the housing 31 is composed of a box 311 with an open bottom end and a bottom plate 312 (parallel to the xy plane) for sealing the open end. On the top plate of the box (where the top plate of the box is a plate parallel to the bottom plate 312), there are clearance holes 313 corresponding to the polarity terminals of each individual battery 32. The polarity terminals of each individual battery 32 pass through and extend out of the corresponding clearance holes 313. The top plate area corresponding to the clearance hole 313 (the top plate area around the clearance hole 313 or the hole wall of the clearance hole 313) is fixedly sealed to the housing of the individual battery 32.

[0279] It should be noted that:

[0280] The polarity terminal of the single cell 32 mentioned here can be the terminal post 321 of the single cell 32. In order to avoid the terminal post 321 of the single cell 32 not being able to extend smoothly out of the clearance hole 313 or the height of extending out of the clearance hole 313 not meeting the set requirements, a terminal post adapter 324 can be connected to the terminal post 321 of the single cell 32, and the overall structure of the terminal post 321 of the single cell 32 and the terminal post adapter 324 can be used as the polarity terminal of the single cell 32.

[0281] A through hole 322 is made in the lower cover of the single cell 32, and a pad 35 is provided between the non-through hole 322 area and the bottom plate 312 of the casing 31 to form an electrolyte sharing channel 33.

[0282] Referring to Figures 22 to 24, this embodiment prepares the above-mentioned high-capacity battery through the following process:

[0283] Step 1: As shown in Figure 22, invert each individual cell and make through holes 322 at the bottom of each individual cell 32 (here, the bottom of the individual cell is the lower cover plate of the individual cell).

[0284] In this step, "inverted" means that the bottom of the single cell 32 is facing upwards and the top is facing downwards. The purpose is to ensure that the electrolyte inside the single cell 32 does not flow out in large quantities when the through hole 322 is opened.

[0285] In this embodiment, the single cell 32 is a commercially available square aluminum-cased lithium battery. Therefore, in this step, a through hole 322 can be directly opened at the bottom of the commercially available square aluminum-cased lithium battery using a tool. Compared with the prior art, there is no need to modify the commercially available square aluminum-cased lithium battery (set a sealing mechanism), which greatly reduces the manufacturing difficulty and cost.

[0286] It should be noted that when the through hole 322 is opened in the single cell 32 and the subsequent processes after opening the through hole 322 are carried out under specific conditions, the following points must be ensured at least under these conditions:

[0287] Fully enclosed cleanroom: In order to maintain the cleanliness of production and avoid contamination by dust and other impurities, lithium battery production workshops are usually designed as fully enclosed cleanroom environments.

[0288] Temperature and humidity control: Extremely low relative humidity and dew point temperature must be maintained to prevent moisture from entering the battery and causing quality problems. Critical processes require even more stringent standards, with the dew point controlled below -40°C and the relative humidity below 0.5%.

[0289] Dust control: Dust is one of the most critical factors to control throughout the manufacturing process because it can affect the electrical performance of batteries and may pose safety hazards.

[0290] In addition, during this step, due to the pressure difference, some free electrolyte in the single cell 32 may still overflow from the single cell 32 after overcoming gravity. If it is not cleaned in time, excessively high temperature or open flame may pose a risk when performing subsequent welding work. Therefore, step 1 of this embodiment also includes a step of cleaning the single cell 32 with electrolyte after waiting for a period of time to allow the electrolyte in the single cell 32 to completely overflow after completing the step of opening the through hole 322 at the bottom of the single cell 32.

[0291] Step 2: As shown in Figures 23 and 24, invert the box 311 with the bottom open end facing upwards, and put the 12 individual batteries with through holes 322 into the box 311 from the open end in the inverted position, ensuring that the terminal post 321 of each individual battery passes through the corresponding clearance hole 313 opened on the top plate of the box 311.

[0292] This step can be implemented in two ways. In the first way, the 12 individual batteries 32 can be arranged into a battery pack along the x direction, and then the pack can be placed into the housing 311 as a whole from the open end of the housing 311.

[0293] The second method involves placing each of the 12 individual cells 32 into the housing 311 one by one from the open end of the housing 311.

[0294] Compared to the second method, the first method is more efficient and can save time costs in large-scale production. This embodiment selects the first method.

[0295] To improve the overall stability of the battery pack, referring to Figure 22, this embodiment also employs two end fixing plates 36 and fixing straps 34 to securely restrain the battery pack. Specifically, in this embodiment, after arranging 12 individual cells 32 along the x-direction into a battery pack, the two end fixing plates 36 are respectively placed against both ends of the battery pack along the x-direction. The fixing straps 34 are then wrapped around the battery pack and the end fixing plates 36. By tightening the fixing straps 34, the end fixing plates 36 are made to tightly adhere to the individual cells 32 at both ends of the battery pack. In this way, multiple individual cells 32 are firmly restrained between the two end fixing plates 36, which not only effectively prevents the individual cells 32 from shifting in the x-direction but also enhances the overall rigidity of the battery pack.

[0296] This embodiment can employ two fixing straps 34, one near the top of the battery pack and the other near the bottom, forming a symmetrical constraint structure around the battery pack. In practical applications, the number and installation position of the fixing straps 34 can be flexibly adjusted according to the specific dimensions of the battery pack, the usage environment, and the stress conditions. For example, for larger battery packs with complex stress conditions, the number of fixing straps 34 can be appropriately increased to provide stronger fixation and protection.

[0297] In addition, the battery pack is fixed by the fixing strap 34 and the two end fixing plates 36, which improves the stability of the overall structure. The stable structure ensures that the individual battery 32 will not easily move or shake during subsequent operations, thus making it easy to put it into the box as a whole from the open end of the box 311.

[0298] To further optimize the performance of the battery pack, this embodiment may also provide a separator 38 between adjacent individual cells 32. The separator 38 has fixing ribs 39 perpendicular to its plane on both sides, with the two sides of the fixing ribs 39 abutting against the sides of the individual cells 32 on both sides of the separator 38. This further improves the structural stability of the battery pack and also optimizes its heat dissipation performance.

[0299] As can be seen from Figure 22, in this embodiment, a separator 38 is provided between every three individual cells 32, and a total of three separators 38 are provided.

[0300] During the operation of a large-capacity battery, as the charging and discharging process proceeds, a chemical reaction occurs inside the individual cell 32, causing a certain degree of volume expansion. In this embodiment, when the individual cell 32 expands, the separator 38 can deform within a certain range to buffer this expansion force, thus maintaining the overall stability of the battery pack structure and preventing the application of additional stress to the casing 31 that could potentially damage it.

[0301] Furthermore, when heat is generated, the separator 38 acts as a heat conduction medium, rapidly transferring the heat generated by the individual cells 32 to all parts of the battery pack, accelerating heat dissipation. This effectively reduces the overall temperature of the battery pack, preventing battery performance degradation or shortened lifespan due to overheating, and ensuring the stability and reliability of the battery under high load operation.

[0302] In other embodiments, the number of separators 38 can be flexibly adjusted based on factors such as battery pack capacity, the number of individual cells 32, and the expected usage environment. For example, if the battery pack capacity is large and the individual cells 32 generate a lot of heat, the number of separators 38 can be appropriately increased to enhance heat dissipation; if the number of individual cells 32 is large, the number of separators 38 can also be increased to ensure structural stability.

[0303] In this embodiment, three fixing ribs 39 are provided on opposite sides of each partition 38. The three fixing ribs 39 are evenly distributed along the z-direction, and each fixing rib 39 is parallel to the xz plane. In the thickness direction (x-direction) of the partition 38, the size of the fixing rib 39 is larger than the thickness of the partition 38. It extends out of the partition 38 on both sides and abuts against the sides of the individual cells 32 on both sides of the partition 38, thereby limiting the individual cells 32 on both sides from the y-direction.

[0304] In other embodiments, the number of fixing ribs 39 can be flexibly adjusted according to various factors such as the specific specifications of the battery pack, the expected external forces it will withstand, and the arrangement of the individual cells 32. For example, if the battery pack is used in an environment with frequent vibration, the number of fixing ribs 39 can be appropriately increased, and they can be installed in key parts of the battery pack that are susceptible to vibration.

[0305] In this embodiment, the one-end open housing 311 can be integrally formed using a stamping process. In terms of manufacturing, integrally forming the one-end open housing 311 using a stamping process has significant advantages. The stamping process enables efficient, mass production, greatly improving production efficiency. Integral forming means reducing complex processes such as splicing and welding, lowering labor and time costs in the production process, and also reducing errors that may arise from assembling multiple parts, improving product consistency and yield. From a structural performance perspective, the integrally formed housing 311 is more robust. Compared to a housing 311 assembled from multiple parts, integral forming eliminates splicing gaps, avoiding the overall structural weakness caused by insufficient strength at gaps. This allows the housing 311 to better maintain structural integrity when subjected to the pressure of the internal battery pack and potential external impacts and compression, further enhancing the structural strength of the battery casing 31 and providing more reliable protection for the battery pack.

[0306] The casing 311, formed by stamping, has an open end and a certain draft angle. In this embodiment, the draft angle can be corrected by using the end fixing plates 36 on both sides, so that the battery pack and the casing 31 can be assembled more precisely. The end fixing plates 36 can be designed as inclined surfaces that complement the draft angle of the casing 311. During assembly, the end fixing plates 36 apply appropriate pressure to make fine adjustments to the sides of the casing 311, compensating for dimensional deviations caused by the draft angle.

[0307] When there is a separator 38 between each individual cell 32, the fixing rib 39 can be welded to the housing 31 by through welding to ensure that a strong and durable connection is formed between the fixing rib 39 and the housing 31, so that the two are tightly combined into a whole structure.

[0308] In this embodiment, the fixing rib 39 is tightly connected to the partition 38 and the shell 31, which has at least the following advantages:

[0309] From a structural strength perspective, this design enhances the rigidity of the entire large-capacity battery to a certain extent. The fixing ribs 39, working in conjunction with the separator 38 and the casing 31, comprehensively improve the structural strength of the casing 31. In practical applications, when the battery is subjected to external impact or compression, the fixing ribs 39 effectively disperse the external force, preventing the casing 31 from deforming or cracking due to excessive localized stress, thus strongly ensuring the safe operation of the battery. Furthermore, the fixing ribs 39 extend beyond the sides of the separator 38 and tightly abut against the sides of the individual battery cells 32, thus limiting the movement of the individual battery cells 32. During daily use of the battery pack, especially under complex conditions such as vibration and bumps, this prevents the displacement of the individual battery cells 32.

[0310] In terms of heat dissipation, since the fixing rib 39 is in close contact with the individual battery cell 32, it can effectively conduct the heat generated by the battery during charging and discharging, and dissipate the heat to the outside through the connection with the casing 31. This helps to maintain the temperature balance inside the battery pack, prevent local overheating, thereby extending the battery's lifespan and improving the overall performance of the battery.

[0311] Step 3: As shown in Figures 25, 26 and 27, with the box 311 in an inverted position, place a pad 35 at the non-through hole part of the bottom of each individual battery 32; then fix and seal the bottom plate 312 to the open end of the box 311.

[0312] As can be seen from Figure 25, in this embodiment, an annular pad 35 is provided at the bottom of each individual battery cell 32. The orthographic projection of the inner hole of the annular pad 35 at the bottom of each individual battery cell 32 covers the through hole 322 on the bottom of each individual battery cell 32. The purpose of adding the pad 35 is mainly to form a gap between the through hole 322 and the bottom plate 312 of the housing 31, which serves as an electrolyte sharing channel 33. There is no need to separately process the electrolyte sharing channel on the bottom plate of the housing 31, making the processing of the housing 31 simpler.

[0313] In some other embodiments, two rectangular pads may be used, both of which extend along the x-direction and are arranged along the y-direction. In the y-direction, the distance between the two rectangular pads needs to be greater than the size of the through hole 322 at the bottom of the single cell 32.

[0314] As shown in Figures 26 and 27, after the pad 35 is set, the bottom plate 312 is welded to the open end of the box 311 by welding.

[0315] Step 4: As shown in Figure 28, flip the product assembled in Step 3 and seal the connection between each clearance hole 313 and the top cover of the single battery 32.

[0316] Since the diameter of the clearance hole 313 is larger than the outer diameter of the terminal post 321 of the single cell 32, in order to ensure sealing, this embodiment adopts a method of welding the edge of the clearance hole 313 on the side closer to the single cell 32 to the upper cover plate of the single cell 32 to achieve a sealed connection, so as to avoid the external environment from interfering with the internal environment of the large-capacity battery through the gap between the clearance hole 313 and the terminal post 321.

[0317] In addition to the welding method used in this embodiment, in some other embodiments, laser welding can also be used to weld the area around each clearance hole 313 of the base plate 312 and the area around the corresponding electrode post 321 on the upper cover of the single cell 32. However, this welding method requires a high wall thickness of the base plate 312 (a thicker base plate 312 may result in poor welding effect, while a thinner base plate 312 may cause high-temperature damage to the inside of the single cell 32).

[0318] In this embodiment, in order to compensate for the loss of electrolyte in each individual cell 32 during the opening of the through hole 322 and this step, and also to ensure that there is enough electrolyte in the large-capacity battery to realize the shared electrolyte system of each individual cell 32, the process also includes an electrolyte injection operation after step 4. Specifically, electrolyte is injected into the large-capacity battery housing 31 through the electrolyte injection port on the housing 31.

[0319] As a large-capacity battery composed of multiple individual cells 32, in order to ensure its excellent performance, formation and aging steps can also be performed on the large-capacity battery after liquid injection.

[0320] Example 6

[0321] Based on the preparation process of Example 5, this embodiment also makes the following two optimized designs, which can be seen in Figures 29 to 31:

[0322] Optimized Design 1: Due to the small gap size between the terminal post 321 of the individual battery 32 and the clearance hole 313, the insulation between the terminal post 321 of the individual battery 32 and the top plate may be difficult to ensure. In addition, if a large-capacity battery experiences thermal runaway, cracks will appear at the welded position between the clearance hole 313 and the top cover of the individual battery 32, causing thermal runaway fumes to leak out from that position. Therefore, this embodiment also includes step 5, that is, setting an insulating seal 323 in the gap between each clearance hole 313 and the terminal post 321. The insulating seal 323 can ensure the insulation between the terminal post 321 and the top plate. At the same time, even if leakage occurs at the welded position, the insulating seal 323 can also serve as a second barrier to prevent the leakage of thermal runaway fumes.

[0323] Optimized Design 2: A terminal adapter 324 is placed on each individual cell 32 terminal 321, tightly pressing the terminal adapter 324 against the insulating seal 323. The terminal adapter 324 is then welded to the individual cell 32 terminal 321. By setting the terminal adapter 324, the insulating seal 323 is pressed tightly, preventing it from detaching in the event of thermal runaway and causing leakage of thermal runaway gas. Therefore, the design of the terminal adapter 324 pressing the insulating seal 323 can act as a third barrier to prevent leakage of thermal runaway gas. Simultaneously, the terminal adapter 324 facilitates heat exchange between the individual cell 32 terminal 321 and heat exchange devices.

[0324] To ensure that the terminal adapter 324 can uniformly apply clamping force to the insulating seal 323 and thus guarantee the insulation and sealing performance of the insulating seal 323, in this embodiment, the insulating seal 323 includes a flexible insulating sealing ring 3231 and a pressure ring 3232. During assembly, the flexible insulating sealing ring 3231 is first placed in the clearance hole 313; then the pressure ring 3232 is placed on the flexible insulating sealing ring 3231. The flexible insulating sealing ring 3231 has a flexible stepped structure, with the small-diameter section of the stepped structure extending into the clearance hole 313 and contacting the upper cover plate of the single cell 32, and the large-diameter section of the stepped structure located outside the top plate and contacting the top of the top plate. The pressure ring 3232 is a metal part.

[0325] In some other embodiments, the insulating seal 323 may also be an insulating seal layer disposed at the gap between the clearance hole 313 and the pole post 321 by a casting process.

Claims

1. A manufacturing process for a high-capacity battery, characterized in that, Includes the following steps: Step 1: Make a through hole at the bottom of the single cell, at which point the single cell is in an inverted position; Step 2: Place the individual battery with through holes into the cylinder with at least one open end in an inverted position, ensuring that the terminal of each individual battery extends out of its corresponding clearance hole, and the cylinder is in an inverted position. Step 3: Insert two pads into the gap between the bottom of the individual battery and the bottom of the cylinder, with the two pads located on both sides of the through hole; Step 4: Repeat steps 1 to 3 to install at least two individual cells with through holes at the bottom inside the cylinder along the length of the cylinder. Step 5: Secure the end cap to the open end of the cylinder and seal it to each clearance hole and the top cover of the individual battery.

2. The manufacturing process of the high-capacity battery according to claim 1, characterized in that: It also includes step 6: installing an insulating seal in the gap between each clearance hole and the pole post.

3. The manufacturing process of the high-capacity battery according to claim 2, characterized in that: It also includes step 7: placing a terminal adapter on each individual battery terminal, pressing the terminal adapter tightly against the insulating seal, and then welding the terminal adapter to the individual battery terminal.

4. The manufacturing process of the high-capacity battery according to any one of claims 1 to 3, characterized in that: It also includes a step of cleaning the electrolyte that overflows from the bottom of the individual cell from the clearance hole before placing the individual cell into the cylinder after the individual cell has been drilled.

5. The manufacturing process of the high-capacity battery according to claim 1, characterized in that: In step 2: When the individual battery is placed into the cylinder, it is necessary to ensure that there is a safe distance between the individual battery terminal and the inner wall of the top of the cylinder.

6. The manufacturing process of the high-capacity battery according to claim 2, characterized in that: In step 5: the end cap is fixed and sealed to the open end of the cylinder by welding while the cylinder is inverted. Then, the whole thing is flipped over and each clearance hole and the top cover of the individual battery are sealed and connected by welding.

7. The manufacturing process of the high-capacity battery according to claim 6, characterized in that: The insulating seal includes a flexible insulating sealing ring and a pressure ring; the specific operation process of step 7 is as follows: first, place the flexible insulating sealing ring in the clearance hole; then, place the pressure ring on the flexible insulating sealing ring; The flexible insulating sealing ring has a flexible stepped structure. The small-diameter section of the stepped structure extends into the clearance hole and contacts the top cover of the single battery cell, while the large-diameter section of the stepped structure is located outside the cylinder and contacts the top of the cylinder. The pressure ring is a metal part.

8. The manufacturing process of the high-capacity battery according to claim 1, characterized in that: Step 5 specifically involves welding the edge of the clearance hole near the individual battery to the top cover of the individual battery to achieve a sealed connection.

9. The manufacturing process of the high-capacity battery according to claim 8, characterized in that: The edge of the clearance hole near the individual battery is sealed to the top cover of the individual battery by filler wire welding.

10. The manufacturing process of the high-capacity battery according to claim 1, characterized in that: It also includes steps such as liquid injection, formation, and aging.

11. A high-capacity battery, characterized in that, The high-capacity battery is manufactured using the high-capacity battery manufacturing process described in any one of claims 1 to 10.

12. A manufacturing process for a high-capacity battery, characterized in that, Includes the following steps: Step 1: Place the top plate with 2n clearance holes on top of n individual cells, so that the terminals of each individual cell pass through the corresponding clearance holes, where n is an integer greater than 1; seal the connection between each clearance hole and the top cover of the individual cell. Step 2: Invert the cells so that the bottom of each cell faces upwards, and make through holes at the bottom of each cell. Step 3: Install pads at the non-through-hole areas at the bottom of each individual cell; Step 4: Fasten the box with one open end, press the bottom plate of the box against the pad, and seal and fix the open end of the box to the top plate.

13. The manufacturing process of the high-capacity battery according to claim 12, characterized in that: It also includes step 5: installing an insulating seal in the gap between each clearance hole and the pole post.

14. The manufacturing process of the high-capacity battery according to claim 13, characterized in that: It also includes step 6: placing a terminal adapter on each individual battery terminal, pressing the terminal adapter tightly against the insulating seal, and then welding the terminal adapter to the individual battery terminal.

15. The manufacturing process of the high-capacity battery according to any one of claims 12 to 14, characterized in that: It also includes a step of cleaning the electrolyte that has overflowed from the individual cells after opening through holes at the bottom of each individual cell and before sealing and fixing the open end of the casing to the top plate.

16. The manufacturing process of the high-capacity battery according to claim 12, characterized in that: In step 1, n individual cells are first arranged into a battery pack in the same direction. Then, two end fixing plates are placed against the two ends of the battery pack, and a fixing strap is placed on the two end fixing plates and the outer periphery of the battery pack to fix the battery pack between the two end fixing plates. Finally, a top plate with 2n clearance holes is placed on top of the n individual cells.

17. The manufacturing process of the high-capacity battery according to claim 16, characterized in that: In step 1, before fixing the battery pack to the two end fixing plates, a step of setting a separator between adjacent individual cells is also included; fixing ribs perpendicular to the plane of the separator are set on opposite sides of the separator, and the two sides of the fixing ribs abut against the sides of the individual cells on both sides of the separator.

18. The manufacturing process of the high-capacity battery according to claim 17, characterized in that: Step 4 also includes the step of welding the box body with one open end to the fixed stiffening plate using a through-welding method.

19. The manufacturing process of the high-capacity battery according to claim 14, characterized in that: The insulating seal includes a flexible insulating sealing ring and a pressure ring; the specific operation process of step 6 is as follows: first, place the flexible insulating sealing ring in the clearance hole; then, place the pressure ring on the flexible insulating sealing ring; The flexible insulating sealing ring has a flexible stepped structure. The small-diameter section of the stepped structure extends into the clearance hole and contacts the top cover of the single battery cell, while the large-diameter section of the stepped structure is located outside the top plate and contacts the top plate. The pressure ring is a metal part.

20. The manufacturing process of the high-capacity battery according to claim 12, characterized in that: Specifically, step 1 involves welding the edge of the clearance hole near the individual battery to the top cover of the individual battery to achieve a sealed connection.

21. The manufacturing process of the high-capacity battery according to claim 12, characterized in that: Step 4 is followed by liquid injection, formation, and aging steps.

22. A manufacturing process for a high-capacity battery, characterized in that, Includes the following steps: Step 1: Invert n individual cells so that the bottom of the cells is facing up, and make through holes in the bottom of each individual cell; where n is an integer greater than 1. Step 2: Invert the box with the bottom opening facing upwards, and put the n individual batteries with through holes into the box from the opening end in an inverted position, ensuring that the terminals of each individual battery pass through the corresponding clearance holes opened on the top plate of the box. Step 3: With the box in an inverted position, place pads on the non-through-hole areas at the bottom of each individual battery cell; The base plate is fixed and sealed to the open end of the box; Step 4: Flip it over and seal the connection between each clearance hole and the top cover of the individual battery.

23. The manufacturing process of the high-capacity battery according to claim 22, characterized in that: It also includes step 5: installing an insulating seal in the gap between each clearance hole and the pole post.

24. The manufacturing process of the high-capacity battery according to claim 23, characterized in that: It also includes step 6: placing a terminal adapter on each individual battery terminal, pressing the terminal adapter tightly against the insulating seal, and then welding the terminal adapter to the individual battery terminal.

25. The manufacturing process of the high-capacity battery according to any one of claims 22 to 24, characterized in that: It also includes the steps of opening through holes at the bottom of each individual cell, fixing and sealing the base plate to the open end of the box, and cleaning the electrolyte that has overflowed from the individual cells.

26. The manufacturing process of the high-capacity battery according to claim 22, characterized in that: In step 2, n individual batteries with through holes are first arranged in the same direction to form a battery pack. Then, two end fixing plates are placed against the two ends of the battery pack respectively. The fixing strap is put on the two end fixing plates and the outer periphery of the battery pack to fix the battery pack between the two end fixing plates. The battery pack is then placed into the box from the open end of the box in an inverted position.

27. The manufacturing process of the high-capacity battery according to claim 26, characterized in that: In step 1, before fixing the battery pack to the two end fixing plates, a step of setting a separator between adjacent individual cells is also included; fixing ribs perpendicular to the plane of the separator are set on opposite sides of the separator, and the two sides of the fixing ribs abut against the sides of the individual cells on both sides of the separator.

28. The manufacturing process of the high-capacity battery according to claim 27, characterized in that: Following step 2, the process also includes welding the enclosure to the fixing stiffeners using a through-welding method.

29. The manufacturing process of the high-capacity battery according to claim 24, characterized in that: The insulating seal includes a flexible insulating sealing ring and a pressure ring; the specific operation process of step 6 is as follows: first, place the flexible insulating sealing ring in the clearance hole; then, place the pressure ring on the flexible insulating sealing ring; The flexible insulating sealing ring has a flexible stepped structure. The small-diameter section of the stepped structure extends into the clearance hole and contacts the top cover of the single battery cell, while the large-diameter section of the stepped structure is located outside the top plate and contacts the top plate. The pressure ring is a metal part.

30. The manufacturing process of the high-capacity battery according to claim 22, characterized in that: Specifically, step 1 involves welding the edge of the clearance hole near the individual battery to the top cover of the individual battery to achieve a sealed connection.

31. The manufacturing process of the high-capacity battery according to claim 22, characterized in that: Step 4 is followed by liquid injection, formation, and aging steps.

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