Patent ID: 12224404

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

With reference toFIGS.1-4, a system10(FIG.1) is provided for manufacturing a plurality of stacked battery cells12(FIG.4c). Each stacked battery cell12has a plurality of first electrodes14, a plurality of second electrodes16, and a plurality of separator sheets18interposed between adjacent first and second electrodes14,16. The plurality of first electrodes14and the plurality of second electrodes16are stacked in an alternating arrangement. Each first electrode14is made of a single, separate electrode sheet having opposing ends. Each first electrode14also comprises a foil tab20extending from at least one of the opposing ends. Each second electrode16is made of a single, separate electrode sheet having opposing ends. Each second electrode16also comprises a foil tab22extending from at least one of the opposing ends. The foil tabs20of the first electrodes14may be bundled to each other and connected to a first electrode terminal (not shown). Similarly, the foil tabs22of the second electrodes16may be bundled to each other and connected to a second electrode terminal (not shown). Each separator sheet18is made of a single, separate sheet.

The system10for manufacturing the stacked battery cells12comprises a plurality of adapter plates24, a conveyor26, first and second separator supply devices28,30, a first electrode supply device32, and a second electrode supply device34. Each stacked battery cell12is stacked on a lift35movably disposed within the respective adapter plate24. The conveyor26is configured to continuously move the adapter plates24in a generally circular path between the supply devices28,30,32,34until the stacked battery cells12comprise a desired number of respective separator sheets18, respective first electrode sheets14, and respective second electrode sheets16. The conveyor26can be a belt driven conveyor, a roller conveyor, or any other suitable conveyor that can continuously move the adapter plates24in a generally circular path. The adapter plates24are moved onto the conveyor26by a conveyor feed device36(FIG.1). Once the stacked battery cells12comprise the desired number of respective separator sheets18, respective first electrode sheets14, and respective second electrode sheets16, the adapter plates24are removed from the conveyor26by a conveyor removal device29(FIG.1) where the stacked battery cells12are transported to another workstation.

With reference toFIGS.1,3a, and3b, each of the first and second separator supply devices28,30is a rotary drum that is configured to continuously rotate in a first rotational direction X1to pick up a plurality of separator sheets18and release the plurality of separator sheets18onto the lifts35of respective adapter plates24as the conveyor26moves the respective adapter plates24in a generally circular path. That is, each of the first and second separator supply devices28,30picks up the separator sheets18from one or more feeding devices (not shown) via vacuum suction, for example, at a first position along a rotary path and releases the separator sheets18onto the lifts35of the respective adapter plates24at a second position along the rotary path. The first and second separator supply devices28,30are positioned directly over the conveyor26and are inhibited from moving in a horizontal direction or vertical direction. In the example illustrated, each of the first and second separator supply devices28,30comprises a plurality of rectangular cutouts40(FIGS.3aand3b) that are aligned with each other along a length of the device28,30. In this way, each separator sheet18is received in a respective cutout40when the separator device28,30picks up the separator sheet18and is removed from the respective cutout40onto the lift35of the respective adapter plate24when the separator device28,30releases the separator sheet18. In the example illustrated, the first and separator supply devices28,30are opposed to each other or between the first and second electrode supply devices32,34.

With reference toFIGS.1and3c, the first electrode supply device32is a rotary drum that is configured to continuously rotate in a first rotational direction X1to pick up the plurality of first electrodes14and release the plurality of first electrodes14onto lifts35of respective adapter plates24as the conveyor26moves the respective adapter plates24in a generally circular path. That is, the first electrode supply device32picks up the first electrodes14from one or more feeding devices (not shown) via vacuum suction, for example, at a first position along a rotary path and releases the first electrodes14onto the lifts35of the respective adapter plates24at a second position along the rotary path. Each adapter plate24comprises a first alignment feature43(FIG.2) at a first end that is configured to receive foil tabs20of the first electrodes14. In this way, the first electrodes14are aligned within the adapter plates24. In the example illustrated, the first alignment feature43forms a slot that receives the foil tabs20. The first electrode supply device32is positioned directly over the conveyor26and is inhibited from moving in a horizontal direction or vertical direction. In the example illustrated, the first electrode supply device32comprises a plurality of rectangular cutouts44(FIG.3c) that are aligned with each other along a length of the device32. In this way, each first electrode14is received in a respective cutout44when the first electrode supply device32picks up the first electrode14and is removed from the respective cutout44onto the lift35of the respective adapter plate24when the first electrode supply device32releases the first electrode14.

With reference toFIGS.1and3d, the second electrode supply device34is a rotary drum that is configured to continuously rotate in a first rotational direction X1to pick up the plurality of second electrodes16and release the plurality of second electrodes16onto the lifts35of respective adapter plates24as the conveyor26moves the respective adapter plates24in a generally circular path. That is, the second electrode supply device34picks up the second electrodes16from one or more feeding devices (not shown) via vacuum suction, for example, at a first position along a rotary path and releases the second electrodes16onto the lifts35of the respective adapter plates24at a second position along the rotary path. Each adapter plate24comprises a second alignment feature45(FIG.2) at a second end that opposes the first end that receives foil tabs22of the second electrodes16. In this way, the second electrodes16are aligned within the adapter plates24. In the example illustrated, the second alignment feature45forms a slot that receives the foil tabs22. The second electrode supply device34is positioned directly over the conveyor26and is inhibited from moving in a horizontal direction or vertical direction. In the example illustrated, the second electrode supply device34comprises a plurality of rectangular cutouts48(FIG.3d) that are aligned with each other along a length of the device34. In this way, each second electrode16is received in a respective cutout48when the second electrode supply device34picks up the second electrode16and is removed from the respective cutout48onto the lift35of the respective adapter plate24when the second electrode supply device34releases the second electrode16. Each of the supply devices28,30,32,34rotate about a fixed axis. Each of the supply devices28,30,32,34may also rotate at a speed between one in a half (1.5)-five (5) meters per second.

With continued reference toFIGS.5and6, a method200for manufacturing stacked battery cells12using the system10will be described in detail. First, at202, the adapter plates24are moved onto the conveyor26by the conveyor feed device36. Then, at206, the conveyor26moves each of the adapter plates24continuously and sequentially between the first separator supply device28to receive a respective separator sheet18, the first electrode supply device32to receive a respective first electrode sheet14, the second separator supply device30to receive a respective separator sheet18, and the second electrode supply device34to receive a respective second electrode sheet16until each stacked battery cell12comprises a desired number of respective separator sheets18, respective first electrode sheets14, and respective second electrode sheets16. It should be understood that the lifts35of the adapter plates24gradually move downwardly in a vertical direction as the sheets14,16,18are disposed thereon. That is, as shown inFIG.5, a control device50is in communication with the lifts35of the adapter plates24and is configured to control the vertical movement of the lifts35. The control device50is a servo driven controller or a pneumatic driven controller, for example. Lastly, at210, the adapter plates24comprising the stacked battery cells12are removed from the conveyor26by the conveyor removal device29and moved to the next workstation.

It should be understood that, in some examples, as shown inFIG.7, each stacked battery cell12may be stacked in a pouch90disposed within the adapter plate24. The pouch90may be made of a material comprising nylon, mylar and/or aluminum. The pouch90is sealed from the top when the stacked battery cell12comprises the desired number of respective separator sheets18, respective first electrode sheets14, and respective second electrode sheets16.

The first electrodes14described above are negative electrodes and the second electrodes16described above are positive electrodes. However, it should be understood that the first electrodes14may be positive electrodes and the second electrodes16may be negative electrodes without departing from the scope of the present disclosure.

The method and system described in the present disclosure can be used for lithium-ion battery pouch cells, prismatic cells, wound cells, uni-polar or bi-polar cells, and solid state batteries, for example. The method and system of the present disclosure provides the benefit of reducing manufacturing time of the stacked battery cell12.

With continued reference toFIG.8, another system310is provided for manufacturing a plurality of stacked battery cells. The system310may be similar or identical to the system10described above, apart from any exception noted below.

The system310comprises a plurality of adapter plates324, a conveyor (not shown), sheet feeding conveyors325a,325b,325c,325cand a supply device328. The adapter plates324are similar or identical to the adapter plates24described above, and therefore, will not be described again in detail. The conveyor is configured to move the adapter plates324along a path (e.g., linear or circular path) to the supply device328such that the stacked battery cell is stacked thereon.

The sheet feeding conveyor325ais configured to feed a first separator sheet318ato the supply device328, the sheet feeding conveyor325bis configured to feed a first electrode sheet314to the supply device328, the sheet feeding conveyor325cis configured to feed a second separator sheet318bto the supply device328, and the sheet feeding conveyor325dis configured to feed a second electrode sheet316to the supply device328.

The supply device328is a rotary drum that is configured to continuously rotate in a first rotational direction to pick up respective sheets314,316,318a,318band release the respective sheets314,316,318a,318bone at a time onto a lift335of a respective adapter plate324. That is, the supply device328picks up the respective sheets314,316,318a,318bfrom the feeding devices325a,325b,325c,325dvia vacuum suction, for example, and releases the respective sheets314,316,318a,318bonto the lift335of the respective adapter plate24. The supply device328is positioned directly over the conveyor and is inhibited from moving in a horizontal direction or vertical direction. The supply device328comprises a plurality of rectangular cutouts (not shown) that are formed in the supply device328and aligned with each other around the supply device328. In this way, the sheets314,316,318a,318bare received in a respective cutout when the supply device328picks up the sheets314,316,318a,318band are removed from the respective cutout onto the lift335of the respective adapter plate324when the supply device328releases the sheets314,316,318a,318b. The supply device328continuously releases sheets314,316,318a,318bonto the lift335of the respective adapter plate324until the stacked battery cell comprises a desired number of respective separator sheets318a,318b, respective first electrode sheets314, and respective second electrode sheets316. The sheets314,316,318a,318bare continuously released sequentially in the following order: a respective separator sheet318a, a respective first electrode sheet314, a respective separator sheet318b, and a respective second electrode sheet316. A control device (not shown) is configured to gradually move the lift335downwardly in a vertical direction as the sheets314,316,318a,318bare disposed thereon. Once the stacked battery cell is stacked, the conveyor moves the adapter plate324comprising the stacked battery cell to the next workstation and another adapter plate324is positioned under the supply device328. The supply device328may rotate at a predetermined speed based on the number of cutouts formed in the supply device328. In one example, the rotational speed may be between one in a half (1.5)-five (5) meters per second.

It should be understood that, in some configurations, the feeding device325cmay be removed from the system310such that the system310includes only one feeding device325a. In this way, the sheets314,316,318aare continuously released sequentially by the supply device328in the following order: a respective separator sheet318a, a respective first electrode sheet314, a respective separator sheet318a, and a respective second electrode sheet316.

With continued reference toFIGS.9and10, another system410is provided for manufacturing a plurality of stacked battery cells. The system410may be similar or identical to the systems10,310described above, apart from any exception noted below.

The system410for manufacturing the stacked battery cells comprises a plurality of adapter plates424, a conveyor (not shown), first and second separator supply devices428,430, a first electrode supply device432, and a second electrode supply device434. The adapter plates424are similar or identical to the adapter plates24,324described above, and therefore, will not be described again in detail. The conveyor is configured to move the adapter plates424along a generally circular path between the supply devices428,430,432,434.

The first and second separator supply devices428,430are rotary drums that are configured to continuously rotate in a first rotational direction to pick up respective separator sheets418and release the respective sheets418onto a respective adapter plate424. The first and second separator supply devices428,430comprise a plurality of rectangular cutouts (not shown) that are formed in the supply devices428,430and are aligned with each other around the first and second separator supply devices428,430.

The first electrode supply device432is a rotary drum that is configured to continuously rotate in a first rotational direction to pick up respective first electrode sheets414and release the respective sheets414onto a respective adapter plate424. The first electrode supply device432comprises a plurality of rectangular cutouts (not shown) that are formed in the first electrode supply device432and are aligned with each other around the first electrode supply device432. The second electrode supply device434is a rotary drum that is configured to continuously rotate in a first rotational direction to pick up respective second electrode sheets416and release the respective sheets416onto a respective adapter plate424. The second electrode supply device434comprises a plurality of rectangular cutouts (not shown) that are formed in the second electrode supply device434and are aligned with each other around the second electrode supply device434.

Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.

As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”

In this application, the term “controller” and/or “module” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components (e.g., op amp circuit integrator as part of the heat flux data module) that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

The term memory is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory. Non-limiting examples of a non-transitory, tangible computer-readable medium are nonvolatile memory circuits (such as a flash memory circuit, an erasable programmable read-only memory circuit, or a mask read-only circuit), volatile memory circuits (such as a static random access memory circuit or a dynamic random access memory circuit), magnetic storage media (such as an analog or digital magnetic tape or a hard disk drive), and optical storage media (such as a CD, a DVD, or a Blu-ray Disc).

The apparatuses and methods described in this application may be partially or fully implemented by a special purpose computer created by configuring a general-purpose computer to execute one or more particular functions embodied in computer programs. The functional blocks, flowchart components, and other elements described above serve as software specifications, which can be translated into the computer programs by the routine work of a skilled technician or programmer.

The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.