WO2008039398A1 - Battery with mandrel for winding electrodes - Google Patents
Battery with mandrel for winding electrodes Download PDFInfo
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- WO2008039398A1 WO2008039398A1 PCT/US2007/020552 US2007020552W WO2008039398A1 WO 2008039398 A1 WO2008039398 A1 WO 2008039398A1 US 2007020552 W US2007020552 W US 2007020552W WO 2008039398 A1 WO2008039398 A1 WO 2008039398A1
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- WIPO (PCT)
- Prior art keywords
- mandrel
- battery
- separator
- negative electrode
- positive electrode
- Prior art date
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/04—Construction or manufacture in general
- H01M10/0431—Cells with wound or folded electrodes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/058—Construction or manufacture
- H01M10/0587—Construction or manufacture of accumulators having only wound construction elements, i.e. wound positive electrodes, wound negative electrodes and wound separators
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M10/00—Secondary cells; Manufacture thereof
- H01M10/24—Alkaline accumulators
- H01M10/28—Construction or manufacture
- H01M10/286—Cells or batteries with wound or folded electrodes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present invention relates generally to the field of batteries. More specifically, the present invention relates to electrodes for batteries and systems and methods for winding such electrodes.
- batteries or cells e.g., lithium-ion or nickel metal hydride cells
- batteries or cells generally include two electrodes (an anode and a cathode) that are contained within a hollow body.
- the electrodes are conductively coupled to external interfaces (e.g., terminals) that may be coupled to other electrical components.
- electrodes for such cells sometimes include a hollow mandrel or core around which an anode, cathode, and separators are wound.
- the winding process often requires the use of double-sided tape and a separate drive bit. After winding, an electrolyte may be introduced into the cell.
- One embodiment relates to a battery comprising a mandrel, a positive electrode, a negative electrode, and a separator provided between the positive electrode and the negative electrode.
- the positive electrode, the negative electrode, and the separator are wound around the mandrel, and the mandrel includes an extension configured to be coupled to a mechanism for winding at least one of the positive electrode, the negative electrode, and the separator around the mandrel.
- Another embodiment relates to a battery comprising a mandrel, a positive electrode, a negative electrode, and a separator provided between the positive electrode and the negative electrode.
- the mandrel comprises an end portion configured to facilitate the flow of an electrolyte from an inner portion of the mandrel to the exterior of the mandrel.
- FIG. 2 is an isometric view of a battery module according to an exemplary embodiment.
- FIG. 3 is an exploded view of a battery including a cell element according to an exemplary embodiment.
- FIG. 6 is an isometric view of separators being wound on a mandrel according to an exemplary embodiment.
- FIG. 7 is an isometric view of separators and an anode being wound on a mandrel according to an exemplary embodiment.
- FIG. 8 is an isometric view of separators, an anode, and a cathode being wound on a mandrel according to an exemplary embodiment.
- FIG. 9 is an isometric view of a cell element according to an exemplary embodiment.
- FIG. 10 is an isometric view of a mandrel and a separator according to an exemplary embodiment.
- FIG. 11 is a side view of a portion of the mandrel shown in FIG. 10 with separators inserted into the mandrel according to an exemplary embodiment.
- FIG. 12 is an isometric view of a mandrel, a separator, and a collar according to an exemplary embodiment.
- FIG. 13 is a side view of a portion of the mandrel shown in FIG. 12 with separators inserted into the mandrel according to an exemplary embodiment.
- FIG. 14 is an isometric view of a mandrel, separators, an anode, and a cathode according to an exemplary embodiment.
- FIG. 15 illustrates mandrels for use in batteries according to various exemplary embodiments.
- FIG. 16 is an isometric view of a mandrel and two plates according to an exemplary embodiment.
- a vehicle 11 is shown according to an exemplary embodiment and includes a battery system or battery module 13.
- the size, shape, configuration, and location of battery module 13 and the type of vehicle 1 1 may vary according to various other exemplary embodiments.
- vehicle 1 1 in FIG. 1 is shown as an automobile, according to various exemplary embodiments, vehicle 11 may comprise a wide variety of differing types of vehicles including, among others, motorcycles, buses, recreational vehicles, boats, and the like.
- vehicle 11 is a hybrid electric or electric vehicle.
- battery module 13 is shown according to an exemplary embodiment.
- Battery module 13 includes a plurality of electrochemical cells or batteries, shown as batteries 10 (e.g., lithium-ion batteries, NiMH batteries, lithium polymer batteries, etc.). Batteries 10 may be positioned within a housing that may include such features as a battery management system, a cooling fan, plenum assembly, etc. Other configurations of battery module 13 may be used in accordance with various other exemplary embodiments.
- batteries 10 e.g., lithium-ion batteries, NiMH batteries, lithium polymer batteries, etc.
- Batteries 10 may be positioned within a housing that may include such features as a battery management system, a cooling fan, plenum assembly, etc. Other configurations of battery module 13 may be used in accordance with various other exemplary embodiments.
- cell element 18 is enclosed within container 12.
- Cover 14 includes an aperture 15 configured to accept a portion of mandrel 20, and an insulator 16 configured to conductively isolate mandrel 20 from cover 14.
- Cover 14, mandrel 20, and insulator 16 are also sealed to prevent leakage of electrolyte, etc.
- battery 10 is a lithium- ion battery.
- battery 10 may be another type of battery (e.g., lithium-polymer, nickel-metal hydride, etc.).
- mandrel 20 is a conductive member comprising a shaft 24 and a body 22.
- Mandrel 20 may comprise aluminum, copper, or another suitable material.
- Shaft 24 (e.g., a rod, bar, extending portion, etc.) is configured to be received and turned by drive mechanism 25 shown in FIG. 6.
- Shaft 24 is a generally cylindrical member that may be configured to act as a terminal of battery 10.
- Shaft 24 includes features (not shown) to couple shaft 24 to drive mechanism 25.
- shaft 24 may have a flat, a hexagonal end, longitudinal splines, a keyway or key, or any other feature that suitably couples shaft 24 to drive mechanism 25.
- shaft 24 may have a hollow portion (e.g., a hexagonal recess or socket) provided on one end that is configured to receive a solid drive shaft or bit on drive mechanism 25.
- body 22 may have a width that is equal to or longer than the width of separator 30 to provide improved support to the winding and to allow one of the two electrode edges (which project beyond the separator) to be conductively attached to body 22.
- cell element 18 is configured to be used with a cell having a generally oval shape and body 22 is a generally flat body with an ovoid cross section. According to other exemplary embodiments, cell element 18 may be configured to be used with a generally cylindrical cell and may have a generally circular or other shaped cross-section.
- Separators 30 are insulating members that are configured to conductively isolate anode 32 from cathode 34. Separators 30 are aligned with and coupled to body 22 of mandrel 20 (e.g., with double-sided tape 17). According to an exemplary embodiment, separators 30 are wider than body 22 of mandrel 20 and overhang the edges of body 22 by approximately 1 cm. Shaft 24 is grasped by drive mechanism 25 with a chuck or other suitable mechanism. Mandrel 20 is turned by drive mechanism 25 so that separators 30 are wound around mandrel 20.
- separators 30 are wound around mandrel 20 approximately three times before anode 32 and/or cathode 34 are added to cell element 18. According to other exemplary embodiments, separators 30 may be wound around mandrel 20 more or fewer times.
- anode 32 is shown being wound on mandrel 20 according to an exemplary embodiment.
- Anode 32 may be a metal foil that is configured to be a negative electrode in cell element 18.
- Anode 32 is placed offset relative to separators 30 such that a portion of anode 32 protrudes slightly to one side of separators 30 and extends from between separators 30.
- Anode 32 may be taped (e.g., using tape 17) to separator 30 or may be slipped between separators 30 and substantially held in place by friction between separators 30.
- cathode 34 is added, as shown in FIG. 8.
- cathode 34 may be a metal foil that is configured to be a positive electrode in cell element 18. Cathode 34 is placed offset relative to separators 30 such that cathode 34 protrudes slightly to the side of separators 30 opposite of anode 32, and extends from between separators 30. Cathode 34 may be taped to separator 30 (e.g., using tape 17) or maybe slipped between separators 30 and substantially held in place by friction between separators 30. It should be noted that the materials used for the cathode, anode, and other components of the cell may differ according to various exemplary embodiments, and the present disclosure should be understood to apply to cells having components formed from any materials now known or later developed for use in such cells.
- anode 32, separators 30, and cathode 34 are wound around mandrel 20 a desired number of times, after which they are cut and taped using tape 17 to prevent unwinding.
- tape 17 is placed axially.
- tape 17 may be wound around cell element 18 circumferentially.
- separators 30, anode 32, and cathode 34 may be secured with multiple pieces of tape 17 that are placed both axially and circumferentially.
- body 22 of mandrel 20 has a width approximately equal to the width of separators 30, and anode 32 and cathode 34 extend past the edges of body 22.
- body 22 may be substantially wider than separators 30 to provide improved support for the separators 30, anode 32 and cathode 34.
- one of either anode 32 or cathode 34 may be welded or otherwise conductively coupled directly to body 22 without the use of plate 26.
- cell element 18 is inserted into a generally non-conductive body, shown as sleeve 36.
- sleeve 36 is configured to conductively isolate anode 32 from container 12.
- Cell element 18 is then inserted into container 12 and cover 14 is coupled to container 12 and cathode 34 so container 12 and cover 14 of battery 10 act as the positive terminal of battery 10.
- Insulator 38 is provided between cell element 18 and the bottom of container 12 to further isolate cell element 18 from container 12.
- sleeve 36 may surround the lower portion of cell element 18 and insulator 38 may not be used.
- container 12 may be substantially non-conductive and may include an opening on the bottom through which a terminal extending outside container 12 may be coupled to cell element 18. According to such an embodiment, sleeve 36 and insulator 38 may be omitted.
- FIGS. 6-9 the winding process depicted in FIGS. 6-9 is an exemplary embodiment and is not meant to be limiting.
- Mandrel 20 may be used with different winding processes and the order and orientation of separators 30, anode 32 and cathode 34 may be different in other exemplary embodiments (e.g., separators 30, anode 32 and cathode 34 may all be added to cell element 18 at the same time).
- Cell element 118 comprises a generally hollow mandrel 120, separators 130, an anode (not shown), and a cathode (not shown).
- Mandrel 120 is a generally thin-walled hollow body that is configured to receive a member or element in the form of a bit 119 which is configured to be rotated by a drive mechanism 25.
- protrusions 127 may extend from a side of slot 125 opposite of that shown in the FIGURES. According to other exemplary embodiments, protrusions 127 may extend from both sides of slot 125. According to one exemplary embodiment, three protrusions 127 are provided, generally evenly spaced along slot 125. According to other exemplary embodiments, more or fewer protrusions 127 may be provided or protrusions 127 may be provided at uneven intervals. According to another exemplary embodiment, a single protrusion 127 may be provided in the form of a continuous ridge or raised portion extending along all or a portion of slot 125.
- separator 130 includes a plurality of apertures 131 that are configured to receive protrusions 127 provided on mandrel 120.
- protrusions 127 may be provided on the opposite side of the recess than that shown in FIG. 9.
- Separator 130 and/or the electrodes are inserted into slot 125. When separator 130 is pulled or pushed against the surface of mandrel 120, separator 130 pivots on an edge 129 of slot 125, urging apertures 131 to engage protrusions 127, substantially coupling separator 130 to mandrel 120 and aligning separator 130.
- protrusions 127 with apertures 131 avoids the use of tape (e.g., tape 17) or other fastening methods that may be otherwise required to couple separators 130 to mandrel 120 and may introduce contaminants to cell element 118 and/or result in a misaligned winding.
- the anode and cathode may also be wound onto mandrel 120 as described above with respect to FIGS. 7 and 8 with the anode and cathode offset so they protrude past separator 130 on opposite ends.
- Cell element 218 comprises a generally hollow mandrel 220, separators 230, an anode (not shown) and a cathode (not shown).
- Mandrel 220 is a generally thin- walled hollow body that is configured to receive a turning bit 219 which is turned by drive mechanism 25.
- Mandrel 220 comprises a recess or slot 225 (e.g., slit, break, cut, etc.) that extends partially through the body of mandrel 220 along its longitudinal axis and is configured to receive separators 230 (and/or the corresponding electrodes).
- mandrel 220 may be squeezed by a collar or collet 232 or other means such that slot 225 is compressed and pinches separators 230, substantially coupling separators 230 to mandrel 220 and aligning separators 230.
- the squeezing of separators 230 in slot 225 avoids the use of tape 17 or other fastening methods to couple separators 130 to mandrel 120 that may introduce contaminants to cell element 118 and may result in a misaligned winding.
- collet 232 may form a permanent part of the battery cell.
- collet 232 may be used only during the winding process of the cell element and be subsequently removed.
- the anode and cathode may also be wound onto mandrel 120 as described above with respect to FIGS. 7 and 8, with the anode and cathode offset so they protrude past separators 230 on opposite ends.
- Cell element 318 comprises a generally hollow mandrel 320, a separator 330, an anode 332, and a cathode 334.
- Mandrel 320 is a generally thin- walled hollow body that is configured to receive a bit 319 which is configured to be rotated by a drive mechanism 25.
- Mandrel 320 comprises one or more edges 321 that have an edge 323 intended to facilitate the passage of electrolyte from the center or inner portion of mandrel 320 to the outside of mandrel 320 where it substantially surrounds anode 332 and cathode 334.
- separators 330, anode 332, and cathode 334 may be wound onto mandrel 320 as described above, with anode 332 and cathode 334 offset so they protrude past separators 330 on opposite ends.
- mandrel 320 is shown in FIG. 14 as having an edge 323 that includes generally wave-like scallops, it should be understood that the contours (e.g., channels, passageways, perforations, apertures, etc.) in mandrel 320 to allow electrolyte flow may have various shapes and arrangements in other exemplary embodiments.
- mandrel 350 may only have scallops 340 along one side.
- a mandrel 352 may have edges with squared castellations 342 on one or both edges.
- a mandrel 354 may include one or more saw-toothed edges 344.
- a mandrel 356 may have apertures or holes 346 provided proximate to one or both edges of mandrel 356 to facilitate the passage of electrolyte through mandrel 320.
- a mandrel 358 may be provided with a single hole or aperture 348 at one or both ends.
- Mandrel 420 is shown according to an exemplary embodiment.
- Mandrel 420 is similar to the embodiment shown in FIGS. 4 and 5 and includes two shafts 424 that are partially surrounded by body 422 and that extend from opposite ends of body 422.
- Shafts 424 are generally cylindrical members that may be configured to be terminals of a battery.
- One or both of shafts 424 e.g., rod, bar, etc.
- Shaft 424 may include features (not shown) for coupling at least one of shafts 424 to drive mechanism 25.
- Body 422 provides a non-conductive body around which separators, an anode, and a cathode (not shown) are wound.
- shafts 424 may be configured to act as terminals of a battery when the wound cell element is inserted into a container.
- shafts 424 may be configured to receive separately provided terminals.
- plates 426 are provided on opposite ends of mandrel 420 and are coupled to shafts 424 and to the anode and cathode, respectively (e.g., by welding). Plates 426 co ⁇ ductively couple each of the anode and the cathode to a shaft 424.
- Shafts 424 may extend through apertures 428 in plates 426. According to an exemplary embodiment, each of the shafts 424 may extend outward through openings in a container (e.g., such as container 12 shown in FIG. 3) and a cover (e.g., such as cover 14 shown in FIG. 3) to provide opposed terminals for a battery. Shafts 424 may be insulated from or conductively coupled to the cover and/or container of the battery cell.
- top and bottom in this description are merely used to identify various elements as oriented in the FIGURES, with “top” corresponding generally to the cover side of the battery or cell and “bottom” corresponding generally to the side opposite the cover. It should be recognized that the orientation of the battery may vary greatly depending on the application and that “top” would still refer generally to the cover side of the battery and “bottom” would refer generally to the side opposite the cover no matter the orientation of the battery relative to the vehicle.
- the term "coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature. [0052] The construction and arrangement of the elements as shown in the various exemplary embodiments is illustrative only.
- the elements and/or assemblies of the mandrel or other components may be constructed from any of a wide variety of materials that provide sufficient strength or durability (aluminum, steel, copper, or other metals; or a suitable polymer) in any of a wide variety of colors, combinations and suitable materials.
- the mandrel or other components may be substantially conductive or non-conductive in various exemplary embodiments.
- Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present inventions.
- Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the exemplary embodiments without departing from the scope of the present inventions as expressed herein.
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Abstract
A battery (100) includes a mandrel, a positive (34) electrode, a negative (32) electrode, and a separator (30) provided between the positive electrode and the negative electrode. The positive electrode, the negative electrode, and the separator are wound around the mandrel (20), and the mandrel includes an extension (24) configured to be coupled to a mechanism (25) for winding at least one of the positive electrode, the negative electrode, and the separator around the mandrel.
Description
BATTERY WITH MANDREL FOR WINDING ELECTRODES
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This Application claims the benefit of U.S. Provisional Patent Application No. 60/847,015, filed September 25, 2006, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present invention relates generally to the field of batteries. More specifically, the present invention relates to electrodes for batteries and systems and methods for winding such electrodes.
[0003] It is known that batteries or cells (e.g., lithium-ion or nickel metal hydride cells) generally include two electrodes (an anode and a cathode) that are contained within a hollow body. The electrodes are conductively coupled to external interfaces (e.g., terminals) that may be coupled to other electrical components.
[0004] It is generally known that electrodes for such cells sometimes include a hollow mandrel or core around which an anode, cathode, and separators are wound. The winding process often requires the use of double-sided tape and a separate drive bit. After winding, an electrolyte may be introduced into the cell.
[0005] It would be advantageous to provide a battery having an improved mandrel that eliminates the need for double-sided tape, eliminates the need for a separate drive bit, and decreases the time needed to fill a cell with electrolyte.
SUMMARY
[0006] One embodiment relates to a battery comprising a mandrel, a positive electrode, a negative electrode, and a separator provided between the positive
electrode and the negative electrode. The positive electrode, the negative electrode, and the separator are wound around the mandrel, and the mandrel includes an extension configured to be coupled to a mechanism for winding at least one of the positive electrode, the negative electrode, and the separator around the mandrel.
[0007] Another embodiment relates to a battery comprising a mandrel, a positive electrode, a negative electrode, and a separator provided between the positive electrode and the negative electrode. The positive electrode, the negative electrode, and the separator are wound around the mandrel, and a recess is provided along a longitudinal axis of the mandrel. A portion of at least one of the positive electrode, the negative electrode, and the separator is retained within the recess.
[0008] Another embodiment relates to a battery comprising a mandrel, a positive electrode, a negative electrode, and a separator provided between the positive electrode and the negative electrode. The mandrel comprises an end portion configured to facilitate the flow of an electrolyte from an inner portion of the mandrel to the exterior of the mandrel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an isometric view of a vehicle according to an exemplary embodiment.
[0010] FIG. 2 is an isometric view of a battery module according to an exemplary embodiment.
[0011] FIG. 3 is an exploded view of a battery including a cell element according to an exemplary embodiment.
[0012] FIGS. 4-5 are isometric views of a mandrel and plate according to an exemplary embodiment.
[0013] FIG. 6 is an isometric view of separators being wound on a mandrel according to an exemplary embodiment.
[0014] FIG. 7 is an isometric view of separators and an anode being wound on a mandrel according to an exemplary embodiment.
10015] FIG. 8 is an isometric view of separators, an anode, and a cathode being wound on a mandrel according to an exemplary embodiment.
[0016] FIG. 9 is an isometric view of a cell element according to an exemplary embodiment.
[0017] FIG. 10 is an isometric view of a mandrel and a separator according to an exemplary embodiment.
[0018] FIG. 11 is a side view of a portion of the mandrel shown in FIG. 10 with separators inserted into the mandrel according to an exemplary embodiment.
[0019] FIG. 12 is an isometric view of a mandrel, a separator, and a collar according to an exemplary embodiment.
[0020] FIG. 13 is a side view of a portion of the mandrel shown in FIG. 12 with separators inserted into the mandrel according to an exemplary embodiment.
[0021] FIG. 14 is an isometric view of a mandrel, separators, an anode, and a cathode according to an exemplary embodiment.
[0022] FIG. 15 illustrates mandrels for use in batteries according to various exemplary embodiments.
[0023] FIG. 16 is an isometric view of a mandrel and two plates according to an exemplary embodiment.
DETAILED DESCRIPTION
[0024] Referring to FIG. 1 , a vehicle 11 is shown according to an exemplary embodiment and includes a battery system or battery module 13. The size, shape, configuration, and location of battery module 13 and the type of vehicle 1 1 may vary according to various other exemplary embodiments. For example, while vehicle 1 1 in FIG. 1 is shown as an automobile, according to various exemplary embodiments,
vehicle 11 may comprise a wide variety of differing types of vehicles including, among others, motorcycles, buses, recreational vehicles, boats, and the like. According to an exemplary embodiment, vehicle 11 is a hybrid electric or electric vehicle.
[0025] Referring to FIG. 2, battery module 13 is shown according to an exemplary embodiment. Battery module 13 includes a plurality of electrochemical cells or batteries, shown as batteries 10 (e.g., lithium-ion batteries, NiMH batteries, lithium polymer batteries, etc.). Batteries 10 may be positioned within a housing that may include such features as a battery management system, a cooling fan, plenum assembly, etc. Other configurations of battery module 13 may be used in accordance with various other exemplary embodiments.
[0026] Referring now to FIG. 3, a cell or battery 10 is shown according to an exemplary embodiment as including a housing or container 12, a cup or cover 14, a cell element 18, and an electrolyte (not shown). Battery 10 may have a circular, oval, or other cross-sectional shape. Cell element 18 comprises a mandrel 20, a plate 26, separators 30, an anode 32, a cathode 34, a sleeve 36, and an insulator 38 (e.g., an insulator disk). Separator 30, anode 32, and cathode 34 are generally flexible members that are wound around a member or element 20 provided in the form of a mandrel (e.g., a body, center member, shaft, rod, etc.), which is turned by a drive mechanism (see, e.g., drive mechanism 25 shown in FIG. 6).
[0027] According to an exemplary embodiment, cell element 18 is enclosed within container 12. Cover 14 includes an aperture 15 configured to accept a portion of mandrel 20, and an insulator 16 configured to conductively isolate mandrel 20 from cover 14. Cover 14, mandrel 20, and insulator 16 are also sealed to prevent leakage of electrolyte, etc. According to an exemplary embodiment, battery 10 is a lithium- ion battery. According to other exemplary embodiments, battery 10 may be another type of battery (e.g., lithium-polymer, nickel-metal hydride, etc.).
[0028] As shown in FIGS. 4-5, mandrel 20 is a conductive member comprising a shaft 24 and a body 22. Mandrel 20 may comprise aluminum, copper, or another
suitable material. Shaft 24 (e.g., a rod, bar, extending portion, etc.) is configured to be received and turned by drive mechanism 25 shown in FIG. 6. Shaft 24 is a generally cylindrical member that may be configured to act as a terminal of battery 10. Shaft 24 includes features (not shown) to couple shaft 24 to drive mechanism 25. According to various exemplary embodiments, shaft 24 may have a flat, a hexagonal end, longitudinal splines, a keyway or key, or any other feature that suitably couples shaft 24 to drive mechanism 25. According to still other exemplary embodiments, shaft 24 may have a hollow portion (e.g., a hexagonal recess or socket) provided on one end that is configured to receive a solid drive shaft or bit on drive mechanism 25. According to an exemplary embodiment, body 22 may have a width that is equal to or longer than the width of separator 30 to provide improved support to the winding and to allow one of the two electrode edges (which project beyond the separator) to be conductively attached to body 22.
[0029] Body 22 provides a conductive body around which separators 30, anode 32, and cathode 34 are wound and to which either anode 32 or cathode 34 may be electrically coupled. According to an exemplary embodiment, shaft 24 may be received by a bore running through body 22. Shaft 24 may further be coupled to body 22 (e.g., by welding) and extend from both ends of body 22. According to another exemplary embodiment, shaft 24 and body 22 may be formed as a single unitary body. According to an exemplary embodiment, shaft 24 may be configured to act as a terminal for battery 10 when cell element 18 is inserted into container 12. According to other exemplary embodiments, shaft 24 may be configured for coupling to a separate terminal.
[0030] According to an exemplary embodiment, cell element 18 is configured to be used with a cell having a generally oval shape and body 22 is a generally flat body with an ovoid cross section. According to other exemplary embodiments, cell element 18 may be configured to be used with a generally cylindrical cell and may have a generally circular or other shaped cross-section.
[0031] Referring now to FIGS. 6-8, a winding process is shown beginning with the winding of separators 30 in FIG. 6. Separators 30 are insulating members that are
configured to conductively isolate anode 32 from cathode 34. Separators 30 are aligned with and coupled to body 22 of mandrel 20 (e.g., with double-sided tape 17). According to an exemplary embodiment, separators 30 are wider than body 22 of mandrel 20 and overhang the edges of body 22 by approximately 1 cm. Shaft 24 is grasped by drive mechanism 25 with a chuck or other suitable mechanism. Mandrel 20 is turned by drive mechanism 25 so that separators 30 are wound around mandrel 20. According to an exemplary embodiment, separators 30 are wound around mandrel 20 approximately three times before anode 32 and/or cathode 34 are added to cell element 18. According to other exemplary embodiments, separators 30 may be wound around mandrel 20 more or fewer times.
[0032] Referring to FIG. 7, anode 32 is shown being wound on mandrel 20 according to an exemplary embodiment. Anode 32 may be a metal foil that is configured to be a negative electrode in cell element 18. Anode 32 is placed offset relative to separators 30 such that a portion of anode 32 protrudes slightly to one side of separators 30 and extends from between separators 30. Anode 32 may be taped (e.g., using tape 17) to separator 30 or may be slipped between separators 30 and substantially held in place by friction between separators 30. According to an exemplary embodiment, after anode 32 is wound around mandrel 20 at least one time, cathode 34 is added, as shown in FIG. 8.
[0033] Referring to FIG. 8, cathode 34 may be a metal foil that is configured to be a positive electrode in cell element 18. Cathode 34 is placed offset relative to separators 30 such that cathode 34 protrudes slightly to the side of separators 30 opposite of anode 32, and extends from between separators 30. Cathode 34 may be taped to separator 30 (e.g., using tape 17) or maybe slipped between separators 30 and substantially held in place by friction between separators 30. It should be noted that the materials used for the cathode, anode, and other components of the cell may differ according to various exemplary embodiments, and the present disclosure should be understood to apply to cells having components formed from any materials now known or later developed for use in such cells.
[0034] Referring now to FIG. 9, anode 32, separators 30, and cathode 34 are wound around mandrel 20 a desired number of times, after which they are cut and taped using tape 17 to prevent unwinding. According to one exemplary embodiment, tape 17 is placed axially. According to other exemplary embodiments, tape 17 may be wound around cell element 18 circumferentially. According to still other exemplary embodiments, separators 30, anode 32, and cathode 34 may be secured with multiple pieces of tape 17 that are placed both axially and circumferentially.
[0035] As shown in FIG. 9, plate 26 is coupled to anode 32 and to shaft 24 (e.g., by welding) to conductively couple anode 32 to mandrel 20. According to an exemplary embodiment, mandrel 20 is coupled to anode 32 and is made of copper or a copper alloy. According to other exemplary embodiments, the positions of anode 32 and cathode 34 may be reversed, with anode 32 protruding past the top of separators 30 and cathode 34 protruding past the bottom of separators 30. If mandrel 20 is coupled to cathode 34, it may be made of aluminum or an aluminum alloy. According to various exemplary embodiments, a conductive path may be created between one of anode 32 or cathode 34, plate 26, and mandrel 20.
[0036] According to an exemplary embodiment, body 22 of mandrel 20 has a width approximately equal to the width of separators 30, and anode 32 and cathode 34 extend past the edges of body 22. According to another exemplary embodiment, body 22 may be substantially wider than separators 30 to provide improved support for the separators 30, anode 32 and cathode 34. According to such an embodiment, one of either anode 32 or cathode 34 may be welded or otherwise conductively coupled directly to body 22 without the use of plate 26.
[0037] Referring back to FIG. 3, after being wound, cell element 18 is inserted into a generally non-conductive body, shown as sleeve 36. According to an exemplary embodiment, sleeve 36 is configured to conductively isolate anode 32 from container 12. Cell element 18 is then inserted into container 12 and cover 14 is coupled to container 12 and cathode 34 so container 12 and cover 14 of battery 10 act as the positive terminal of battery 10. Insulator 38 is provided between cell element 18 and the bottom of container 12 to further isolate cell element 18 from container 12.
According to other exemplary embodiments, sleeve 36 may surround the lower portion of cell element 18 and insulator 38 may not be used. According to still other exemplary embodiments, container 12 may be substantially non-conductive and may include an opening on the bottom through which a terminal extending outside container 12 may be coupled to cell element 18. According to such an embodiment, sleeve 36 and insulator 38 may be omitted.
[0038] It should be understood that the winding process depicted in FIGS. 6-9 is an exemplary embodiment and is not meant to be limiting. Mandrel 20 may be used with different winding processes and the order and orientation of separators 30, anode 32 and cathode 34 may be different in other exemplary embodiments (e.g., separators 30, anode 32 and cathode 34 may all be added to cell element 18 at the same time).
[0039] Referring now to FIGS. 10-11, a cell element 118 is shown according to an exemplary embodiment. Cell element 118 comprises a generally hollow mandrel 120, separators 130, an anode (not shown), and a cathode (not shown). Mandrel 120 is a generally thin-walled hollow body that is configured to receive a member or element in the form of a bit 119 which is configured to be rotated by a drive mechanism 25. Mandrel 120 comprises a recess or slot 125 (e.g., slit, break, cut, etc.) that extends at least partially through the body of mandrel 120 along its longitudinal axis and is configured to receive separators 130 and/or at least one of the anode and cathode. According to an exemplary embodiment, slot 125 may extend through the entire thickness of mandrel 120. Mandrel 120 further comprises a plurality of protrusions 127 (e.g., nubs, pegs, projections, etc.) that extend from a side of slot 125 and are configured to engage apertures 131 provided in separators 130 and/or the electrodes. According to other exemplary embodiments, protrusions 127 may extend from a side of slot 125 opposite of that shown in the FIGURES. According to other exemplary embodiments, protrusions 127 may extend from both sides of slot 125. According to one exemplary embodiment, three protrusions 127 are provided, generally evenly spaced along slot 125. According to other exemplary embodiments, more or fewer protrusions 127 may be provided or protrusions 127 may be provided at uneven intervals. According to another exemplary embodiment, a single protrusion 127 may
be provided in the form of a continuous ridge or raised portion extending along all or a portion of slot 125.
[0040] According to an exemplary embodiment, separator 130 includes a plurality of apertures 131 that are configured to receive protrusions 127 provided on mandrel 120. According to an exemplary embodiment, protrusions 127 may be provided on the opposite side of the recess than that shown in FIG. 9. Separator 130 and/or the electrodes are inserted into slot 125. When separator 130 is pulled or pushed against the surface of mandrel 120, separator 130 pivots on an edge 129 of slot 125, urging apertures 131 to engage protrusions 127, substantially coupling separator 130 to mandrel 120 and aligning separator 130. The engagement of protrusions 127 with apertures 131 avoids the use of tape (e.g., tape 17) or other fastening methods that may be otherwise required to couple separators 130 to mandrel 120 and may introduce contaminants to cell element 118 and/or result in a misaligned winding. According to an exemplary embodiment, the anode and cathode (not shown in FIGS. 10 and 11) may also be wound onto mandrel 120 as described above with respect to FIGS. 7 and 8 with the anode and cathode offset so they protrude past separator 130 on opposite ends.
[0041] Referring now to FIGS. 12-13, a cell element 218 is shown according to an exemplary embodiment. Cell element 218 comprises a generally hollow mandrel 220, separators 230, an anode (not shown) and a cathode (not shown). Mandrel 220 is a generally thin- walled hollow body that is configured to receive a turning bit 219 which is turned by drive mechanism 25. Mandrel 220 comprises a recess or slot 225 (e.g., slit, break, cut, etc.) that extends partially through the body of mandrel 220 along its longitudinal axis and is configured to receive separators 230 (and/or the corresponding electrodes).
[0042] According to an exemplary embodiment, mandrel 220 may be squeezed by a collar or collet 232 or other means such that slot 225 is compressed and pinches separators 230, substantially coupling separators 230 to mandrel 220 and aligning separators 230. The squeezing of separators 230 in slot 225 avoids the use of tape 17 or other fastening methods to couple separators 130 to mandrel 120 that may
introduce contaminants to cell element 118 and may result in a misaligned winding. According to an exemplary embodiment, collet 232 may form a permanent part of the battery cell. According to another exemplary embodiment, collet 232 may be used only during the winding process of the cell element and be subsequently removed. According to an exemplary embodiment, the anode and cathode (not shown) may also be wound onto mandrel 120 as described above with respect to FIGS. 7 and 8, with the anode and cathode offset so they protrude past separators 230 on opposite ends.
[0043] While FIGS. 10-13 generally illustrate exemplary embodiments of one or more separators being retained within a slot or recess such as slots 125, 225, it should be understood that such slots or recesses may further be used to retain other components of battery 10. For example, according to an exemplary embodiment, one or more terminals for battery 10 may be provided within and secured by a recess in the mandrel. According to another exemplary embodiment, slots 125, 225 may receive an anode and/or cathode in addition to the separators.
[0044] Referring now to FIG. 14, a cell element 318 is shown according to an exemplary embodiment. Cell element 318 comprises a generally hollow mandrel 320, a separator 330, an anode 332, and a cathode 334. Mandrel 320 is a generally thin- walled hollow body that is configured to receive a bit 319 which is configured to be rotated by a drive mechanism 25. Mandrel 320 comprises one or more edges 321 that have an edge 323 intended to facilitate the passage of electrolyte from the center or inner portion of mandrel 320 to the outside of mandrel 320 where it substantially surrounds anode 332 and cathode 334. As shown in FIG. 14, separators 330, anode 332, and cathode 334 may be wound onto mandrel 320 as described above, with anode 332 and cathode 334 offset so they protrude past separators 330 on opposite ends.
[0045] Although mandrel 320 is shown in FIG. 14 as having an edge 323 that includes generally wave-like scallops, it should be understood that the contours (e.g., channels, passageways, perforations, apertures, etc.) in mandrel 320 to allow electrolyte flow may have various shapes and arrangements in other exemplary embodiments. For example, referring to FIG, 15, according to an exemplary
embodiment, mandrel 350 may only have scallops 340 along one side. According to another exemplary embodiment, a mandrel 352 may have edges with squared castellations 342 on one or both edges.
[0046] According to another exemplary embodiment, a mandrel 354 may include one or more saw-toothed edges 344. According to another exemplary embodiment, a mandrel 356 may have apertures or holes 346 provided proximate to one or both edges of mandrel 356 to facilitate the passage of electrolyte through mandrel 320. Alternatively, a mandrel 358 may be provided with a single hole or aperture 348 at one or both ends. Those reviewing this disclosure will recognize that various other configurations for the mandrel may also be provided according to other exemplary embodiments to allow electrolyte to pass through the mandrel. It is intended that such other embodiments are within the scope of the present disclosure.
[0047] Referring now to FIG. 16, a mandrel 420 is shown according to an exemplary embodiment. Mandrel 420 is similar to the embodiment shown in FIGS. 4 and 5 and includes two shafts 424 that are partially surrounded by body 422 and that extend from opposite ends of body 422. Shafts 424 are generally cylindrical members that may be configured to be terminals of a battery. One or both of shafts 424 (e.g., rod, bar, etc.) may be configured to be received and rotated by drive mechanism 25 (see e.g., FIG. 14). Shaft 424 may include features (not shown) for coupling at least one of shafts 424 to drive mechanism 25. According to various exemplary embodiments, shaft 424 may have a flat, a hexagonal end, longitudinal splines, a keyway or key, or any other feature that suitably couples shaft 424 to drive mechanism 25. According to other exemplary embodiments, shaft 424 may have a hollow portion (e.g., a hexagonal recess or socket) provided on one end that is configured to receive a solid drive shaft orbit on drive mechanism 25.
[0048] Body 422 provides a non-conductive body around which separators, an anode, and a cathode (not shown) are wound. According to an exemplary embodiment, shafts 424 may be configured to act as terminals of a battery when the wound cell element is inserted into a container. According to other exemplary embodiments, shafts 424 may be configured to receive separately provided terminals.
According to an exemplary embodiment, plates 426 are provided on opposite ends of mandrel 420 and are coupled to shafts 424 and to the anode and cathode, respectively (e.g., by welding). Plates 426 coπductively couple each of the anode and the cathode to a shaft 424. Shafts 424 may extend through apertures 428 in plates 426. According to an exemplary embodiment, each of the shafts 424 may extend outward through openings in a container (e.g., such as container 12 shown in FIG. 3) and a cover (e.g., such as cover 14 shown in FIG. 3) to provide opposed terminals for a battery. Shafts 424 may be insulated from or conductively coupled to the cover and/or container of the battery cell.
[0049] It should be understood that the various exemplary embodiments are provided for illustration, and not limitation, and may be utilized separately or in a variety of combinations depending on the particular application. All such combinations of the various exemplary embodiments contained herein are within the scope of this disclosure.
[0050] It should be noted that references to "top" and "bottom" in this description are merely used to identify various elements as oriented in the FIGURES, with "top" corresponding generally to the cover side of the battery or cell and "bottom" corresponding generally to the side opposite the cover. It should be recognized that the orientation of the battery may vary greatly depending on the application and that "top" would still refer generally to the cover side of the battery and "bottom" would refer generally to the side opposite the cover no matter the orientation of the battery relative to the vehicle.
[0051] For the purpose of this disclosure, the term "coupled" means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.
[0052] The construction and arrangement of the elements as shown in the various exemplary embodiments is illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited herein (e.g., materials for formation of the conductive and insulating components, technology for the internal components of the cell, the shape of the cell, etc.). For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. It should be noted that the elements and/or assemblies of the mandrel or other components may be constructed from any of a wide variety of materials that provide sufficient strength or durability (aluminum, steel, copper, or other metals; or a suitable polymer) in any of a wide variety of colors, combinations and suitable materials. The mandrel or other components may be substantially conductive or non-conductive in various exemplary embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present inventions. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration and arrangement of the exemplary embodiments without departing from the scope of the present inventions as expressed herein.
Claims
1. A battery comprising: a mandrel; a positive electrode; a negative electrode; and a separator provided between the positive electrode and the negative electrode; wherein the positive electrode, the negative electrode, and the separator are wound around the mandrel; and wherein the mandrel includes an extension configured to be coupled to a mechanism for winding at least one of the positive electrode, the negative electrode, and the separator around the mandrel.
2. The battery of Claim 1 , wherein the mandrel comprises a conductive material and is configured to act as a terminal for the battery.
3. The battery of Claim 1, wherein the mandrel comprises a recess provided along a longitudinal axis of the mandrel, wherein a portion of at least one of the positive electrode, the negative electrode, and the separator is retained within the recess.
4. The battery of Claim 3, wherein the mandrel comprises a surface defining a portion of the recess, the surface having a plurality of projections configured to engage the at least one of the positive electrode, the negative electrode, and the separator retained within the recess.
5. The battery of Claim 4, wherein the at least one of the positive electrode, the negative electrode, and the separator retained within the recess includes a plurality of apertures configured to receive the plurality of projections.
6. The battery of Claim 1 , further comprising: a clamping device configured to compress the mandrel and secure the positive electrode, the negative electrode, and the separator to the mandrel.
7. The battery of Claim 1 , wherein the mandrel has a generally oval cross-sectional shape.
8. The battery of Claim 1, wherein the mandrel comprises an end portion configured to facilitate the flow of an electrolyte from an inner portion of the mandrel to the exterior of the mandrel.
9. A battery comprising: a mandrel; a positive electrode; a negative electrode; and a separator provided between the positive electrode and the negative electrode; wherein the positive electrode, the negative electrode, and the separator are wound around the mandrel; and wherein a recess is provided along a longitudinal axis of the mandrel, and a portion of at least one of the positive electrode, the negative electrode, and the separator is retained within the recess.
10. The battery of Claim 9, wherein the mandrel comprises a surface defining a portion of the recess, the surface having a plurality of projections configured to engage the at least one of the positive electrode, the negative electrode, and the separator retained within the recess.
11. The battery of Claim 10, wherein the at least one of the positive electrode, the negative electrode, and the separator retained within the recess includes a plurality of apertures configured to receive the plurality of projections.
12. The battery of Claim 9, further comprising: a clamping device configured to compress the mandrel and secure the positive electrode, the negative electrode, and the separator to the mandrel.
13. The battery of Claim 9, wherein the mandrel comprises a conductive material and is configured to act as a terminal for the battery.
14. The battery of Claim 9, wherein the mandrel has a generally oval cross-sectional shape.
15. The battery of Claim 9, wherein a portion of the positive electrode extends beyond a first side of the separator and a portion of the negative electrode extends beyond a second side of the separator generally opposite the first side.
16. The battery of Claim 9, wherein the mandrel is configured to be coupled to a mechanism for winding at least one of the positive electrode, the negative electrode, and the separator around the mandrel.
17. The battery of Claim 9, wherein the mandrel comprises an end portion configured to facilitate the flow of an electrolyte from an inner portion of the mandrel to the exterior of the mandrel.
18. A battery comprising: a mandrel; a positive electrode; a negative electrode; and a separator provided between the positive electrode and the negative electrode; wherein the mandrel comprises an end portion configured to facilitate the flow of an electrolyte from an inner portion of the mandrel to the exterior of the mandrel.
19. The battery of Claim 18, wherein the end portion comprises a plurality of apertures.
20. The battery of Claim 18, wherein the end portion comprises a saw- toothed shaped edge.
21. The battery of Claim 18, wherein the end portion comprises a wavy shaped edge.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US84701506P | 2006-09-25 | 2006-09-25 | |
US60/847,015 | 2006-09-25 |
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WO2008039398A1 true WO2008039398A1 (en) | 2008-04-03 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2007/020552 WO2008039398A1 (en) | 2006-09-25 | 2007-09-24 | Battery with mandrel for winding electrodes |
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Cited By (2)
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EP2311131A2 (en) * | 2008-08-13 | 2011-04-20 | Johnson Controls Saft Advanced Power Solutions LLC | Mandrel with drive member for electrochemical cells |
US20120084975A1 (en) * | 2010-10-06 | 2012-04-12 | Medtronic, Inc. | Common carrier for the integrated mandrel battery assembly |
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US4212179A (en) * | 1978-10-12 | 1980-07-15 | The Gates Rubber Company | Driven mandrel and method |
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EP2311131A2 (en) * | 2008-08-13 | 2011-04-20 | Johnson Controls Saft Advanced Power Solutions LLC | Mandrel with drive member for electrochemical cells |
EP2311131A4 (en) * | 2008-08-13 | 2013-12-04 | Johnson Controls Saft Advanced | Mandrel with drive member for electrochemical cells |
US20120084975A1 (en) * | 2010-10-06 | 2012-04-12 | Medtronic, Inc. | Common carrier for the integrated mandrel battery assembly |
US9299971B2 (en) * | 2010-10-06 | 2016-03-29 | Medtronic, Inc. | Common carrier for the integrated mandrel battery assembly |
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