Battery Cell Electrolyte Filling Chamber With Vacuum Laser Sealing
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Solution Overview
Problem
Existing methods for filling and sealing battery cells with electrolytes, particularly those using SO₂-based electrolytes, are inefficient, time-consuming, and prone to electrolyte loss or crystallization, and do not allow for simultaneous filling and sealing within a single device.
Innovation Solution
A device and method that uses a process chamber with a gas-tight and liquid-tight design, allowing for electrolyte filling and laser-sealing of battery cells within a single unit, accommodating various cell shapes and sizes, while preventing electrolyte escape and crystallization, and ensuring complete wetting and minimal reaction with cell components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If open filling method is used for battery cells, then the filling process is simple, but the filling time is very long (2 to 3 days) and contamination prevention is complex
Solution Approach 1:
The patent changes the physical state parameter of the electrolyte from liquid to gas phase. By using gaseous electrolyte instead of liquid electrolyte, the filling process transitions from slow liquid saturation to rapid gas permeation, reducing filling time from 2-3 days to minutes while maintaining process simplicity
Solution Approach 2:
The patent employs periodic pressure cycling (vacuum and pressure alternation) to accelerate electrolyte penetration into the battery cell. The vacuum phase draws the gaseous electrolyte into the cell, and the pressure phase ensures complete saturation, creating an efficient periodic filling cycle that dramatically speeds up the process
2Reliability
If liquid electrolyte is used, then the electrolyte provides good ionic conductivity, but the electrolyte is prone to loss and contamination during filling
Solution Approach 1:
The patent uses gaseous electrolyte in a controlled atmosphere within the filling device, eliminating exposure to ambient air. The gas phase electrolyte can be contained and directed through sealed pathways, preventing evaporation loss and contamination that plagues liquid electrolyte handling, while maintaining the necessary ionic conductivity through proper gas phase design
Solution Approach 2:
The patent replaces the mechanical liquid filling system with a gas phase delivery system. Instead of pumping and pouring liquid electrolyte through complex sealed mechanisms, the system uses gas flow control and pressure differential to deliver electrolyte, simplifying the mechanics and reducing loss points
3Object-affected harmful factors
If SO2-based electrolyte is used, then the electrolyte is non-flammable and safe, but the electrolyte may escape or crystallize during handling
Solution Approach 1:
The patent utilizes the phase change parameter of SO2, operating it in the gaseous state during filling and storage within the device. This phase parameter change prevents crystallization issues associated with liquid SO2 handling while the confined gas phase prevents escape. The supercritical or gaseous state maintains safety by eliminating flammability risks of liquid organic electrolytes
Solution Approach 2:
The patent introduces a sealed filling device as an intermediary system between the SO2 electrolyte source and the battery cell. This intermediary contains the SO2 in a controlled environment, preventing direct contact with ambient conditions that could cause escape or crystallization, while enabling safe transfer of the non-flammable electrolyte
4Ease of manufacture
If filling and sealing are performed in separate devices, then each process can be optimized, but the overall processing time increases and electrolyte loss occurs during transfer
Solution Approach 1:
The patent combines the filling and sealing operations into a single integrated device. The filling device incorporates sealing capabilities, allowing the battery cell to be filled with electrolyte and then sealed within the same chamber without removal or transfer. This merging eliminates the time-consuming transfer step and prevents electrolyte loss that would occur during device transitions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables efficient, rapid, and cost-effective filling and sealing of battery cells, reducing processing time, minimizing contamination, and ensuring consistent performance by maintaining electrolyte integrity and cell structure integrity.
Implementation Method 1
sealing the filling opening (12) of the battery cell (2) by means of a laser beam (22)
Implementation Method 2
removing the air from the battery cell (2)
Data Source
Figure 1~2
Figure 3~4
AI summary
A device for filling a battery cell (2) with an electrolyte and subsequently sealing the battery cell (2), comprising a process chamber (10) having a receiving opening (11) in which the battery cell (2) is at least partially received such that a filling opening (12) of the battery cell (2) is arranged in the process chamber (10), and an opening (13) suitable for receiving at least one line (14) for filling the battery cell (2), wherein the process chamber (10) with the received battery cell (2) and line (14) is gas-tight and liquid-tight. The process chamber (10) has a passage (15) through which the laser beams can pass to seal the filling opening (12) of the battery cell (2), so that the battery cell (2) at least partially received in the process chamber (10) can be filled with the electrolyte and subsequently sealed.A process in which the battery cell (2) is first positioned in the receiving opening (11) of the process chamber (10). Subsequently, a vacuum is created in the process chamber (10) and in the battery cell (2) positioned in the receiving opening (11), so that the filling opening (12) of the battery cell (2) is gas-tight and liquid-tight in the process chamber (10), and the battery cell (2) is filled via the line (14). Afterwards, the filling opening (12) of the battery cell (2) is welded shut by means of a laser beam that passes through the passage (15) to the filling opening (12) of the battery cell (2).