Prismatic Electrochemical Cell

Patent metadata

Field	Value
Publication number	US-2017331141-A1
Application number	US-201615153340-A
Country	US
Kind code	A1
Filing date	May 12, 2016
Priority date	May 12, 2016
Publication date	Nov 16, 2017
Grant date	—

Abstract

A method of manufacturing an electrochemical cell is provided. The cell includes a rigid housing and an electrode assembly disposed in the housing. The method includes providing a housing that includes a first end, a second end formed separately from the first end, and a tubular sidewall formed separately from each of the first end and the second end. After the electrode assembly is inserted into the sidewall, the first end is welded to one end of the sidewall, and the second end is welded to the other end of the sidewall.

First claim

What is claimed is,:

1 . A method of manufacturing an electrochemical cell that comprises a rigid cell housing having the shape of a rectangular prism and an electrode assembly disposed in the cell housing, the method including the following steps:
providing a cell housing first end; providing a cell housing second end; providing a cell housing sidewall in the form of a tube having a rectangular cross-sectional shape, the cell housing sidewall formed separately from each of the cell housing first end and the cell housing second end; inserting the electrode assembly into the cell housing sidewall; welding the cell housing first end to one end of the cell housing sidewall; and welding the cell housing second end to an end of the cell housing sidewall opposed to the one end of the cell housing sidewall.

2 . The method of claim 1 , wherein
the electrode assembly comprises positive electrode plates alternating with negative electrode plates and separated by at least one separator to form an electrode stack, wherein the electrode assembly defines a stack axis that extends parallel to a stacking direction of the positive electrode plates, the negative electrode plates and the at least one separator, the cell housing sidewall includes a pair of major sides joined by a pair of minor sides, where each side of the pair of major sides is larger in area than each side of the pair of minor sides, and the step of inserting the electrode assembly into the cell housing sidewall includes orienting the electrode stack within the cell housing such that the stack axis extends in a direction that is normal to, and passes through, each side of the pair of minor sides.

3 . The method of claim 1 , wherein the electrochemical cell comprises a connector disposed in the cell housing between the electrode assembly and the cell housing first end, the method comprising
electrically connecting one end of the connector to a terminal that protrudes through the cell housing first end; electrically connecting another end of the connector to an electrode plate of the electrode assembly; and folding the connector such that the one end of the connector overlies the another end of the connector, and such that the cell housing first end abuts the one end of the cell housing sidewall.

4 . The method of claim 3 , wherein the method steps of claim 3 , which include
electrically connecting one end of the connector to a terminal that protrudes through the cell housing first end; electrically connecting another end of the connector to an electrode plate of the electrode assembly; and folding the connector such that the one end of the connector overlies the another end of the connector, and such that the cell housing first end abuts the one end of the cell housing sidewall, are performed before the method step of welding the cell housing first end to one end of the cell housing sidewall.

5 . The method of claim 1 , wherein
the electrode assembly comprises positive electrode plates alternating with negative electrode plates and separated by at least one separator, each of the positive electrode plates comprise
an electrically conductive first substrate;
a first coating disposed on the first substrate, where the first coating is formed of a first active material;
a first clear lane that is disposed along an edge of the positive electrode, plate, the first clear lane being free of the first coating; and
a first opening disposed within the first clear lane,
each of the negative electrode plates comprise
an electrically conductive second substrate;
a second coating disposed on the second substrate, where the second coating is formed of a second active material;
a second clear lane that is disposed along an edge of the negative electrode plate, the second clear lane being free of the second coating; and
a second opening disposed within the second clear lane; and
the method includes the following method steps: inserting an electrically conductive first inner plate through each first opening such that the first inner plate extends in a direction perpendicular to each positive electrode plate, and is electrically connected to at least one of the positive electrode plates, and inserting an electrically conductive second inner plate through each second opening such that the second inner plate extends in a direction perpendicular to each negative electrode plate, and is electrically connected to at least one of the negative electrode plates.

6 . The method of claim 5 , thither comprising
folding each positive electrode plate along a first fold line that extends along a margin of the opening, whereby the first clear lane overlies a side of the electrode stack and the first inner plate; and folding each negative electrode along a second fold line that extends along a margin of the opening, whereby the second clear lane overlies a side of the electrode stack and the second inner plate.

7 . The method of claim 6 , further comprising
disposing an electrically conductive first outer plate over folded first clear lanes such that the first outer plate overlies the first inner plate and the first clear lanes are disposed between the first outer plate and the first inner plate, and disposing an electrically conductive second outer plate over folded second clear lanes such that the second outer plate overlies the second inner plate and the second clear lanes are disposed between the second outer plate and the second inner plate.

8 . The method of claim 7 , further comprising
welding the first inner plate, the folded first clear lanes, and the first outer plate together to form an electrical connection between the first inner plate, the folded first clear lanes, and the first outer plate, and welding the second inner plate, the folded second clear lanes, and the second outer plate together to form an electrical connection between the second inner plate, the folded second clear lanes, and the second outer plate.

9 . The method of claim 8 , further comprising
electrically connecting the first outer plate to a terminal that protrudes through the cell housing and is electrically isolated from the cell housing, and electrically connecting the second outer plate to the cell housing.

10 . The method of claim 9 , wherein a first connector is used to electrically connect the first outer plate to the terminal, and a second connector is used to electrically connect the second outer plate to the cell housing.

11 . The method of claim 9 , wherein a connector is used to electrically connect the first outer plate to the terminal, and the second outer plate is electrically connected to the cell housing via direct contact with the cell housing.

12 . The method of claim 1 , wherein
the electrode assembly comprises positive electrode plates alternating with negative electrode plates and separated by at least one separator, each of the positive electrode plates and the negative electrode plates including
an electrically conductive substrate;
a coating disposed on the substrate, where the coating is formed of an active material;
a clear lane that is disposed along an edge of the substrate, the clear lane being free of the coating; and
an opening disposed within the clear lane,
the method including the following method steps: inserting an electrically conductive inner plate through each opening of at least one of the positive electrode plates and the negative electrode plates such that the inner plate extends in a direction perpendicular to each substrate, and is electrically connected to the substrate.

13 . The method of claim 12 , further comprising

Assignees

• Bosch Battery Systems Llc
• Bosch Gmbh Robert

Inventors

• Schneider Dan
• Buckholz Jeffrey
• E Liguo

Classifications

• H01M50/133

  Thickness · CPC title

• H01M50/566

  by welding, soldering or brazing · CPC title

• H01M10/658

  by thermal insulation or shielding · CPC title

• H01M50/55

  on the same side of the cell · CPC title

• H01M50/271

  Lids or covers for the racks or secondary casings · CPC title