CONVERTER CELL WITH A CELL HOUSING, A BATTERY, WITH AT LEAST TWO OF THE SAID CONVERTER CELLS, AND A METHOD FOR THE MANUFACTURE OF A CONVERTER CELL

An electrochemical energy converter device (1) with at least one in particular rechargeable electrode assembly (2), which is provided so as to make electrical energy available, at least temporarily, in particular to a consumer load, which has at least two electrodes (3, 3a) of differing polarity, with at least one current conducting device (4, 4a), which is provided so as to be electrically connected, preferably materially connected, with one of the electrodes (3, 3a) of the electrode assembly (2), with a cell housing (5) with a first housing part (6), wherein the first housing part (6) is provided so as to enclose the electrode assembly (2) at least in certain sections.

DETAILED DESCRIPTION

FIGS. 1A to 1Dshow schematically details of a preferred form of embodiment of an inventive electrochemical energy converter device, i.e. a converter cell1with a first housing part6. The first load-bearing element7and the second load-bearing element7aare advantageously designed as load-bearing layers.

FIG. 1Ashows that an edge section of the first housing part6is insert moulded with a second polymer material21. A current collector14is insert moulded by the second polymer material21, in particular in a gas-tight manner, and in particular is connected with the first housing part6in an essentially rigid manner. The first housing part6has the first load-bearing element7, the second load-bearing element7aand a functional device8, wherein the functional device8spaces apart the load-bearing elements7,7a.

FIG. 1Bshows that collector tabs13are welded onto the current collector14. The collector tabs13are also electrically connected, in particular materially connected, with electrodes of a first polarity of an electrode assembly, not represented. The said electrical connection has been created after the electrode assembly, not represented, has been inserted into the first housing part6, and before the cell housing is closed.

FIG. 1Cshows the first housing part6and a second housing part6a, whose edge sections are in each case insert moulded with the second polymer material21. In each case one current collector14,14ais connected with one of the housing parts6,6aby means of the second polymer materials21. Groups of collector tabs13,13aare welded onto the current collectors14,14a. The said groups of collector tabs13,13aare electrically connected with electrodes of differing polarity of the same electrode assembly, not represented. Thus the first current collector14has a polarity that differs from that of the second current collector14a. The cell housing is not yet closed.

FIG. 1Dshows schematically a detail of the converter cell1, after the cell housing5has been closed by the material connection of the first housing part6with the second housing part6a. The second polymer materials21of the edge sections of the housing parts6,6ahave thereby been fused with one another. The current collectors14,14aextend out of the cell housing5. The current collectors14,14aalso extend into the cell housing5.

FIG. 2shows schematically two layered composites18,18afor a first housing part. The first load-bearing element7and the second load-bearing element7aare advantageously designed as load-bearing layers.

The layered composite18has two load-bearing elements7,7a, which surround, i.e. enclose, four functional devices8,8a,8b,8c. The individual functional devices fulfil different functions and exhibit different functional elements for this purpose.

According to a first variant, the fourth functional device8chas a pressure sensor, a thermocouple and a cell control device, not represented, which processes signals from the named sensors, and controls the operation of the electrode assembly, likewise not represented. The first functional device8is designed as a cotton layer with the first component of a2-component polyurethane sealant. The third functional device8bis designed as a layer with the second component of the 2-component polyurethane sealant. The first functional device6is spaced apart from the third functional device8bby the second functional device8a, and the components are separated from one another. If a foreign body penetrates into the first housing part and thereby breaks through into the second functional device8a, the two components then come into contact in the section of the penetrating foreign body, and the formation of the polyurethane sealant is initiated. The polyurethane sealant serves to reduce or close the opening, through which water from the surroundings might penetrate into the interior of the cell housing in an undesirable manner.

According to a second variant, the second carrier element7aexhibits an arrangement of recesses or holes, which enable a substance, particularly from the electrode subassembly not shown, to pass through it to the fourth functional device8c. The fourth functional device8cexhibits a pressure sensor, a thermocouple and a sensor for hydrogen fluoride, wherein the sensors are not shown. The third functional device8binsulates the second functional device8achemically and electrically from the electrical subassembly. The third functional device8bexhibits functional elements, however, for the signal exchange between the second functional device8aand the aforementioned sensors. The second functional device8aexhibits a cell control device which is not shown and which processes signals from the aforementioned sensors and controls the operation of the electrode subassembly, which is likewise not shown. The first functional device8chas a cotton layer with alum as the flame-retardant filler and is used to protect the second functional device8alying thereunder.

The layered composite18ahas only one functional device8. Here the pressure sensor, the thermocouple and the cell control device are part of the same functional device8.

FIG. 3shows schematic sections through various configurations of the first housing part6with differing functional devices8,8a,8b,8c, and also first and second layered sections10,10a. The functional device8is surrounded by the first load-bearing element7and the second load-bearing element7a. The first load-bearing element7and the second load-bearing element7aare advantageously designed as load-bearing layers. The functional device8has two layered sections10,10a, wherein the first layered section has a greater wall thickness than the second layered section10a. The functional device8ahas a plurality of first layered sections10, in which run passages for a temperature-regulating medium. The functional device8bhas a plurality of first layered sections10, which are filled with a foam. For this purpose the functional device8bis filled with an expandable filler, which forms voids when supplied with an activation energy. The functional device8chas a voided structure, in particular a honeycomb structure, which serves to provide a weight saving together with an increased bending stiffness for the first housing part6.

FIG. 4shows a schematic view of a first housing part6with first layered sections10and second layered sections10aof the functional device. The first layered sections10, also marked with the letter “H”, have a greater wall thickness than the second layered sections10a, also marked with the letter “L”. The first load-bearing element7and the second load-bearing element7aare advantageously designed as load-bearing layers.

FIG. 5shows schematically a section through a first housing part6with an, in particular metallic, inlay22, which extends both into the functional device8and also outside of the said functional device. For simplicity the adjacent load-bearing elements are not represented. The inlay22serves to provide stiffening for the first housing part6, in particular it serves to increase the bending stiffness of the first housing part6. The inlay22is profiled for enhanced bending stiffness.

FIG. 6shows a schematic section through a preferred form of embodiment of a converter cell. An electrode assembly2is inserted into a first housing part, and is electrically connected with current collectors14,14a. Not represented are collector tabs, which serve to provide the electrical connection between a current collector14,14aand an electrode of the electrode assembly2. Both current collectors14,14ahave contact sections12,12a. Of the first housing part only the second polymer material21is represented. Load-bearing elements and functional devices are not represented, in order that the contact sections12,12acan be better discerned. The contact sections12,12aextend out of the second polymer material21in the direction of the functional device, not represented. The contact sections12,12aserve to provide the electrical connection, in particular the supply, to the functional device, not represented.

FIG. 7shows schematically a processing device20for the manufacture of a layered composite18for a first housing part. The first load-bearing element7, the second load-bearing element7a, and two functional devices8,8a, are unwound from various stock holdings. The first load-bearing element7and the second load-bearing element7aare advantageously designed as load-bearing layers. The said layers are supplied to the processing device20, here designed as a double belt press20. In particular the layers that are laid one upon another are connected with one another in the double belt press20under the influence of heat to form a layered composite18. The layered composite18is fed onto a stock holding19.

FIG. 8shows schematically a processing device20for the manufacture of a layered composite18for a preferred form of embodiment of a first housing part, with a plurality of functional devices, wherein one of the said functional devices is designed as a populated, flexible circuit board8a. The first functional device8is firstly unwound. The circuit boards8aare individually placed onto the first functional device8by a grab, preferably with a minimum separation distance between two circuit boards. A further functional device8band also two load-bearing elements7,7aare unwound. The first load-bearing element7and the second load-bearing element7aare advantageously designed as load-bearing layers. The circuit board8ais enclosed by the load-bearing elements7,7abefore the layers are supplied to the double belt press20. The layered composite18is created in the double belt press20, in particular under the influence of heat. The layered composite18is fed onto a stock holding19.

FIG. 9shows schematically the cutting to length of moulding blanks23from a prepared layered composite18, in particular by means of a parting device20. If one of the functional devices is designed as a circuit board the layered composite18is separated between two such circuit boards.

FIGS. 10A to 10Eshow schematically the manufacture of a first housing part6from a moulding blank23, with the supply of a second polymer material21into the edge section of the moulding blank23, i.e. the first housing part6, with the formation of an accommodation space11for an electrode assembly2, with the insert moulding of current collectors14,14aand of the edge section of the moulding blank23, in a processing device20. Although not represented, the moulding blank23has the first load-bearing element, at least one of the said functional devices, and also the second load-bearing element. The first load-bearing element7and the second load-bearing element7aare advantageously designed as load-bearing layers.

FIG. 10Ashows the moulding blank23and also the current collectors14,14a, which are inserted into the processing device, here designed as a moulding tool20. The two-part moulding tool is not yet closed. One part of the moulding tool20is designed with a depression, the other part of the moulding tool20is designed with a protrusion. The depression and protrusion serve to form an accommodation space in the moulding blank23, i.e. the first housing part, for the electrode assembly, not represented. Before the moulding tool20, equipped with depression and protrusion, is closed the moulding blank23is heated to a working temperature that corresponds at least to the softening temperature of the first polymer material.

FIG. 10Bshows the moulding tool23during the closing procedure, wherein the accommodation space11is formed in the moulding blank23by means of the depression and the protrusion. The moulding blank23thereby has a working temperature that corresponds at least to the softening temperature of the first polymer material.

FIG. 10Cshows the closed moulding tool20. After plastic deformation the inserted moulding blank23has the accommodation space11. The current collectors14,14aare held in the moulding tool20in predetermined positions relative to the moulding blank23, in particular in the edge section of the moulding blank23. The moulding blank23preferably has a working temperature that corresponds at least to the softening temperature of the first polymer material, in particular such that the moulding blank23can enter into an intimate material connection with the second polymer material, not represented.

FIG. 10Dshows the closed moulding tool20, and also the moulding blank23, inserted as inFIG. 10c, at a later point in time. Heated second polymer material21is supplied through two passages to the moulding tool20. The second polymer material21fills voids provided in the moulding tool20, which are arranged in edge sections of the moulding blank23. The current collectors14,14aalso extend through the voids. With the supply of the second polymer material21the edge sections of the moulding blank23and also the current collectors14,14aare insert moulded. The moulding blank23preferably has a working temperature that corresponds at least to the softening temperature of the first polymer material, in particular such that the moulding blank23can enter into intimate material connections with the second polymer material21.

After the supply of the second polymer material21its temperature, and also the temperature of the moulded moulding blank23are lowered, such that they also fall below the softening temperature of the first polymer material. The first housing part6is then ready to be extracted.

FIG. 10Eshows the opened moulding tool20and also the first housing part6that has been removed from the mould. The first housing part6has the two load-bearing elements, at least one of the functional devices, in the edge section the second polymer material21, the accommodation space11, and also the current collectors14,14a. After the extraction of the first housing part6the moulding tool20is ready for the manufacture of the next first housing part.

FIG. 11shows various views and sections of a first housing part6with an accommodation space11for an electrode assembly.

FIGS. 12A and 12Bshow schematically a converter cell1with a two-part cell housing5, wherein the first housing part6is designed as a tub, and the second housing part6ais designed as a cover. The interior of the tub corresponds to the accommodation space11. Not represented is the second polymer material, which is arranged in the edge sections of the housing parts6,6a. Two current conducting devices4,4aextend, at least in certain sections, through one of the housing parts into the surroundings of the converter cell1.

FIG. 12Ashows that the current conducting devices4,4aare led through the second housing part6ainto the surroundings. The fact that the current conducting devices4,4aare materially connected with the second housing part6a, and in particular in a gas-tight manner, is not represented.

FIG. 12Bshows that the current conducting devices4,4aare led through the first housing part6into the surroundings. The fact that the current conducting devices4,4aare materially connected with the first housing part6, and in particular in a gas-tight manner, is not represented.

FIG. 13shows schematically a converter cell1with a two-part cell housing5, wherein the housing parts6,6aare spaced apart by means of a frame of the second polymer material21. The electrode assembly, not represented, is accommodated by the frame. Thus the housing parts6,6aare in each case designed without an accommodation space. Two of the said current conducting devices14,14aextend out of the frame21into the surroundings of the converter cell1.

FIGS. 14A to 14Dshow schematically further preferred forms of embodiment of converter cells1, in each case with a two-part cell housing5, and in each case with two current collectors14,14a, which extend into the surroundings of the converter cell. Edge sections of the said housing parts6,6aare in each case surrounded by the second polymer material21. The said edge sections are materially connected with one another, in particular in a gas-tight manner. Thus the housing parts6,6ajointly form the cell housing around the electrode assembly, not represented. The current collectors14,14aextend out of different housing parts6,6a, in particular in each case out of the second polymer material21, which in each case connects one of the said current collectors with one of the said housing parts in a gas-tight manner. The housing parts6,6aare in each case designed with an accommodation space. The two housing parts6,6aare advantageously of symmetrical design. In this manner storage costs are reduced.

FIGS. 14A and 14Bshow a converter cell1, in which the fluid passages14,14aextend out of the cell housing in the same direction.

FIGS. 14C and 14Dshow a converter cell1, in which the fluid passages14,14aextend out of the cell housing in opposite directions.

FIGS. 15A to 15Dshow schematically further preferred forms of embodiment of converter cells1, in each case with a two-part cell housing5, and with current conducting devices4,4a, which in each case terminate essentially on a cover surface of the cell housing5. Edge sections of the said housing parts6,6aare in each case surrounded by the second polymer material21. The said edge sections are materially connected with one another, in particular in a gas-tight manner. Thus the housing parts6,6ajointly form the cell housing around the electrode assembly, not represented. The current conducting devices4,4aare arranged in different housing parts6,6a, in particular in each case in the second polymer material21, which in each case connects one of the said current conducting devices with one of the said housing parts in a gas-tight manner. The current conducting devices4,4aterminate on cover surfaces of different housing parts6,6a. The housing parts6,6aare in each case designed with an accommodation space. The two housing parts6,6aare advantageously of symmetrical design. In this manner storage costs are reduced.

FIGS. 15A and 15Bshow a converter cell1, in which the current conducting devices4,4aextend in the same direction.

FIGS. 15C and 15Dshow a converter cell1, in which the current conducting devices4,4aextend in opposite directions.

FIGS. 16A to 16Dshow schematically further preferred forms of embodiment of converter cells, in each case with a two-part cell housing5, each with a converter assembly2and two fluid passages24,24a. Not represented are the current conducting devices of the converter cell1. Edge sections of the said housing parts6,6aare in each case surrounded by the second polymer material21. The said edge sections are materially connected with one another, in particular in a gas-tight manner. Thus the parts of the housing6,6ajointly form the cell housing around the converter assembly2, not represented. The fluid passages24,24aextend out of the cell housing, in particular out of the second polymer material, into the surroundings of the converter cell1.

According to a first variant, the first fluid passage24serves to supply the fuel. The second fluid passage24aserves both to supply the oxidising agent and also to remove the educt. For this purpose the second fluid passage24ahas a separating wall, not represented.

According to a second variant, the particularly controllable fluid outlets24,24aare used for the exchange of oxygen, particularly from the surroundings or another source of oxygen, with the electrode subassembly, wherein the electrode subassembly absorbs oxygen during discharging, wherein the electrode subassembly gives off oxygen during charging. The fluid outlets24,24amay be opened and closed by the control device. Not shown are two gas sensors, which are used to measure the throughput through these fluid outlets24,24a. These gas sensors may be operated or read by the control device. At least one of these fluid outlets24,24ais configured to be connected to a fluid-conveying device which does not belong to the converter cell.

FIGS. 16A and 16Bshow a converter cell1, whose fluid passages24,24aextend in the same direction.

FIGS. 16C and 16Dshow a converter cell1, whose fluid passages24,24aextend in opposite directions.

LIST OF REFERENCE NUMBERS