CN1168169C - 电化学电池制造方法以及密封电化学电池组件 - Google Patents
电化学电池制造方法以及密封电化学电池组件 Download PDFInfo
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Abstract
本发明提供密封电化学电池的方法。在所公开的方法中,粘合组分的涂层涂覆在外金属接点上,外金属接点充当从电池到设备的接触引线,电池装在设备内。从而粘合层涂覆并密封接点表面上。可通过在接点表面上直接热密封粘合膜来完成涂覆工艺。另一方面,粘合组分的悬浮水液可喷涂在接点表面上,或者可将该组分辊涂接点上,之后进行热处理,使得粘合剂熔化并流动。之后把该涂覆过的接点焊接到金属箔形式的对应集电体上。将完整的电池组件热密封在最终闭合密封元件内,使密封接点由此延伸。
Description
技术领域
本申请要求1999年3月22申请的U.S.序号No.60/125638,题为“A Methodto Treat Tabs for Hermetic Sealing of Electrochemical Cells in Plastic Bags”的申请为优先权。
背景技术
本发明涉及制备电化学电池的接触引线的经济方法和由此得到的电池。本发明尤其涉及处理电化学电池上的金属接触接头以及此后把所述电池封装在最后闭合密封件中的方法,从而得到制造成本低廉、具有最佳密封性的小型电池。
电化学电池代表可充电电池技术中的现有技术状况。这种电池经常封装在可充电聚合物电池组件中。该电池组件利用本领域公知的预定分子式的离子导体来提供高能量密度、高性能可靠性和延长的储藏寿命。对满足小型电子设备中电池尺寸减小和形状要求的电化学电池可实现极大降低电池的重量。当进行高速率循环、机械冲撞、热冲击、振荡、过电压、低电压、短路、自动电池充电、钉渗透(nail penetration)和高压力实验时,这些电池所表现的结果优良。这些性能使电化学电池更为广泛应用于许多领域,包括移动电话、寻呼机、折叠式计算机、手提终端和无绳通讯设备。在此讨论的情况下,术语“电池(battery)”和“电池(cell)”可互换使用。
密封性也是电化学电池特别重要的一项性能。现有技术认为密封电池保持其制造的气密状态极为重要,甚至在长期储存或使用之后也是如此。传统电池技术常利用金属外壳以得到足够的刚性和密封性。在具有金属外壳的电化学电池中,提供密封的一种方法是在外壳中焊接密封元件。然而,与焊接相邻的外壳将热量传到所含的电解质中,不可避免地导致电解质蒸发。当这些气体从电池外壳逸出时,在焊接处留下针孔,这危及整个电池结构的密封性。因此,在金属外壳上简单地焊接密封不能足以确保气密封性。此外,尽管金属外壳结构本质上坚固,但仍有许多缺陷,包括过重以及结构限制(即只能限定如柱形和长方形的简单几何形状构成)。
然而,通过采用如多层塑料密封盒的最终闭合密封元件来充当电池外壳,可克服这些缺点以及相关缺点。在电化学电池中电极与隔板的粘结消除了对坚固电池外壳的要求,从而极大降低了电池重量。因此,电化学电池可封装在薄且柔的多层盒中,其重量降低而且可形成最小厚度的多个几何体。近年来这种密封元件的使用已较流行,用于如聚合物电解质基锂或锂离子电池的电化学电池,类似于在此引用作为参考的U.S.专利申请No.09/405200所述。
电化学电池的多层封装一般包括最后一层薄金属箔如铝,以提供氧气和水分阻挡层。然后箔层一般密封在如尼龙或聚酯的聚合物材料片和如聚乙烯的低温聚烯层之间,聚合物材料片具有优良的机械完整性,低温聚烯层用于热密封以便形成叠层。当给出足够宽度时,在整个延长时间期限期间这种聚合物层的结合可提供密封。
以这种方法实现密封性受到对盒内电池经过通常为金属接点形式的接触引线电连接到外部接点的要求限制。接点将电流传送到电池的正极端和负极端,并从正极端和负极端流出。为使粘合牢固,通常在高温和高压下完成塑料密封盒的封装。因此,限定接点厚度以使热密封层沿接点周围流动,产生气密封。当进行电化学电池的封装时,高温和高压可导致封装材料的变形以及金属接点穿透粘合层。因此,接点延伸到封装外并经过密封区,结果减弱了一般为密封特征的强且均匀的粘合/粘接。因此,各个接点之间和接点与金属箔叠层之间的无意识电短路仍是主要问题。
因此,希望提供确保密封性的改进工艺,从而防止损害电池性能和使用者安全性的电池退化。
发明内容
本发明的目的是提供制造电化学电池的改进方法。
本发明的另一目的是提供电化学电池的改进密封,从而实现电解质和接点的密封性。
本发明的再一目的是改进电化学电池设计的适应性。
本发明的还一目的是增强电化学电池的密封性并提供小型电池结构。
本发明的还一目的是为容纳小尺寸塞孔的电化学电池提供低分布密封,并改善电池外观。
本发明的还一目的是提供一种方法,通过该方法可加强金属与粘合层的粘接以便塑料电池外壳的密封。
本发明的还一目的是研制适合于高速自动化的快速和便宜的密封方法。
为有效实现这些和其它目的,本发明提供密封电化学电池的方法。在所公开的方法中,粘合组分的涂层涂覆在外金属接点上,外金属接点充当从电池到电池安放在其中的设备的接触引线。粘合层涂覆并密封接点表面。通过在接点表面上直接热封接粘合膜可完成涂覆过程。另一方面,可将粘合组分的悬浮水液喷射在接点表面上,或者接点可在组分中辊涂,之后进行热处理,使得粘合层熔化并流动。此后涂覆过的接点焊接到金属箔形式的对应集电体上。整个电池组件热密封在最终闭合密封元件内,从而密封接点延伸过整个组件。
附图说明
图1表示用最终闭合密封元件密封之前的本发明工艺的电化学电池示意图。
图2表示在密封最终闭合密封元件之后的图1的电化学电池的金属接点。
具体实施方式
本发明涉及密封电化学电池组件及其制造方法。该组件由多个电池组成,电池具有金属接点形式的接触引线,金属接点由此延伸用于在电池与将电池装在其中的设备之间传送电流。每个金属接点由相对平面来确定,平面中的一个或两个上有粘合组分的涂层,用于密封接点。之后与处理过的接点一起把电池用最终闭合密封元件密封,从而热密封塑料电池外壳,将电化学电池密封在其中。
现参考图1-2,其中相同元件用相同标号表示,提供本发明的电化学电池组件10,包括一个电化学电池12,电化学电池12具有多个双电池14。双电池14可以以单独、邻接的室制备,其中多个阳极、阴极和隔板元件进行热层压并切割。在将元件切割成单个电池之后,电池插入室中,然后密封该室。另一方面,电池12可装在Z-形支管内,其中每个双电池14包括插在一对充当基底的平面隔板膜之间的预定形状和尺寸的阳极。在未与阳极接触的每个隔板膜的表面上,阴极位于其上,从而与对应的阳极重叠对正。之后在由双电池之间的空间确定的双电池界面上进行叠合,隔板膜连接相互重叠对正的相邻双电池。后一实施例还在登记为U.S.专利申请No.09/405200中进一步描述,并在此引用作为参考。
电化学电池组件10还包括最终闭合密封元件,在此塑料电池外壳16所示。电池外壳16包括相互重叠对正的上密封层16a和下密封层16b。如图2所示,密封元件16包含用于沿密封缘17密封电化学电池12的叠层型结构。具体所示,上密封层16a和下密封层16b中每个最少包含三层。聚合物盖18和18’由具有优良机械完整性的聚合物组成,例如聚酯或尼龙,用于绝缘保护以及气密封电化学电池组件10。金属层20和20’由轻质材料如铝制备,从而提供额外的水分密封阻挡层。为附加密封性提供粘合层22和22’并相互热封接到预定宽度。然而,粘合层22和22’的材料组分根据制造及性能要求而改变,这里所用的所需材料的例子包括聚烯烃如聚乙烯、聚乙烯异丁烯酸酯的离子键树脂如Surlyn(DuPont公司的注册商标)或层压粘合剂如Adcote(Morton International的注册商标)。尽管有包括每个密封层16a和16b的三个特征层,应理解密封元件16的结构只用来说明,层的总数可根据电池制造者的需要和电池的最终用途而变化。例如,可具有粘合层与金属层之间的层,以及金属与聚合物层之间的层,从而改善层间粘接。
如上所述,在柔性塑料电池外壳如密封元件16内密封电化学电池的固有问题在于对接触引线的需要,接触引线形成电池12与将电池装在其中的设备之间的电连接。该接触引线通常采用金属接点如铝接点30和铜接点30’的形式。接点30和30’由金属制备,与电池12的阳极和阴极电连接。因此接点30和30’充当粘合层22和22’之间的阻挡层,并防止其间形成最优气密封。为使该问题得到缓和,本发明包含在密封密封元件16之前预处理金属接点30和30’。
现描述电池组件10的制备。
如下方式制备用于密封的金属接点30和30’。用预选的溶剂如丙酮清洗接点30和30’,从而去除并处理掉接点表面上的油或碎屑。干燥接点,之后用热封接的粘合材料如聚乙烯或其它聚烯烃、Surlyn、Adcote或其它可与用于制备密封元件16的材料密封匹配的材料涂覆。可通过浸涂、喷涂、辊涂、刷涂或任何其它常用涂覆工艺涂覆涂层。然后干燥接点30和30’,放置在烘箱中以熔化粘合层。粘合层流动并均匀润湿,涂覆在金属接点的表面上,形成强的金属-粘合层粘接。然后将每个接点焊接到对应的集电体上并热密封在密封元件16内。该密封给电池12提供尺寸降低的美观外形,并且不妨碍电池12插入塞孔中,其中利用空间非常重要。
如下例子提供了完成上述工艺的说明。应理解这些例子只说明了该公开预料的材料结合的类型,而未限定在密封电化学电池制备中的应用。
例子1
用丙酮或类似溶剂清洗厚度50m的铝箔集电体,去除其表面上的任何处理油,然后干燥。利用喷枪和EAA粘合剂的悬浮水液,对铝接点涂覆5m粘合层。然后铝接点放置在约250℃的烘箱中并烧结约5分钟。该热处理使得EAA熔化并流动,从而均匀覆盖铝接点表面。然后将铝接点焊接到电池的铝栅板。以相同方法处理铜接点,并焊接到电池的铜箔集电体上,从而形成电极叠层。然后电极叠层放置在塑料密封盒内部。沿叠层周围在约130℃温度和约10psi的压力下热密封该盒。该密封是气密的并可承受高温储存而不泄漏。
例子2
用丙酮清洗厚度50m的铝箔集电体,去除其表面上的任何处理油,然后干燥。利用50%的Adcote(Morton International的注册商标)和50%的乙醇的混合物,然后辊涂覆铝接点。然后铝接点放置在约250℃的烘箱中并烧结约5分钟。该热处理使得EAA熔化并流动,从而均匀覆盖铝接点表面。然后将铝接点焊接到电池的铝栅板。以相同方法处理铜接点,并焊接到电池的铜箔集电体上,从而形成电极叠层。然后电极叠层放置在塑料密封盒内部。沿叠层周围在约130℃温度和约10psi的压力下热密封该盒。
本发明工艺中采用的密封可实现气密封,而同时可承受高温储存而不泄漏。由于许多应用需要对本发明的电池频繁充电,电池容易在电池供电的设备与充电器之间操作。因此,电池能与各种连接器结构匹配,从而相同电池可用于各种类型的设备。
对本领域技术人员而言,显然可对上述和所示结构进行各种变化。因此,本发明的特定公开范围在如下权利要求中提出。
Claims (31)
1.制造电化学电池的方法,包括如下步骤:
提供负极材料和正极材料中的每个,其中所述电极材料相互处于工作电连接的状态;
提供负集电体和正集电体中的每个;
为所述负和正电极材料中的每个提供充当正和负极端的接触引线,其中所述接触引线从电化学电池组件向外延伸,所述电极材料包含在电化学电池组件内;
将密封粘合组分的涂层涂覆在所述接触接点,从而均匀覆盖所述接点;和
将所述电化学电池组件密封对正地插入在最终闭合密封元件中,使所述接触引线由此突出。
2.按权利要求1的制造方法,其中所述粘合组分可从由聚烯烃、离子键树脂和润滑粘合剂组成的材料组中选择。
3.按权利要求1的制造方法,其中所述涂覆步骤可通过从浸涂、喷涂、辊涂和刷涂组成的涂覆方法组中选择的方法来进行。
4.按权利要求1的制造方法,还包括在所述涂覆步骤之后热处理所述接触引线的步骤。
5.按权利要求4的制造方法,其中所述金属接点在150℃-375℃的温度下热处理。
6.按权利要求1的制造方法,其中所述电池热密封在所述最终闭合密封元件内。
7.按权利要求1的制造方法,其中所述密封元件包括塑料电池外壳。
8.按权利要求1的制造方法,其中所述电池外壳还包括相互重叠对正的上密封层和下密封层。
9.按权利要求8的制造方法,其中所述上和下密封层中的每个包括多层。
10.按权利要求9的制造方法,其中所述层还包括聚合物罩层、金属层和粘合层中的每个。
11.按权利要求1的制造方法,其中所述接触引线的一个由铝制备。
12.按权利要求11的制造方法,其中所述接触引线的第二个由铜制备。
13.密封电化学电池组件,包括:
电化学电池,包括:
负极材料和正极材料,其中所述电极材料相互工作电连接;
正集电体;
负集电体;和
用于所述负极和正极材料中的每个、充当正极端和负极端的接触引线,其中所述接触引线从电化学电池组件向外延伸,所述电极材料包含在电化学电池组件内;
密封粘合组分的涂层,涂覆在所述接触接点上,从而均匀覆盖在所述接点上;和
最终闭合密封元件,所述电化学电池组件密封对正插入其内,使所述接触引线由此突出。
14.按权利要求13的电化学电池组件,其中所述涂层从由聚烯烃、离子键树脂和润滑粘合剂组成的材料组中选择。
15.按权利要求14的电化学电池组件,其中所述涂层通过浸涂、喷涂、辊涂和刷涂组成的涂覆方法组中选择的方法来进行。
16.按权利要求13的电化学电池组件,其中所述接触引线在涂覆所述涂层之后进行热处理。
17.按权利要求16的电化学电池组件,其中所述金属接点在150℃-375℃的温度下进行热处理。
18.按权利要求13的电化学电池组件,其中所述电池热密封在所述最终闭合密封元件内。
19.按权利要求13的电化学电池组件,其中所述密封元件包括塑料电池外壳。
20.按权利要求19的电化学电池组件,其中所述电池外壳还包括相互重叠对正的上密封层和下密封层。
21.按权利要求20的电化学电池组件,其中所述上和下密封层中的每个包括多层。
22.按权利要求21的电化学电池组件,其中所述层还包括每个聚合物罩层、金属层和粘合层。
23.按权利要求13的电化学电池组件,其中所述接触引线的一个由铝制备。
24.按权利要求13的电化学电池组件,其中所述接触引线的第一个由铜制备。
25.按权利要求13的电化学电池组件,其中所述电化学电池还包括多个双电池。
26.按权利要求25的电化学电池组件,其中所述双电池由进行热层压并切割的多个阳极、阴极和隔板元件在单独的邻接室内制成。
27.按权利要求26的电化学电池组件,其中所述元件切割成单个电池并插入所述室中。
28.按权利要求27的电化学电池组件,其中在所述元件插入之后气密封所述室。
29.按权利要求25的电化学电池组件,其中每个双电池包括预定形状和尺寸的阳极,阳极插在一对充当基底的平面隔板膜之间。
30.按权利要求29的电化学电池组件,其中阴极位于在不与所述阳极接触的每个所述隔板膜的表面上,从而重叠对正。
31.按权利要求30的电化学电池组件,其中在由所述双电池之间的空间确定的双电池界面上进行叠层,所述隔板膜连接相互重叠对正的相邻双电池,从而形成Z-形支管。
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