WO2023275696A1 - Batterie haute énergie à faible résistance thermique et à régulation de température améliorée - Google Patents

Batterie haute énergie à faible résistance thermique et à régulation de température améliorée Download PDF

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Publication number
WO2023275696A1
WO2023275696A1 PCT/IB2022/055914 IB2022055914W WO2023275696A1 WO 2023275696 A1 WO2023275696 A1 WO 2023275696A1 IB 2022055914 W IB2022055914 W IB 2022055914W WO 2023275696 A1 WO2023275696 A1 WO 2023275696A1
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WO
WIPO (PCT)
Prior art keywords
layer
battery cell
cap unit
current collector
active material
Prior art date
Application number
PCT/IB2022/055914
Other languages
English (en)
Inventor
Abhishek Kumar Tiwari
Original Assignee
Abhishek Kumar Tiwari
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Abhishek Kumar Tiwari filed Critical Abhishek Kumar Tiwari
Publication of WO2023275696A1 publication Critical patent/WO2023275696A1/fr

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Classifications

    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/102—Primary casings; Jackets or wrappings characterised by their shape or physical structure
    • H01M50/103—Primary casings; Jackets or wrappings characterised by their shape or physical structure prismatic or rectangular
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/147—Lids or covers
    • H01M50/148—Lids or covers characterised by their shape
    • H01M50/15—Lids or covers characterised by their shape for prismatic or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/147—Lids or covers
    • H01M50/155—Lids or covers characterised by the material
    • H01M50/164—Lids or covers characterised by the material having a layered structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H01M50/147—Lids or covers
    • H01M50/166—Lids or covers characterised by the methods of assembling casings with lids
    • H01M50/169—Lids or covers characterised by the methods of assembling casings with lids by welding, brazing or soldering
    • 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 generally relates a rechargeable battery and particularly relates to a battery with jelly rolled electrodes and improved physical feature such as improved energy storage, thermal cooling and reduced internal resistance.
  • the present invention more particularly relates to a battery cell with low internal resistance and a method of manufacturing the same.
  • the primary obj ective of the present invention is to provide a battery cell with effect cooling rate, reduced thermal resistance and improved energy storage capacity.
  • Another objective of the present invention is to provide a method for manufacturing the battery cell with semi-automated process.
  • Yet another objective of the present invention is to provide a cap structure and a form factor of the battery that allows maximum straight line travel path to the electrons.
  • the embodiments in the present invention provide a high energy battery cell with low impedance and improved thermal management.
  • the battery cell comprises an active material core, a cap unit, and a housing.
  • the active material core comprises a strip comprised of active material layers and current collector layers arranged in a spatially optimized manner.
  • the cap unit comprises a positive cap unit and a negative cap unit.
  • the cap unit is connected to the current collector layers.
  • the housing is a shell-like structure to encapsulate the active material core and the cap unit connected together.
  • the housing creates an impermeable structure around the active material core to shield from an environment reaction.
  • the housing comprises a first insulator unit and a second insulator layer, wherein a one-way pressure valve is connected between the first insulator layer and the second insulation layer.
  • the active material layer comprises a cathode layer and an anode layer separated by a thin separator layer.
  • the cathode layer and the anode layer are layer on outside with the current collector layer.
  • the strip is jelly-rolled in a square shaped spiral forming four straight line sides with curved corners.
  • the curved corner of innermost layer in the jelly roll structure has an arc radius of 0.707mm.
  • the arc radius is modifiable according to the battery cell size.
  • the cathode layer is attached with an aluminium layer and the anode layer is attached with a copper layer.
  • the aluminium layer and the copper layer form the current collector layer.
  • a height of the aluminium layer is 5mm higher than the cathode layer on top side and a height of the copper layer is 5mm higher than the anode layer on bottom side during a placement of the battery cell in a top-down manner.
  • the cap unit comprises a flat top and a clip connected to a lower surface of the flat top.
  • the clip is provided on each side of the lower surface of the flat top having 5mm length.
  • the first insulator layer has four micro slots on each side to pass a 5mm current collector length from both anode and cathode.
  • the embodiments of the present invention also provide a method for high speed manufacturing of a high energy battery cell.
  • the method comprising the steps of: a) creating a strip of active material core comprising a first current collector, an anode layer, a separator, a cathode layer and a second current collector; b) jelly-rolling the strip of active core in a square spiral with an arc corner, wherein a radius and an arc angle is determined according to an overall size of the battery cell; c) cutting a 5mm length on the first current collector and the second current collector on the arc corners to create an isolated leaf of height 5mm on each side of the jelly-roll; d) pressing the leaves simultaneously through a robotic pressing clamp from both sides of the jelly roll; e) inserting a first insulator layer in a box format around the jelly roll with leaves coming out of a micro slot provided on each side of insulator layer, wherein the width of micro slot is equal to thickness of the pressed leaves; f) placing a cap unit over the
  • a height of the first current collector is 5mm higher than the cathode layer on a top side and a height of the second current collector (a copper layer) is 5mm higher than the anode layer on bottom side during a placement of the battery cell in a top-down manner.
  • the first insulator layer is inserted from a bottom side of the jelly roll in a manner that leaves are snuggle fit into the micro slots.
  • an autonomous filler apparatus is placed vertically above a central axis of the jelly roll to fill an electrolyte in the first insulator layer acting as a box structure around the jelly roll. After sensing an electrolyte fill to an optimum level, the autonomous filler apparatus is removed and an upper insulator layer is placed with snuggle fitting the leaves on top.
  • the upper insulator layer is thermally connected with the first insulator layer to create a chamber around the jelly roll.
  • the method reduces an electron travel length by 90% leading to reduction in an internal resistance of a battery cell by a factor of 10.
  • a square spiral creates a straight-line electron flow reducing the internal resistance further by a factor of 11 leading to slow heat generation and increasing a battery cell safety during an operation.
  • the battery cell has packing void of 0% during a placement of four cells adjacent to each other in a given area with respect to a battery cell with a cylindrical form factor and an increase of 28.26% active material resulting in increasing of energy storage by a factor of 28.26%.
  • the battery cell increases a thermal regulation in respect to a battery cell with a prismatic form factor by having an intercell gap of 2.25mm in respect to negligible gap provided in prismatic form factor.
  • FIG. 1 illustrates a battery cell with a hybrid cell structure and improved form factor, according to one embodiment of the present invention.
  • FIG. la-ld illustrates various perspective views of the battery cell shown in FIG. 1, according to one embodiment of the present invention.
  • FIG. 2a-2d illustrates various perspective exploded views of the battery cells shown in FIG. 1, according to one embodiment of the present invention.
  • FIG. 3a-3e illustrates various perspective view of a cap in the battery cell for transmission of current to a load or from a source, according to one embodiment of the present invention.
  • FIG. 4a-4c illustrates various perspective view of a clip shaped current collector provided in the cap shown in FIG. 3a-3f, according to one embodiment of the present invention.
  • FIG. 5a-5d illustrates a graphical representation of the battery cell during charging in comparison to conventional battery cells at 1C charging rate, according to one embodiment of the present invention.
  • FIG. 6a-6d illustrates a graphical representation of the battery cell during charging in comparison to conventional battery cells at 1C discharging rate, according to one embodiment of the present invention.
  • FIG. 7a and FIG. 7b illustrates an electron flow in a conventional cylinder batter cells and the present invention’s battery cell respectively, according to one embodiment of the present invention.
  • FIG. 8 illustrates a flow diagram of method for a high-speed manufacturing of a high energy battery cell, according to one embodiment of the present invention.
  • FIG. 8a illustrates a jelly roll of the battery cell with a robotic clamping unit for clamping a clip in the cap unit with the leaves, according to one embodiment of the present invention.
  • FIG. 9a illustrates an internal resistance of a conventional battery cell, according to one embodiment of the present invention.
  • FIG. 9b illustrates an internal resistance of the present battery cell, according to one embodiment of the present invention.
  • the battery cells especially Lithium-ion cells are made in two form factors, a prismatic cell and a cylindrical cell.
  • Each form factor has its own pros and cons while both the forms factors suffer from one common lagging i.e. high internal resistance which generally is main cause of heating of lithium cells during operation further leading to reduction of cell life or fire incidents.
  • the high energy battery cell comprises an active material core, a cap unit, and a housing (as shown in FIG. 2a-2d).
  • the active material core 101 comprises a strip comprised of active material layers and current collector layers arranged in a spatially optimized manner.
  • the active material layer and current collector layer are organized in vertical layering format, where an aluminium strip forms a bottom layer, a cathode layer is adhered over the aluminium strip, a separator layer with selective porosity is adhered over the cathode layer, an anode layer adhered to a copper layer is formed over separator layer. All the layers are calendared into a microstrip and then jelly rolled into a square shaped spiral.
  • the cap unit 102 comprises a positive cap unit 102a and a negative cap unit 102b.
  • the positive cap unit 102a is connected to the aluminium layer 103a which acts as electrons transfer medium from cathode during charging and discharging, while the negative cap unit 102b is connected to the copper layer 103b.
  • the housing 101 is a shell-like structure to encapsulate the active material core and the cap unit which are connected together.
  • the housing 101 creates an impermeable structure around the active material core to shield from an environment reaction.
  • the housing 101 comprises a first insulator unit 101a and a second insulator layer (provided in the cap unit) 101b.
  • a one-way pressure valve is connected between the first insulator layer and the second insulation layer.
  • the enclosed final battery cell is shown in FIG. la- Id.
  • the comer in the jelly roll structure is provided with the curvature with innermost layer in the jelly roll structure has an arc radius of 0.707mm.
  • the arc radius is modifiable according to the battery cell size.
  • the cathode layer is attached with an aluminium layer and the anode layer is attached with a copper layer.
  • the aluminium layer and the copper layer form the current collector layer.
  • the jelly roll is created in a manner that height of the aluminium layer is 5mm higher than the cathode layer on top side and a height of the copper layer is 5mm higher than the anode layer on bottom side during a placement of the battery cell in a top-down manner.
  • the positive terminal of battery cell made by the aluminium layer is kept on the top side and a positive cap unit is connected at the top while the negative terminal made by the copper layer is kept at the bottom and is connected with the negative cap unit.
  • the positive and negative cap unit comprises a flat top and a clip connected to a lower surface of the flat top. The clip is provided on each side of the lower surface of the flat top having 5mm length (as shown in FIG. 4a-4c).
  • a strip of active material core comprising a first current collector, a cathode layer, a separator, an anode layer and a second current collector.
  • the layering process is automated in nature and each layer thickness is selected before initiating the layering.
  • a dryer is used to dry the anode and cathode layer over the current collector layers.
  • three layers formed by the cathode layer with the first current collector layer, a separator layer and the anode layer with the second current collector layer are aligned vertically and calendared against each other (801).
  • the calendared layers create single strip called as an active material core which is jelly-rolled in a square spiral with an arc-shaped corner (802).
  • the arc corners of jelly roll are cut to a vertical length of 5mm on the first current collector and the second current collector in order to create an isolated leaf on each side of the jelly-roll (803).
  • each side of the said jelly-roll will have an leaf which is not in contact with leaves on adjacent sides.
  • the leaves are then simultaneously pressed from both sides through a robotic pressing clamp to create a thin dense sheet of leaf on each side of the jelly-roll.
  • a box shaped insulator called as a first insulator layer is slide over the jelly roll (804).
  • the box has a top part open and at least four slots on each side over the bottom part, wherein each slot has equivalent width as the sheet of leaf (805).
  • the sheet of leaves (made of copper) comes out of the insulator while rest of the jelly roll is housed within the insulator.
  • a top part (an exact replica of bottom part is then placed on the top with sheet of the leaves (made of aluminium) coming out of at least four micro-slots provided on the top part.
  • the top part is then thermally joined with the insulator.
  • the cap unit is then placed over the leaves on both side of jelly roll.
  • the cap unit comprises a flat top and a clip on each side connected to a lower surface of the flat top.
  • the clip and the flat top are made up of a conducting material and the clip is thermally pressed against the leaves from both sides through a robotic clamping apparatus (806).
  • the radial robotic apparatus comprises four clamping like structures with micro resistors 806a which are connected to a power supply unit.
  • the clamping structure are aligned parallel to the clip through a gap created by the cutting of the leaves (so four clamping structures for four sides enters through the gap in a counter clockwise orientation as shown in FIG. 8A.
  • the thermal pressing is done for 5-10 milliseconds to create a metallic bond between the leaves and the clips.
  • a height of the first current collector is 5mm higher than the cathode layer on a top side and a height of the second current collector (a copper layer) is 5mm higher than the anode layer on bottom side during a placement of the battery cell in a top-down manner.
  • the first insulator layer is inserted from a bottom side of the jelly roll in a manner that leaves are snuggle fit into the micro slots.
  • an autonomous filler apparatus is placed vertically above a central axis of the jelly roll to fill an electrolyte in the first insulator layer acting as a box structure around the jelly roll. After sensing an electrolyte fill to an optimum level, the autonomous filler apparatus is removed and an upper insulator layer is placed with snuggle fitting the leaves on top.
  • the upper insulator layer is thermally connected with the first insulator layer to create a chamber around the jelly roll.
  • the method reduces an electron travel length by 90% leading to reduction in an internal resistance of a battery cell by a factor of 10.
  • a conventionally used battery cell with form factor 18650 is used, then the total strip length will be 700mm and an average travel length of an electron can be 400mm and a maximum travel length can be 800 mm due to tapping of electron with positive and negative cap at the end of strips.
  • the average travel length of the electron is 40mm and maximum travel length is 80mm which 10 times lower than the conventional battery cell.
  • a square spiral creates a straight-line electron flow reducing the internal resistance further by a factor of 11 leading to slow heat generation and increasing a battery cell safety during an operation.
  • the housing unit comprises a bottom conductive layer acting as negative terminal of the said battery cell and the side walls of the housing unit is made of an insulator material.
  • each cap unit comprises at least four clips and a combination of the clips with direct connection to the flat top.
  • the clips are arranged in a manner that alternatively they are connected to aluminium and copper cleaves to create a series connection between the caps to increase an output voltage of battery cell by a factor of 4 leading to improvement in range of a vehicle.
  • the present invention provides a battery cell with high energy storage capacity with respect to conventionally used cells while maintaining the internal resistance very low in comparison to the conventional cells that allows to reduce the heat generation and increase the safety of the battery cell while in usage despite having high volume of active material.
  • the present battery cell increase thermal management or heat transfer due to relatively small form factor than the prismatic battery cells and similar to cylindrical battery cells.
  • the present battery cells have an air gap on all sides from where the heat exchange can be done, hence better thermal management along with low internal resistance leads to higher battery life and safer performance.
  • the low internal resistance of the battery and straight line structure allows a faster charge and discharge rates without damaging the battery cell’s chemical structure.
  • the battery cell is easy to manufacture and increase in production speed can be achieved in comparison to low manufacturing speed of conventional cells which require welding of tap on the strip of active material.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Secondary Cells (AREA)

Abstract

Les modes de réalisation de la présente invention concernent une cellule de batterie à haute énergie présentant une faible impédance et une gestion thermique améliorée. La cellule de batterie comprend un noyau de matériau actif, une unité couvercle et un boîtier. Le noyau de matériau actif comprend une bande composée de couches de matériau actif et de couches de collecteur de courant disposées de manière spatialement optimisée. L'unité couvercle comprend une unité couvercle positif et une unité couvercle négatif. L'unité couvercle est reliée aux couches de collecteur de courant. Le boîtier est une structure de type coque destinée à encapsuler le noyau de matériau actif et l'unité couvercle reliés ensemble. Le boîtier crée une structure imperméable autour du noyau de matériau actif pour protéger contre une réaction environnementale. Le boîtier comprend une première unité isolante et une seconde couche isolante, une soupape de pression unidirectionnelle étant raccordée entre la première couche isolante et la seconde couche isolante.
PCT/IB2022/055914 2021-06-27 2022-06-25 Batterie haute énergie à faible résistance thermique et à régulation de température améliorée WO2023275696A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN202141023628 2021-06-27
IN202141023628 2021-06-27

Publications (1)

Publication Number Publication Date
WO2023275696A1 true WO2023275696A1 (fr) 2023-01-05

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050277019A1 (en) * 2004-04-30 2005-12-15 A123 Systems Inc. Low impedance layered battery apparatus and method for making the same
US20120177957A1 (en) * 2008-10-16 2012-07-12 Lenovo (Singapore) Pte. Ltd. Battery with pressure relief channel

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050277019A1 (en) * 2004-04-30 2005-12-15 A123 Systems Inc. Low impedance layered battery apparatus and method for making the same
US20120177957A1 (en) * 2008-10-16 2012-07-12 Lenovo (Singapore) Pte. Ltd. Battery with pressure relief channel

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