Battery and method for producing a battery
Patent Information
- Application Number
- PCT/DE2026/100363
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2025-03-28
- Filing Date
- 2026-03-23
- Publication Date
- 2026-10-01
Smart Images
Figure DE2026100363_01102026_PF_FP_ABST
Abstract
Description
[0001] P250360 DE
[0002] - 1 - Battery and method for manufacturing a battery
[0003] The invention relates to a battery and a method for manufacturing a battery. The battery comprises several prismatic battery cells arranged adjacent to one another.
[0004] For example, DE 102020 110700 A1 discloses a battery and a method for manufacturing a battery for a motor vehicle, wherein the battery has several prismatic battery cells arranged in a battery housing of the battery and each has two terminals for electrical contacting the battery cell and a cell housing with an outflow opening.
[0005] Furthermore, EP 2958 180 B1 discloses a battery cell configured to have a structure in which an electrode arrangement comprising positive electrodes, negative electrodes, and separators, each arranged between the positive and negative electrodes, is mounted in a battery housing, wherein the electrode arrangement is provided with a deformation element whose cross-sectional width is reduced discontinuously or continuously. The battery housing comprises one or more housing elements, each made of a metal sheet, wherein the housing elements are coupled to one another in a state in which the electrode arrangement is mounted in the housing elements.
[0006] The object of the invention is to provide an alternative battery and a method for manufacturing the battery. In particular, the manufacturing costs and complexity of the battery are to be reduced while simultaneously improving the electrical energy flow. This object is achieved by the subject matter of claim 1 and the subject matter of claim 6. Preferred embodiments can be found in the dependent claims, the description, and the figures.
[0007] A battery according to the invention comprises several prismatic battery cells arranged adjacent to one another, each battery cell comprising a battery cell housing, an electrode arrangement therein, and a first connection element and P250360 DE
[0008] -2 -a second connection element for electrically contacting the electrode arrangement, wherein at least one battery cell housing has at least one opening for passing at least one connection element from the interior of the battery cell housing to the outside, wherein each electrode arrangement has several electrode layers, wherein each electrode layer has at least one connection tab, wherein several connection tabs are formed indirectly via a collector or directly to form a respective connection element, wherein the respective connection element is passed directly through the at least one opening, wherein at least one of the two connection elements has electrical insulation from the battery cell housing at least in the region of the respective opening, wherein a fluidic seal is arranged in each opening between the respective connection element and the battery cell housing,wherein a first terminal element of each battery cell is connected to a second terminal element of each adjacent battery cell outside the respective battery cell housing.
[0009] The battery cell casing and the electrode assembly thus form a battery cell. The battery has several such battery cells that are electrically connected to each other. The electrode assembly of each battery cell comprises several electrode layers with terminals, namely at least positive electrodes, negative electrodes, and separators, which are arranged between the positive and negative electrodes. The first terminal is, for example, designed as a positive electrical connection, and the second terminal is, for example, designed as a negative electrical connection. To connect several battery cells to each other, the first and second terminals are electrically connected.
[0010] In this configuration, several connecting tabs are, for example, indirectly grouped via a collector and passed directly through the at least one opening without any further intermediate element. In other words, the connecting element is designed as a collector that connects several connecting tabs. Alternatively, several connecting tabs are directly grouped into a single connecting element and passed directly through the at least one opening without any intermediate element. In other words, the P250360 DE
[0011] - 3 - The connection element is designed as a plurality of connection lugs. If several connection lugs are passed directly through the at least one opening, a fluidic seal is provided within or between the connection lugs.
[0012] The battery cell housing has at least one opening that leads from the inside of the battery cell housing to the outside, or at least one or both of the connecting elements. For example, there is exactly one opening in the battery cell housing for each connecting element. For example, both connecting elements are electrically insulated from the battery cell housing at least in the area of their respective openings. Alternatively, only one of the two connecting elements is electrically insulated from the battery cell housing at least in the area of its respective openings, while the other connecting element of the battery cell has no electrical insulation but only increased electrical resistance.
[0013] The fluidic seal at the opening is designed to create a fluid-tight seal within the battery cell housing. This prevents any fluid, particularly a gas or liquid, from flowing through the opening. The battery cells are arranged adjacent to one another and electrically connected via the terminal elements. For example, the terminal elements can be connected by welding outside the battery cell housing, particularly by laser or ultrasonic welding. The terminal elements can be connected at least indirectly via a terminal rail or directly. For example, the terminal elements may have a coating to reduce contact resistance and / or to protect against condensation.
[0014] According to one embodiment, the fluidic closure is formed either directly by deforming the battery cell housing in the area of the opening or by an insert element arranged in the area of the opening. For example, the insert element is metallurgically bonded to the battery cell housing and / or the at least one terminal element. For example, the battery cell housing or the at least one terminal element is overmolded with the insert element. The insert element can be formed in one piece or in multiple parts. P250360 DE
[0015] - 4 - be. For example, the insert element projects at least partially into the opening. For example, the insert element comes into axial contact with the battery cell housing at least partially in the area of the opening. The insert element can have at least one elastic element, in particular a seal or sealant made of a polymer, rubber, or silicone. Furthermore, the insert element can be at least partially cylindrical and / or flange-shaped and have an undercut contour, wherein the undercut contour is inserted through the opening from one side of the battery cell housing and snaps into place on the other side of the battery cell housing to fix the axial position of the insert element in the opening and to create the fluidic seal between the battery cell housing and the terminal element.For example, the battery cell housing is made of aluminum, an aluminum alloy, or a steel alloy, wherein the battery cell housing is pressed or crimped in the area of the opening, preferably from the outside and inside. By pressing or crimping the battery cell housing, the battery cell housing is plastically deformed in such a way that the material of the battery cell housing is displaced towards the terminal element, so that a fluidic seal is created in the opening between the battery cell housing and the terminal element.
[0016] According to one embodiment, the battery cell housing is formed from a single sheet of metal. For example, the battery cell housing is formed by forming sections of a single sheet of metal. To close the battery cell housing, at least two adjacent sections of metal sheet are joined together by a material bond. For example, the desired geometry of the metal sheet can be cut from sheet metal by punching, roll cutting, or laser cutting. In particular, the metal sheet has a substantially constant wall thickness, so that all side surfaces of the battery cell housing have substantially the same thickness. Advantageously, no additional components, such as lids, are necessary to close the battery cell housing. The battery cell housing is closed by forming and bonding or welding at least two sections of the metal sheet. P250360 DE
[0017] - 5 - Forming the metal sheet creates the enclosure for the electrode assembly, the enclosure being designed to allow the electrode assembly to be inserted into it during assembly. During the forming of the metal sheet, for example, sections of the metal sheet are bent or folded. In particular, notches can be made in the metal sheet before bending to simplify the bending or folding process. According to one embodiment, at least five sections of the metal sheet are formed by bending. This creates all six side surfaces of the enclosure, leaving the enclosure partially open to allow the electrode assembly to be inserted through the open side. Specifically, the electrode assembly is inserted into the partially formed enclosure over a relatively long edge, namely along the longitudinal side of the enclosure.In particular, the need to pull the electrode assembly through the housing is eliminated. This approach saves time and costs and simplifies manufacturing. Furthermore, inserting the electrode assembly into the housing allows for a simplified visual inspection of its position within the housing.
[0018] According to one embodiment, an opening is formed on two opposite surfaces of each battery cell housing, with a first and second connection element arranged and connected to each other in a cavity formed between each pair of battery cell housings. The battery comprises several battery cells arranged adjacent to one another, the battery cells coming into contact with the surfaces of the respective battery cell housing that have an opening with a connection element. The respective connection element of each battery cell protrudes from the opening in the battery cell housing and is connected when the battery cells are spaced apart, preferably at a single contact point, after which the battery cells are brought into contact with one another, with the connection elements being arranged in the cavity provided to receive the two connection elements.This allows for savings in manufacturing costs and installation space. By creating a single contact point for connecting the terminal elements, the electrical energy flow can be improved. For example, the respective opening is formed in the two largest side surfaces of the battery cell housing, so that the battery cells are stacked in series along the long side edges. P250360 DE.
[0019] - 6 - Preferably all battery cell housings, and in particular all battery cells, are identically designed.
[0020] According to one embodiment, at least one opening is formed in a free surface of the respective battery cell housing, with a first and second connection element being connected to each other in the area of the free surface. The battery comprises several battery cells arranged adjacent to one another, with the battery cells bearing against the surfaces of the respective battery cell housing that do not have an opening. Thus, the surfaces with openings remain free, so that in this context, a free surface is understood to be a surface that does not bear against another surface of an adjacent battery cell housing. The respective connection element of each battery cell protrudes from the opening in the battery cell housing and, when the battery cells are stacked—that is, when the battery cells are already positioned and bearing against each other—is preferably connected at a single contact point.This allows for savings in manufacturing costs. By creating a single contact point for connecting the terminal elements, the electrical energy flow can be improved. For example, the respective opening is formed in relatively small side surfaces of the battery cell housing, particularly in side surfaces with a comparatively short edge, so that the battery cells are stacked in series along the long edges. For example, the respective battery cell housing can have a double sheet thickness on the inside of the respective opening, preferably formed by folding offcut metal sheets. Preferably, all battery cell housings, and especially all battery cells, are identical.
[0021] A method according to the invention for manufacturing a battery according to the invention comprises the following process steps: providing at least one battery cell housing with at least one opening for passing through at least one connection element, passing the at least one connection element from inside the battery cell housing through the opening to the outside, forming a fluidic seal in the opening between the at least one connection element and the battery cell housing, and connecting a first connection element of a respective battery cell to a second connection element of an ande-P250360 DE
[0022] - 7 -ren, for example, an adjacent battery cell located outside the respective battery cell housing. For example, at least one battery cell housing is manufactured by forming several integrally joined metal sheet sections. This allows for savings in manufacturing costs. Preferably, all battery cell housings, and in particular all battery cells, are manufactured identically.
[0023] According to one embodiment, at least one fluidic seal is formed by deforming the battery cell housing. For example, the battery cell housing is pressed or crimped from the inside and outside in the area of the opening and thereby plastically deformed in such a way that a fluidic seal is created in the opening between the battery cell housing and the terminal element.
[0024] According to one embodiment, at least one fluidic closure is formed by shaping an insert element that projects at least partially into the opening. For example, the insert element also bears at least partially axially against the battery cell housing in the region of the opening. The insert element can include an elastic element, in particular a seal or sealant, which bears against the battery cell housing in the opening and / or axially to create at least a partial fluidic closure.
[0025] According to one embodiment, the insert element is at least partially cylindrical and / or flange-shaped and has an undercut contour. For example, the area of the insert element with the undercut contour is inserted through the opening from one side of the battery cell housing and snaps into place on the other side of the battery cell housing to fix the axial position of the insert element in the opening and to create the fluidic seal between the battery cell housing and the terminal element.
[0026] According to one embodiment, at least one fluidic seal is formed by a material-bonded connection of an insert element located in the area of the opening to the battery cell housing and / or the at least one terminal element. For example, the insert element can be glued or welded in the area of the opening to create the fluidic seal. P250360 DE
[0027] - 8 - In particular, the insert element is formed in one piece or in multiple parts and is arranged in a ring shape around the connecting element, wherein the material-bonded connection of the insert element is formed completely circumferentially.
[0028] Further measures improving the invention are described in more detail below, together with a description of preferred embodiments of the invention, with reference to the figures.
[0029] Figure 1 shows a highly simplified schematic representation of a battery cell.
[0030] Figure 2 is a highly simplified schematic representation of a section of a battery according to a first embodiment of the invention.
[0031] Figure 3 shows a highly simplified schematic representation of a section of a battery according to a second embodiment of the invention.
[0032] Figure 4 is a highly simplified schematic representation of a detail section of the battery according to the invention as shown in Figure 3.
[0033] Figure 5 shows a highly simplified schematic representation of two sections during the process for manufacturing a battery cell according to a first embodiment.
[0034] Figure 6 shows a highly simplified schematic representation of two sections during the process for manufacturing a battery cell according to a second embodiment.
[0035] Figure 7 shows a highly simplified schematic representation of two sections during the process for manufacturing a battery cell according to a third embodiment, P250360 DE
[0036] - 9 - Figure 8 shows a highly simplified schematic representation of two sections during the process for manufacturing a battery cell according to a fourth embodiment,
[0037] Figure 9 shows a highly simplified schematic representation of an electrode arrangement according to a first embodiment,
[0038] Figure 10 shows a highly simplified schematic representation of an electrode arrangement according to a second embodiment.
[0039] Figure 11 shows a highly simplified schematic representation of a section of the battery according to the invention as shown in Figures 3 and 4, as well as
[0040] Figure 12 shows a highly simplified schematic representation of a metal sheet for the manufacture of a battery cell housing.
[0041] Figure 1 shows a highly simplified representation of a battery cell 2, comprising the battery cell housing 3 and the electrode assembly 4 with a first terminal element 5 and a second terminal element 6. The battery cell housing 1 accommodates the electrode assembly 3 internally and completely encloses it, i.e., on all six sides. For example, the battery cell housing 3 is formed by forming a single sheet of metal. In this case, the battery cell housing 3 has an opening 7 for each terminal element 5, 6, allowing the respective terminal element 5, 6 to pass from the interior of the battery cell housing 3 to the outside. Both terminal elements 5, 6 have electrical insulation from the battery cell housing 3, at least in the area of the respective opening 7.In each opening 7 a fluidic closure 8 is arranged between the respective connection element 5, 6 and the battery cell housing 3, with different embodiments of the fluidic closure being shown in Figures 5 to 7.
[0042] Figure 2 shows a section of a battery 1 with several battery cells 2. The battery cells 2 are identical. A through-hole 7 is formed in a free area 3.4, 3.5 of the respective battery cell housing 3, wherein a first terminal element 5 of one battery cell 2 is connected to a second terminal element.
[0043] The terminal elements 5 and 6 of each battery cell 2 are connected to each other in the area of the free surfaces 3.4, 3.5. The other terminal element of each battery cell 2 is located on the opposite side of the battery cell 2, which is not shown. The battery 1 comprises several adjacent battery cells 2, with the battery cells 2 contacting the surfaces of the respective battery cell housing 3 that do not have an opening 7. The respective terminal element 5, 6 of each battery cell 2 protrudes from the opening 7 in the respective battery cell housing 3 and, in the stacked state of the battery cells 2 shown here, is connected at a single contact point by a laser beam 10. This allows for savings in manufacturing costs and improved electrical energy flow.In the present case, the respective opening 7 is formed in a relatively small side surface of the respective battery cell housing 3, in particular in a respective side surface which has a comparatively short side edge, so that the battery cells 2 are stacked in a row on side surfaces with long side edges.
[0044] Figure 3 shows a section of another battery 1 with several battery cells 2 during the formation of an electrical connection, while Figure 4 shows a detailed view of the connection area in the assembled state. A larger section of the battery 1 according to Figures 3 and 4 is shown in Figure 8. The battery cells 2 are identical. In this case, an opening 7 is formed on two opposite surfaces 3.1, 3.2 of the respective battery cell housing 3, wherein a first and second connection element 5, 6 are arranged and connected to each other in a cavity 3.3 formed between each pair of battery cell housings 3, which is shown only in Figure 4. The battery 1 comprises several battery cells 2 arranged adjacent to one another, with the battery cells 2 bearing against the surfaces 3.1, 3.2 of the respective battery cell housing 3, which have an opening 7 with connection elements 5, 6.The respective connection element 5, 6 of each battery cell 2 protrudes from the opening 7 in the battery cell housing 3 and, in a spaced-apart state of the battery cells 2 (shown only in Figure 3), is connected at a single contact point by a laser beam 10. Then, as shown in Figure 4, the battery cell housings 2 are crimped in the area of the openings 7 to form a fluidic seal 8 and brought into contact with each other, with the interconnected An-P250360 DE.
[0045] - 11 - End elements 5, 6 are accommodated in the cavity 3.3, which is created by caulking the battery cell housings 2. This allows for savings in manufacturing costs and installation space. Furthermore, by forming a single contact point for connecting the terminal elements 5, 6, the electrical energy flow can be improved. In this case, the respective opening 7 is formed in the largest areas 3.1, 3.2 of the respective battery cell housing 3, so that the battery cells 2 are stacked in series along their long side edges.
[0046] Figures 5, 6, 7, and 8 show different configurations of the fluidic closure 8. The section of each figure above a dashed dividing line 11 shows the opening 7 before the fluidic closure 8 is formed, and the section of each figure below a dashed dividing line 11 shows the opening 7 after the fluidic closure 8 is formed. The fluidic closure 8 is formed either directly by reshaping the battery cell housing 3 in the area of the opening 7 or by an insert element 9 arranged in the area of the opening 7.
[0047] According to Figure 5, the fluidic closure 8 is formed by deforming the battery cell housing 3, in particular by caulking the battery cell housing 3 in the area of the opening 7 from the inside and outside. The battery cell housing 3 is plastically deformed in the area of the opening 7 by caulking.
[0048] As shown in Figure 6, the fluidic seal 8 is formed by shaping an insert element 9 that partially projects into the opening 7. The insert element 9 also partially abuts the battery cell housing 3 axially in the region of the opening 7. The insert element 9 comprises several sealing compounds 12 that come into contact with the battery cell housing 3 both within the opening and axially. To form the fluidic seal 8, the insert element 9 is pressed together with the sealing compounds 12.
[0049] According to Figure 7, the fluidic closure 8 is formed by a material-bonded connection of an insert element 9 arranged in the area of the opening 7 to the battery cell housing 3 and the connection element 5. In this case, the insert element 9 is bonded in the area of the opening 7 using an adhesive 13.
[0050] - 12 -to create the fluidic closure 8. The insert element 9 can be designed in one piece or in multiple parts and arranged in a ring shape around the connecting element 5, wherein the material-bonded connection of the insert element 9 is formed completely circumferentially.
[0051] As shown in Figure 8, the fluidic closure 8 is formed by pressing in an insert element 9 that partially projects into the opening 7. The insert element 9 also partially abuts the battery cell housing 3 axially in the region of the opening 7. In this case, the insert element 9 is partially cylindrical and partially flange-shaped. The cylindrical part of the insert element 9 has an undercut contour 18. The undercut contour 18 is pressed through the opening 7 from one side of the battery cell housing 3 and snaps into place on the other side of the battery cell housing 3 to fix the axial position of the insert element 9 in the opening 7 and to create the fluidic closure 8 between the battery cell housing 3 and the connection element 5.
[0052] Figure 9 shows an electrode arrangement 4 according to a first embodiment. The electrode arrangement 4 has several electrode layers 15, each electrode layer 15 having at least one terminal 16. In this embodiment, several terminal 16s are directly combined to form a respective terminal element 5, 6, with each terminal element 5, 6 passing directly, i.e., without an intermediate element, through a respective opening 7 in the battery cell housing 3. The respective closure is not shown for the sake of simplicity.
[0053] Figure 10 shows an electrode arrangement 4 according to a second embodiment. The electrode arrangement 4 has several electrode layers 15, each electrode layer 15 having at least one terminal 16. In this embodiment, several terminal 16s are indirectly combined via a collector 17 to form a respective terminal element 5, 6. The respective collector 17 is connected to several terminal 16s and forms the respective terminal element 5, 6, wherein the respective terminal element 5, 6 is passed directly, i.e., without further intermediate elements, through a respective opening 7 in the battery cell housing 3. The respective closure is not shown for the sake of simplicity. P250360 DE
[0054] - 13 - Figure 11 shows a larger section of the battery 1 according to Figures 3 and 4. As can be seen from Figure 11, every second battery cell 2 is rotated by 180° so that the contact of the terminal elements 5, 6 alternates from left to right. The terminal elements 5, 6 are formed by openings (not shown here) in the largest surfaces 3.1, 3.2 of the respective battery cell housing 3, so that the battery cells 2 are stacked in a row along their long side edges. The respective battery cell housing 3 is cuboid in shape, with the two largest surfaces 3.1, 3.2 facing opposite directions on the respective battery cell housing 3.
[0055] Figure 12 shows a metal sheet 3.6 configured to form a battery cell housing 3 according to the invention by forming several integrally connected metal sheet sections. The metal sheet 3.6 has seven integrally connected metal sheet sections, with three metal sheet sections arranged horizontally in a row and five metal sheet sections arranged vertically in a row. A notch 14, in particular a recess, is formed between each pair of metal sheet sections to facilitate folding, in particular bending, of the respective metal sheet section. Furthermore, two openings 7 are formed in the metal sheet sections, the openings 7 being designed to allow passage of a respective connecting element (not shown in detail here). The position and geometry of the openings 7 are only exemplary and can be modified. P250360 DE
[0056] - 14 - List of reference symbols
[0057] 1 battery
[0058] 2 battery cells
[0059] 3 battery cell housings
[0060] 3.1 Area
[0061] 3.2 Area
[0062] 3.3 Cavity
[0063] 3.4 Area
[0064] 3.5 Area
[0065] 3.6 Sheet metal
[0066] 4 Electrode arrangement
[0067] 5 first connection element
[0068] 6 second connection element
[0069] 7 Breakthrough
[0070] 8 Closure
[0071] 9 insert element
[0072] 10 Laser beam
[0073] 11 Dividing line
[0074] 12 Sealant
[0075] 13 Adhesive
[0076] 14 notch
[0077] 15 Electrode position
[0078] 16 connecting flags
[0079] 17 collectors
[0080] 18 Undercut contour
Claims
P250360 DE - 15 - Patent claims 1. Battery (1) comprising several adjacent prismatic battery cells (2), • wherein each battery cell (2) has a battery cell housing (3), an electrode arrangement (4) arranged therein, and a first connection element (5) and a second connection element (6) for electrically contacting the electrode arrangement (4), • wherein at least one battery cell housing (3) has at least one opening (7) for passing at least one connection element (5, 6) from the interior of the battery cell housing (3) to the outside, • wherein each electrode arrangement (4) has several electrode layers (15), wherein each electrode layer (15) has at least one terminal tab (16), wherein several terminal tabs (16) are either indirectly combined via a collector (17) or directly to form a respective terminal element (5, 6), wherein the respective terminal element (5, 6) is passed directly through the at least one opening (7), • wherein at least one of the two connection elements (5, 6) has electrical insulation to the battery cell housing (3) at least in the area of the respective opening (7), • wherein in each opening (7) a fluidic closure (8) is arranged between the respective terminal element (5, 6) and the battery cell housing (3), • wherein a first terminal element (5) of a respective battery cell (2) is connected to a second terminal element (6) of a respective adjacent battery cell (2) outside the respective battery cell housing (3).
2. Battery (1) according to claim 1 , characterized in that the fluidic closure (8) is formed either directly by deforming the battery cell housing (3) in the area of the opening (7) or P250360 DE - 16 - is formed by an insert element (9) arranged in the area of the opening (7).
3. Battery (1) according to claim 1 or claim 2, characterized in that the battery cell housing (3) is formed from a single metal sheet (3.6).
4. Battery (1) according to any one of claims 1 to 3, characterized in that a perforation (7) is formed on two opposite surfaces (3.1, 3.2) of the respective battery cell housing (3), wherein a first and second connection element (5, 6) are arranged in a cavity (3.3) formed between each of two battery cell housings (3) and are connected to each other.
5. Battery (1) according to any one of claims 1 to 3, characterized in that at least one opening (7) is formed on a free surface (3.4, 3.5) of the respective battery cell housing (3), wherein a first and second connection element (5, 6) are connected to each other in the area of the free surfaces (3.4, 3.5).
6. Method for manufacturing a battery (1) according to any one of the preceding claims, comprising the method steps: • Providing at least one battery cell housing (3) with at least one opening (7) for passing at least one terminal element (5, 6), • Passing the at least one connection element (5, 6), which is formed either from several connection tabs (16) or from a collector (17) connected to the connection tabs (16), directly from the inside of the battery cell housing (3) through the opening (7) to the outside, • Forming a fluidic seal (8) in the opening (7) between the at least one terminal element (5, 6) and the battery cell housing (3), and P250360 DE - 17 - Connecting a first terminal element (5) of a respective battery cell (2) to a second terminal element (6) of an adjacent battery cell (2) outside the respective battery cell housing (3).
7. Method according to claim 6, characterized in that at least one fluidic closure (8) is formed by reshaping the battery cell housing (3).
8. Method according to claim 6, characterized in that at least one fluidic closure (8) is formed by forming an insert element (9) that projects at least partially into the opening (7).
9. Method according to claim 6, characterized in that at least one fluidic closure (8) is formed by materially bonding an insert element (9) arranged in the area of the opening (7) with the battery cell housing (3) and the at least one connection element (5, 6).
10. Method according to any one of claims 6 to 9, characterized in that the at least one battery cell housing (3) is produced by forming several one-piece connected metal sheet sections of a metal sheet (3.6).