WO2024251064A1 - 一种大容量电池的制备工艺 - Google Patents

一种大容量电池的制备工艺 Download PDF

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Publication number
WO2024251064A1
WO2024251064A1 PCT/CN2024/096988 CN2024096988W WO2024251064A1 WO 2024251064 A1 WO2024251064 A1 WO 2024251064A1 CN 2024096988 W CN2024096988 W CN 2024096988W WO 2024251064 A1 WO2024251064 A1 WO 2024251064A1
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WO
WIPO (PCT)
Prior art keywords
cover plate
electrolyte
shell
cylinder
hole
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/CN2024/096988
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English (en)
French (fr)
Inventor
雷政军
陈孟奇
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D Aus Energy Storage Technology Xian Co Ltd
Original Assignee
D Aus Energy Storage Technology Xian Co Ltd
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Filing date
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Publication of WO2024251064A1 publication Critical patent/WO2024251064A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted 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
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • 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
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6554—Rods or plates
    • 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
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
    • 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
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/258—Modular batteries; Casings provided with means for assembling
    • 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
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/271—Lids or covers for the racks or secondary casings
    • 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
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/291—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by their shape
    • 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
    • H01M50/30—Arrangements for facilitating escape of gases
    • H01M50/35—Gas exhaust passages comprising elongated, tortuous or labyrinth-shaped exhaust passages
    • H01M50/367—Internal gas exhaust passages forming part of the battery cover or case; Double cover vent systems
    • 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
    • H01M50/50—Current conducting connections for cells or batteries
    • H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
    • H01M50/509—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the type of connection, e.g. mixed connections
    • H01M50/512—Connection only in parallel
    • 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
    • H01M50/60—Arrangements or processes for filling or topping-up with liquids; Arrangements or processes for draining liquids from casings
    • H01M50/673—Containers for storing liquids; Delivery conduits therefor
    • H01M50/682—Containers for storing liquids; Delivery conduits therefor accommodated in battery or cell casings
    • 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 application relates to the field of batteries, and specifically to a preparation process for large-capacity batteries.
  • An existing large-capacity battery as shown in FIG1 , includes a battery pack body formed by a plurality of single cells connected in parallel and a shared pipe assembly located at the bottom of the battery pack body; the shared pipe assembly is used to connect the inner cavities of the plurality of single cells so that all the single cells in the battery pack are in one electrolyte system.
  • the battery pack can enhance the uniformity of the electrolyte of each single cell in the battery pack through the shared pipe assembly, improve the cycle life, and can also replenish the electrolyte for the battery pack through the shared pipe assembly, thereby extending the service life of the battery pack and improving the safety of the battery pack.
  • this type of shared pipeline assembly is formed by directly sealing and plugging multiple sections of sub-pipes 01 and intermediate connecting pipes 02 that are interference fit with each other; at this time, the multiple sections of sub-pipes 01 are arranged one by one on the lower cover plate 03 of the single battery, and the sub-pipes extend along the arrangement direction of the single battery 2, and are extruded integrally with the lower cover plate 03, and are connected to the opening of the lower cover plate 03.
  • the two ends of the sub-pipeline 01 are used as connecting ends with the middle connecting tube 02 .
  • one end of the sub-pipeline on the two single cells is squeezed into the two ends of the middle connecting tube 02 .
  • the shared pipeline assembly requires that each sub-pipeline 01 and the intermediate connecting pipe 02 be coaxial during the plugging process to achieve effective connection.
  • the coaxiality of each sub-pipeline and the intermediate connecting pipe 02 is difficult to ensure due to the following reasons:
  • the sub-pipeline and the lower cover are an integrated part. If the position of the sub-pipeline on the lower cover is slightly deviated, or the size of each sub-pipeline is slightly deviated, the coaxiality of each sub-pipeline will deviate when plugged in;
  • this solution may cause the sub-pipes to be displaced relative to the lower cover plate, or the lower cover plate to be displaced relative to the cylinder during insertion, thereby causing damage to the battery.
  • the purpose of this application is to provide a preparation process for large-capacity batteries to overcome the problem that existing large-capacity batteries share pipeline components that are difficult to assemble.
  • the technical solution of the present application is to provide a preparation process of a large-capacity battery, which is special in that it includes the following steps:
  • the semi-finished shell comprising a cylinder with two opposite open ends and a first cover plate fixed to any open end of the cylinder, the first cover plate being provided with an electrolyte sharing chamber;
  • the second cover plate is sealed and welded to the open end of the top of the cylinder body, and after each single cell pole extends out of the corresponding third through hole on the second cover plate, the second cover plate area corresponding to the third through hole is fixedly sealed to the single cell housing;
  • the present invention places a plurality of single cells in a semi-finished shell with a shared electrolyte chamber, uses a second cover plate to seal the cylinder, and opens holes in the shell of the single cells through the unpacking process, so that the shared electrolyte chamber and the electrolyte area of each single cell cavity are connected, and the electrolyte of each single cell is shared to ensure The consistency of each single cell, that is, the electrolyte chambers of each single cell are connected so that the electrolytes of all single cells are in the same system, which reduces the differences between the electrolytes of each single cell and improves the consistency between each single cell to a certain extent, thereby improving the cycle life of large-capacity batteries to a certain extent.
  • the electrolyte sharing chamber of the present application is formed on the first cover plate, and does not need to be plugged in.
  • the arrangement direction of the single battery cells there is no need to consider the coaxial plugging problem, and the requirements for processing accuracy and assembly accuracy are relatively low.
  • no special tooling is required, and the assembly process is relatively simple, which greatly reduces the processing difficulty and processing cost of such large-capacity batteries with a shared system, and can realize mass production.
  • the poles of each single cell of the present application extend out of the top of the shell (the top of the shell is the second cover plate.
  • the gap between the pole and the shell needs to be sealed).
  • the pole has a better heat dissipation effect; in addition, when the pole extends out of the shell, if the battery temperature is too high, it is also convenient to use heat exchange equipment to timely remove the heat of the pole, so as to ensure that such large-capacity batteries operate at the optimal temperature.
  • the large-capacity battery manufacturing process of the present application requires the operation of capacity sorting and sorting each single battery in order to maintain the consistency of multiple single batteries in the initial state of the battery module.
  • multiple single cells are directly installed in a sealed housing, and the multiple single cells are in a unified electrolyte system (equivalent to multiple single cells forming a large-capacity battery cell), which reduces the differences between the single cells. Therefore, the production process of the large-capacity battery can omit the work of capacity separation and sorting, thereby improving the cycle life of the large-capacity battery and also improving the production efficiency of the large-capacity battery.
  • the step of processing the second cover plate further includes:
  • the unpacking steps also include:
  • the present application forms a second channel on the second cover plate as a gas chamber; during the unpacking process, a hole is opened in the single battery shell so that the gas area of the inner cavity of each single battery is connected with the gas chamber, This makes the gas paths of each single cell connected, and the gases of all single cells are in the same environment, achieving gas balance, reducing the differences between each single cell, improving the consistency between each single cell, and further improving the cycle life of large-capacity batteries.
  • the semi-finished shell of the present application can be a split part or an integrated part; when it is a split part, an aluminum extrusion process is used to integrally form a cylinder with two relatively open ends, and an aluminum extrusion process or a casting process is used to integrally form a first cover plate, and then the first cover plate is sealed and fixed to any open end of the cylinder.
  • a casting process is used to integrally form the semi-finished shell. Compared with the structure of the split setting, the leakage points are further reduced, and it is easier to make the entire shell a better closed system, but the casting process has a draft angle, which needs to be corrected later.
  • a hole is opened in the single battery shell by using external force or the electrolyte itself, and after the inner cavity of the electrolyte shared chamber and the electrolyte area of the inner cavity of each single battery are connected, it also includes the step of injecting electrolyte into the inner cavity of each single battery through the electrolyte shared chamber to form the entire large-capacity battery.
  • a plurality of single cells that have been sorted by capacity are arranged in the semi-finished outer shell.
  • a sealing connector is added between the third through hole and the pole, and the outer shell area corresponding to the third through hole is fixedly sealed with the single cell housing by the sealing connector;
  • the second cover plate is seal-welded to the open end of the top of the cylinder, and after each single cell pole and the hollow component extend out of the corresponding third through hole on the second cover plate, the top of the hollow component is seal-connected to the second area of the second cover plate; the second area is the area corresponding to any one of the third through holes on the second cover plate.
  • the present application places multiple single cells in a housing, which is a split structure, including a cylinder that can accommodate multiple single cells, and a first cover plate and a second cover plate that seal the open end of the cylinder.
  • An electrolyte sharing chamber is provided on the first cover plate, and the electrolyte sharing chamber is connected with the electrolyte area of the inner cavity of each single cell located in the outer shell, so that the electrolyte of each single cell is shared to ensure the consistency of each single cell, that is, the electrolyte chamber of each single cell is connected so that the electrolyte of all single cells is in the same system, which reduces the difference between the electrolytes of each single cell, improves the consistency between each single cell to a certain extent, and thus improves the cycle life of the large-capacity battery to a certain extent.
  • the electrolyte shared chamber of the present application does not need to be plugged in, and there is no need to consider the coaxial plug-in problem in the arrangement direction of the single battery cells, and the requirements for processing accuracy and assembly accuracy are relatively low. At the same time, no special tooling is required, and the assembly process is relatively simple, which greatly reduces the processing difficulty and processing cost of such large-capacity batteries with a shared system, and can realize mass production.
  • the present application can place each single battery from the open end of the top of the cylinder into the inner cavity of the semi-finished shell, which is convenient for assembly.
  • the poles of each single cell in the present application extend out of the top of the shell (the top of the shell here is the second cover plate.
  • the gap between the pole and the shell needs to be sealed).
  • the pole has a better heat dissipation effect; in addition, when the pole extends out of the shell, if the battery temperature is too high, it is also convenient to use heat exchange equipment to timely export the heat of the pole in the later stage, which can ensure that such large-capacity batteries operate at the optimal temperature.
  • FIG1 is a schematic diagram of a large-capacity battery structure in the background art
  • FIG2 is a schematic diagram of the structure of a large-capacity battery in Example 1;
  • FIG3 is a schematic diagram of a large-capacity battery explosion in Example 1;
  • FIG4 is a schematic diagram of the structure of a commercially available square shell battery in Example 1;
  • FIG5 is a schematic diagram of the housing structure in Example 1;
  • FIG6 is a schematic structural diagram of the first cover plate in Example 1;
  • FIG7 is another schematic diagram of the structure of the first cover plate in Example 1;
  • FIG8 is another schematic diagram of the structure of the first cover plate in Example 1 (the electrolyte sharing chamber is tubular);
  • FIG9 is a schematic diagram of the structure of the second cover plate in Example 1.
  • FIG10 is a schematic structural diagram of a large-capacity battery after a heat transfer connector is added in Example 1;
  • FIG11 is a schematic structural diagram of a heat transfer connector in Example 1.
  • FIG12 is a schematic diagram of the structure of the second cover plate in Example 2.
  • FIG13 is a schematic diagram of the housing structure in Example 3.
  • Figure 14 is a schematic diagram of the cylinder structure in Example 4.
  • orientation or positional relationship indicated by the terms “top, bottom” and the like is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing this application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.
  • first, second, third, fourth are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.
  • the large-capacity battery involved in the present application includes a shell and a plurality of single cells arranged in parallel in the shell; the single cells described here can be square shell batteries or multiple commercially available soft-pack batteries connected in parallel.
  • the inner cavity of each single cell includes an electrolyte area and a gas area.
  • each single cell in the shell can be set according to specific needs.
  • the shell can be a square shell, and each single cell can be arranged along the length of the shell.
  • the outer shell can also be a cylindrical hollow shell, and each single battery can be arranged along the circumference of the outer shell.
  • the stability of the square shell battery in the cylindrical hollow shell is more difficult to ensure.
  • the energy density of the energy storage device formed by such large-capacity batteries is general, but the large-capacity battery of this structure has better heat dissipation performance.
  • the present application prefers a square shell as the outer shell.
  • the housing of this application can adopt the following structural forms, taking a rectangular housing as an example:
  • the outer shell is a split structure, including a cylinder with open top and bottom, a first cover plate and a second cover plate;
  • This type of cylinder structure can be formed by aluminum extrusion:
  • a cylinder with open top and bottom is formed by aluminum extrusion, and then a first cover plate with an electrolyte sharing chamber is processed and fixed to the open end of the bottom of the cylinder.
  • the cylinder and the first cover plate may also be an integral part, and may generally be integrally formed by a casting process
  • the outer shell is a split structure, including a cylinder with open top and bottom, a second cover plate, and a hollow box that can be used as a shared chamber for electrolyte;
  • this type of cylinder structure can be formed by aluminum extrusion:
  • an aluminum extrusion method is used to form a cylinder with open top and bottom, and then a hollow box is covered on the open end of the bottom of the cylinder and sealed to the open end.
  • the inner cavity of the hollow box is connected with the electrolyte area of each single battery, and the open end of the top of the cylinder is sealed by the second cover (each single battery pole needs to extend out of the cover) to ensure that the electrolyte does not contact the outside.
  • the cylinder of this scheme is formed by welding four rectangular plates. However, due to the large number of welds, the overall strength and sealing of the cylinder are relatively poor.
  • the length direction of the shell is defined as the x direction
  • the width direction of the shell is defined as the y direction
  • the height direction of the shell is defined as the z direction.
  • the large-capacity battery of this embodiment includes 9 single cells 2 connected in parallel.
  • the quantity can be adjusted according to actual needs.
  • the single cell 2 is a square shell battery, which includes an upper cover plate, a lower cover plate, a cylinder and a battery cell assembly; the battery cell assembly described here can also be referred to as an electrode assembly, which is arranged in sequence by a positive electrode, a diaphragm, and a negative electrode, and is assembled by a lamination or winding process.
  • the upper cover plate, the cylinder, and the lower cover plate constitute the single cell shell, and the battery cell assembly is arranged in the single cell shell.
  • the housing 1 of this embodiment is a rectangular housing, comprising a cylindrical body 4 with a rectangular cross section and open ends at the top and bottom, a first cover plate 5 covering the open end at the bottom of the cylindrical body 4, and a second cover plate 6 covering the open end at the top.
  • the first cover plate 5 is provided with an electrolyte sharing chamber 7.
  • the first cover plate 5 can adopt different structural forms, but it is necessary to ensure the sealing of the connection part between it and the bottom open end of the cylinder 4 when it covers the bottom open end of the cylinder 4, and it is necessary to ensure that the inner cavity of the electrolyte shared chamber 7 set on the first cover plate 5 and the inner cavity of each single battery 2 are connected.
  • a flat plate that matches the shape of the bottom open end of the cylinder 4 is selected as the first cover plate 5, and the sealing between the first cover plate 5 and the bottom open end of the cylinder 4 is ensured by welding the first cover plate 5 to the edge of the bottom open end of the cylinder 4.
  • the cylinder 4 is a rectangular cylinder, so the flat plate is a rectangular flat plate, and the area can be slightly larger than the area of the bottom open end of the cylinder 4, and it is fixed to the bottom open end of the cylinder 4 by fusion welding; the area can also be slightly smaller than the area of the bottom open end of the cylinder 4, and it is fixed to the bottom open end of the cylinder 4 by embedding welding.
  • the structure of the first cover plate 5 and the electrolyte shared chamber 7 in this embodiment may be the structure shown in FIG5 and FIG6, and a first channel extending along the length direction of the first cover plate 5 is provided on the first cover plate 5 as the electrolyte shared chamber 7.
  • the first channel may also be formed directly on the first cover plate 5 by using a bending or aluminum extrusion process, and the inner surface of the first cover plate 5 is raised in a direction away from the inner surface of the first cover plate 5.
  • the first channels in Figures 5, 6 and 7 all protrude in a direction away from the top of the cylinder. It should be noted that the electrolyte sharing chamber 7 in Figure 7 is open at both ends and needs to be sealed.
  • the structure of the first cover plate 5 and the electrolyte sharing chamber 7 of this embodiment can also be the structure shown in FIG8 .
  • the electrolyte sharing chamber 7 is a hollow tube, and the cross section can be rectangular or circular. It is an integral part with the first cover plate 5, and can be formed by aluminum extrusion process like the cylinder 4.
  • a hollow tube is used as the electrolyte sharing chamber 7, it is necessary to open a second through hole 8 that penetrates the inner cavity of the electrolyte sharing chamber 7 on the tube wall and the first cover plate 5, so that the inner cavity of the electrolyte sharing chamber 7 and the inner cavity of each single battery 2 are connected.
  • each second through hole 8 there can be multiple second through holes 8, and the number is equal to that of each single battery 2, and each second through hole 8 corresponds to and is connected with the first through hole; or a long strip-shaped second through hole 8 extending along the length direction of the electrolyte shared chamber 7 can be directly opened in the first cover plate 5 and the electrolyte shared chamber 7, and the size of the second through hole 8 needs to ensure that when the first cover plate 5 is welded to the open end at the bottom of the cylinder 4, the second through hole 8 is connected with the first through holes of all the single batteries 2.
  • an injection port may be further provided in the electrolyte shared chamber 7. After the inner cavities of each single cell 2 and the electrolyte shared chamber are connected, electrolyte may be injected again into the inner cavities of each single cell 2 and the electrolyte shared chamber through the injection port to ensure the continuity of the electrolyte. The electrolyte may also be replaced later through the injection port.
  • the structure of the second cover plate 6 of this embodiment is shown in FIG9 , and a third through hole 9 is provided on the second cover plate 6 to allow the poles of each single battery 2 to extend out; the second cover plate 6 covers the open end at the top of the cylinder 4 and is sealed and connected to the open end; preferably, the shape of the second cover plate 6 is adapted to the shape of the open end at the top of the cylinder 4, which is a rectangular cylinder 4 in this embodiment, so the flat plate is a rectangular flat plate, and its area can be slightly larger than the area of the open end at the top of the cylinder 4, and it is fixed to the open end at the top of the cylinder 4 by fusion welding; the area can also be slightly smaller than the area of the open end at the top of the cylinder 4, and it is fixed to the open end at the top of the cylinder 4 by embedding welding.
  • Step 1 Process the housing 1, including the barrel 4, the first cover plate 5 with the electrolyte sharing chamber 7, and the second cover plate 6.
  • Step 2 seal-weld the first cover plate 5 with the electrolyte sharing chamber 7 to the open end at the bottom of the cylinder 4.
  • Step 3 sorting by capacity, screening multiple single cells that meet the requirements; opening a first through hole at the bottom of the single cell housing and sealing it with a sealing assembly; arranging multiple single cells with sealing assemblies at the first through holes in the cylinder 4 of step 2;
  • the first through hole with the sealing component needs to correspond to the first channel to ensure that after the sealing component is opened by external force or the electrolyte itself, the electrolyte area in the inner cavity of each single cell and the electrolyte shared chamber 7 are connected;
  • the seal needs to be The assembly corresponds to the second through hole 8, ensuring that after the sealing assembly is opened by external force or the electrolyte itself, the electrolyte area in the inner cavity of each single cell and the electrolyte sharing chamber 7 are connected;
  • the sealing component may adopt the sealing components disclosed in Chinese patents CN218525645U and CN218525614U.
  • Step 4 seal and weld the second cover plate 6 to the open end of the top of the cylinder 4.
  • the shells of some single cells 2 with smaller sizes in the z direction may have problems with poor welding or even be unable to be welded to the large-capacity battery shell, making it difficult to ensure the sealing of the third through hole 9 and the single cell shell.
  • a weak portion may be provided in the peripheral area of the third through hole 9.
  • the weak portion in this embodiment may be an annular groove with the center of the third through hole 9 as the center point and opened along the peripheral area of the third through hole 9.
  • the weak portion may also be a long strip groove opened in the peripheral area of the third through hole 9.
  • a sealing connector may also be provided between the third through hole 9 and the pole, the sealing connector comprising a hollow member; the bottom of the hollow member is used to be sealed and connected to the first area of the single cell, and the top of the hollow member is sealed and connected to the second area of the second cover plate; the first area is the area around any pole in the upper cover plate of any single cell; the second area is the area corresponding to any third through hole on the second cover plate.
  • the area corresponding to the third through hole is the surrounding area on the outer surface of the second cover plate corresponding to any third through hole; or the area corresponding to the third through hole is the wall of the third through hole.
  • the area around the pole is the area around the insulating seal on the pole.
  • the insulating seal is a part on the single cell used to insulate the pole from the upper cover plate.
  • first cover plate 5, the second cover plate 6 and the open end of the cylinder 4 may also be fixed by bonding or screwing.
  • the sealing performance or connection reliability is relatively weak.
  • Step 5 Use external force or the electrolyte itself to open the sealing component, and the electrolyte in the shared chamber 7
  • the inner cavity of the battery is connected with the electrolyte area of each single cell.
  • the electrolytes in the inner cavities of each single cell 2 are connected through the electrolyte shared chamber 7.
  • the electrolyte can be injected into the electrolyte shared chamber 7 to ensure the continuity of the electrolyte.
  • the single cells 2 are connected in parallel.
  • the single cells 2 may be connected in parallel between step 4 and step 5.
  • the heat transfer connector 13 shown in FIG. 10 and FIG. 11 can be used to connect all the single cells 2 in parallel.
  • the heat transfer connector 13 is a slender member, which is used to connect to the positive or negative electrode of each single cell 2; and a clamping portion for installing a heat transfer tube is provided on the slender member along the axial direction.
  • the present embodiment adds a gas chamber 10 on the second cover plate 6 to serve as a gas sharing chamber or an explosion relief channel.
  • the structure of the second cover plate 6 in this embodiment is similar to that of the first cover plate 5 in Embodiment 1, and the gas chamber 10 may be a second channel formed on the second cover plate 6, and the second channel protrudes in a direction away from the bottom of the cylinder.
  • the second channel may also be formed integrally with the second cover plate 6 by bending or aluminum extrusion process.
  • the gas chamber 10 may also be a hollow tube disposed on the second cover plate 6, and may be integrally formed with the second cover plate 6 by aluminum extrusion, and its structure is shown in Figure 12.
  • the second cover plate 6 and the tubular gas chamber 10 may be separate structures, but the processing is more complicated.
  • a fifth through hole penetrating the inner cavity of each single cell 2 needs to be opened on the top of the shell of each single cell 2;
  • the second channel structure When the gas chamber 10 of the second channel structure is selected, after the second cover plate 6 is fixed to the open end of the top of the cylinder 4, the second channel is directly connected to the gas area of the inner cavity of each single battery through the fifth through hole. Pass.
  • a fourth through hole penetrating the inner cavity of the gas chamber 10 needs to be opened on the tube wall and the second cover plate 6.
  • the gas chamber 10 is connected to the gas area of the inner cavity of each single battery 2 through the fourth through hole and the fifth through hole.
  • the size of the fourth through hole needs to ensure that when the second cover plate 6 is welded to the open end of the top of the cylinder 4, the fourth through hole is connected to the fifth through holes of all single batteries 2.
  • an exhaust valve and an explosion-proof membrane can be set on the gas chamber 10, or only an exhaust valve can be set; the exhaust valve can be opened manually or automatically, and the exhaust valve is opened regularly, and the gas in the gas zone of each single battery 2 can be discharged through the gas chamber 10 and the exhaust valve; when the explosion-proof membrane is set, the exhaust valve and the explosion-proof membrane are located at both ends of the gas chamber 10, and the explosion-proof membrane is used to break through the explosion-proof membrane and discharge the hollow component when any single battery 2 has thermal runaway, so that this type of large-capacity battery has higher safety performance.
  • the gas chamber 10 When the gas chamber 10 is used as an explosion relief channel, the gas chamber 10 covers the explosion relief portion on the top of each single battery 2. When the explosion relief portion of any single battery 2 is broken by the internal smoke, the gas area in the internal cavity of the single battery 2 is connected to the internal cavity of the gas chamber 10.
  • the explosion relief part described in this embodiment includes an explosion relief opening or explosion-proof opening with an explosion relief membrane arranged on the top of the single battery 2, or an explosion relief opening with an explosion relief valve, etc.
  • the housing 1 of this embodiment adopts the second structural form mentioned above, and its structure is shown in FIG. 13 , including a cylinder 4, a second cover plate 6 and a hollow box 14 serving as a shared chamber for electrolyte.
  • the structure and forming method of the cylinder 4 and the second cover plate 6 are the same as those of Embodiment 1 or Embodiment 2, and will not be described in detail here;
  • the hollow box 14 covers the open end of the bottom of the cylinder 4, and its top is sealed and connected to the open end of the bottom of the cylinder 4; it can be connected by welding or gluing, but welding has relatively higher sealing and connection reliability, so this embodiment adopts welding.
  • the hollow box body 14 is a hollow box body 14 with a rectangular cross-section, and a second through hole 8 that penetrates the first through hole is opened on the top of the hollow box body 14.
  • the inner cavity of the hollow box body 14 is connected with the electrolyte area of the inner cavity of each single battery 2 through the first through hole and the second through hole 8; as above, there can be multiple second through holes 8, and the number is equal to that of each single battery 2, and each second through hole 8 corresponds to and penetrates the first through hole one by one; it is also possible to directly open a long strip-shaped second through hole 8 extending along the length direction of the hollow box body 14 on the top of the hollow box body 14, and the size of the second through hole 8 needs to ensure that when the hollow box body 14 is welded to the open end at the bottom of the cylinder 4, the second through hole 8 penetrates the first through holes of all the single batteries 2.
  • the preparation process is basically the same as that in the above embodiment and will not be described in detail here.
  • a plurality of partitions 15 are provided in the inner cavity of the cylinder 4 to divide the inner cavity of the cylinder 4 into a plurality of mounting cavities for the single battery cells 2 .
  • FIG14 The specific structure is shown in FIG14 .
  • a single cell 2 is fixed in each single cell 2 installation cavity.
  • the side walls of each single cell 2 near the middle part are in contact with the partition 15.
  • the two single cells 2 near the outermost part have one side wall in contact with the partition 15 and the other side wall in contact with the side wall of the cylinder 4.
  • the installation stability of each single cell 2 in the housing can be improved.
  • It can prevent the individual cells 2 from swelling, which would lead to reduced cycle performance of large-capacity batteries.
  • the heat generated during the charging and discharging of the individual cells 2 can be transmitted to the outside through the partition 15, reducing the risk of thermal runaway.
  • the strength of the cylinder 4 can also be enhanced.
  • Two or more single cells 2 may be fixed in each single cell 2 installation cavity.
  • the partition 15 and the rectangular cylinder 4 can be extruded as a whole.
  • two or more sub-rectangular cylinders 4 can be extruded first, and then the sub-rectangular cylinders 4 are spliced and welded to form a rectangular cylinder 4 of the required size.
  • two sub-rectangular cylinders 4 that can accommodate five single cells 2 can be extruded, and the extra single cell 2 installation cavity can be used as an electrolyte storage tank.
  • the electrolyte storage tank is connected to the electrolyte sharing chamber and is used to add electrolyte to such large-capacity batteries.
  • each reinforcing rib 11 is located in the middle of the side wall of the single cell 2 installation cavity.
  • the second cover plate 6 excluding the gas chamber can be eliminated, and the edge of the upper cover plate of each single battery 2 is sealed and welded to the top open end of each single battery 2 installation cavity, so that the top open end of the cylinder 4 is sealed.

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Abstract

一种大容量电池的制备工艺包括加工外壳（1）、组装半成品外壳（1）、预制单体电池（2）、预制单体电池（2）装入半成品外壳（1）、密封、开包以及并联的步骤。将具有密封组件的多个分容分选后的单体电池（2）置于具有电解液共享腔室（7）的半成品外壳内部（1），利用第二盖板（6）密封筒体（4），通过开包过程，打开密封组件，使得电解液共享腔室（7）和各个单体电池（2）内腔的电解液区贯通，各单体电池（2）电解液共享来保障各单体电池（2）的一致性，提升了大容量电池的循环寿命。电解液共享腔室（7）为成型在第一盖板（5）上，无需插接，对加工精度以及装配精度要求较低。

Description

一种大容量电池的制备工艺 技术领域
本申请涉及电池领域，具体为一种大容量电池的制备工艺。
背景技术
目前市场上多通过并联或串联多个单体电池使其成为大容量电池(也可称之为电池模组或电池组)。
现有的一种大容量电池，其结构如图1所示，包括由若干单体电池并联形成的电池组主体和位于电池组主体底部的共享管路组件；共享管路组件，用于将若干单体电池的内腔全部贯通，以使电池组中所有单体电池均处于一个电解液体系下。该电池组通过共享管路组件能够加强电池组内各个单体电池电解液的均一性，提高循环寿命，还能通过该共享管路组件为电池组补充电解液，延长电池组的使用寿命，同时提高电池组的使用安全性。
但是，此类共享管路组件由多段子管路01以及中间连接管02相互间过盈配合直接进行密封插接形成；此时多段子管路01一一设置在单体电池下盖板03上，子管路沿单体电池2排布方向延伸，且与下盖板03一体挤压成型，并与下盖板03开孔相通。
装配时，将子管路01的两端作为与中间连接管02的连接端，两个单体电池连接时，两个单体电池上的子管路一端分别挤入中间连接管02的两端中。
该共享管路组件在插接过程中要求各个子管路01以及中间连接管02同轴，才能实现有效连接，但是，由于以下原因使得各个子管路以及中间连接管02的同轴度难以保证：
1)子管路与下盖板为一体件，若各个一体件上，子管路在下盖板的位置略有偏差，或各个子管路自身尺寸略有偏差，则会导致，插接时，各个子管路的同轴度出现偏差；
2)将上述一体件与筒体焊接时，会因为焊接过程的差异，有可能会出现子管路相对于筒体的位置出现不一致的情况，进而导致插接时，各个子管路同轴度出现偏差；
3)该方案，在插接时，需要利用专用工装，由于工装使用不当，或者因 施工人员操作问题，稍有不慎，就会使得各个子管路的同轴度出现偏差；
另外，在插接时，各个子管路之间的偏差会随着插接数量的增多而加大，导致插接数量越多，各个子管路之间的同轴度越难以保证；导致装配过程中，成品率随着插接数量的增多而降低。
综上，该方案因相邻两个单体电池的子管路很难同轴所以在插接时，可能会导致子管路相对于下盖板发生位移，或导致下盖板相对于筒体发生位移，进而导致电池损坏。
发明内容
本申请的目的是提供一种大容量电池的制备工艺，克服现有大容量电池共享管路组件难以组装的问题。
本申请的技术方案是提供一种大容量电池的制备工艺，其特殊之处在于，包括以下步骤：
加工外壳：
加工半成品外壳，该半成品外壳包括相对两端敞口的筒体以及固定在筒体任一敞口端的第一盖板，第一盖板设有电解液共享腔室；
加工用于固定在筒体另一敞口端的第二盖板，并在第二盖板加工与各个单体电池极柱对应的第三通孔；
单体电池装入半成品外壳：
将多个单体电池排布在半成品外壳内；
密封：
将第二盖板密封焊接在筒体顶部敞口端，各个单体电池极柱伸出第二盖板上对应第三通孔后，将第三通孔对应的第二盖板区域与单体电池壳体固定密封；
开包：
利用外力或者电解液自身，在单体电池壳体开孔，使电解液共享腔室内腔和各个单体电池内腔的电解液区贯通。
本申请将多个单体电池置于具有电解液共享腔室的半成品外壳内部，利用第二盖板密封筒体，通过开包过程，在单体电池壳体开孔，使得电解液共享腔室和各个单体电池内腔的电解液区贯通，各单体电池电解液共享来保障 各单体电池的一致性，即，将各单体电池的电解液腔连通，使所有单体电池的电解液处于同一体系下，减少了各单体电池电解液之间的差异，一定程度上提升了各单体电池之间的一致性，从而一定程度上提升了大容量电池的循环寿命。
本申请电解液共享腔室为成型在第一盖板上，无需插接，在单体电池排布方向，无需考虑插接同轴问题，对加工精度以及装配精度要求较低；同时无需专用工装，装配过程较为简单，大大降低了此类具有共享体系大容量电池的加工难度及加工成本，可实现批量化生产。
另外，本申请各个单体电池极柱伸出外壳顶部(此处所述外壳顶部即为第二盖板，为了确保，整体外壳的密封性，需要将极柱与外壳之间的间隙密封)。相对于极柱位于外壳内部的结构，极柱散热效果较好；另外，当极柱伸出外壳后，若电池温度过高，还便于后期利用换热设备将极柱的热量及时导出，可以确保此类大容量电池运行在最佳温度。
另外，本申请的大容量电池制作工艺相比现有电池模组制作时为了保持电池模组初始状态时多个单体电池的一致性相差较小，需要对各单体电池进行分容分选的操作；
而本申请中将多个单体电池直接安装在一个密封外壳内，且多个单体电池处于统一电解液体系内(相当于将多个单体电池构成了一个大容量的电池单体)，减小了各单体电池之间的差异性，因此该大容量电池的制作过程可以省略分容分选的工作，提升了大容量电池循环寿命的同时还提高了大容量电池的制作效率。
为了进一步地优化上述大容量电池的性能，加工第二盖板的步骤中，还包括：
在第二盖板加工气体腔室；
开包步骤中还包括：
利用外力或者电解液自身，在单体电池壳体开孔，使气体腔室内腔和各个单体电池内腔的气体区贯通。
本申请在第二盖板上，形成第二通道，作为气体腔室；在开包过程中，在单体电池壳体开孔，使得各个单体电池内腔的气体区与气体腔室贯通，进 而使得各单体电池气路连通，所有单体电池的气体处于同一环境下，达到气体平衡，减少了各单体电池之间的差异，提升了各单体电池之间的一致性，从进一步提升了大容量电池的循环寿命。
进一步地，本申请半成品外壳可以为分体件，也可以为一体件；当为分体件时，采用铝挤压工艺一体成型相对两端敞口的筒体，采用铝挤压工艺或铸造工艺一体成型第一盖板，之后将第一盖板密封固定在筒体任一敞口端。当为分体件时，采用铸造工艺一体成型半成品外壳。相对分体设置的结构，易漏点进一步减少，更易使得整个外壳为一个较优的密闭体系，但是采用铸造工艺，存在拔模斜度，后期需要修正。
进一步地，为了形成了更完整的SEI膜,使大容量电池具有更稳定的循环能力，开包过程中，利用外力或电解液自身，在单体电池壳体开孔，电解液共享腔室内腔和各个单体电池内腔的电解液区贯通后，还包括通过电解液共享腔室向各个单体电池内腔注入电解液，对整个大容量电池进行化成的步骤。
为了进一步地减小各个单体电池之间的差异性，单体电池装入半成品外壳步骤中，将多个分容分选后的单体电池排布在半成品外壳内。
进一步地，为了克服，当各个单体电池沿z方向的尺寸不完全相等，难以保证第三通孔与单体电池壳体之间(或第三通孔与极柱之间)密封性的问题，在密封步骤中，在第三通孔和极柱之间增设密封连接件，利用密封连接件将第三通孔对应的外壳区域与单体电池壳体固定密封；
密封步骤具体为：
将作为密封连接件中空构件的底部和单体电池的第一区域密封连接，第一区域为位于所述任一单体电池的上盖板中任一极柱周边的区域；
将第二盖板密封焊接在筒体顶部敞口端，各个单体电池极柱以及中空构件伸出第二盖板上对应第三通孔后，将中空构件的顶部与所述第二盖板的第二区域密封连接；所述第二区域为位于第二盖板上任一一个第三通孔对应的区域。
本申请的有益效果是：
本申请将多个单体电池置于一个外壳内部，外壳为分体结构，包括可以容纳多个单体电池的筒体，以及密封筒体敞口端的第一盖板和第二盖板，且 在第一盖板设有电解液共享腔室，利用该电解液共享腔室和位于外壳内的各个单体电池内腔的电解液区贯通，使得各单体电池电解液共享来保障各单体电池的一致性，即，将各单体电池的电解液腔连通，使所有单体电池的电解液处于同一体系下，减少了各单体电池电解液之间的差异，一定程度上提升了各单体电池之间的一致性，从而一定程度上提升了大容量电池的循环寿命。
本申请电解液共享腔室无需插接，在单体电池排布方向，无需考虑插接同轴问题，对加工精度以及装配精度要求较低；同时无需专用工装，装配过程较为简单，大大降低了此类具有共享体系大容量电池的加工难度及加工成本，可实现批量化生产。
另外，本申请可以将各个单体电池从筒体顶部敞口端放置在半成品外壳内腔，组装方便。
同时，本申请各个单体电池极柱伸出外壳顶部(此处外壳顶部，即为第二盖板，为了确保，整体外壳的密封性，需要将极柱与外壳之间的间隙密封)。相对于极柱位于外壳内部的结构，极柱散热效果较好；另外，当极柱伸出外壳后，若电池温度过高，还便于后期利用换热设备将极柱的热量及时导出，可以确保此类大容量电池运行在最佳温度。
附图说明
图1为背景技术中大容量电池结构示意图；
图2为实施例1大容量电池结构示意图；
图3为实施例1大容量电池爆炸示意图；
图4为实施例1中市售方壳电池结构示意图；
图5为实施例1中外壳结构示意图；
图6为实施例1中第一盖板的一种结构示意图；
图7为实施例1中第一盖板的另一种结构示意图；
图8为实施例1中第一盖板的另一种结构示意图(电解液共享腔室为管状)；
图9为实施例1中第二盖板结构示意图；
图10为实施例1中增设传热连接件后，大容量电池的结构示意图；
图11为实施例1中传热连接件的结构示意图；
图12为实施例2中第二盖板结构示意图；
图13为实施例3中外壳结构示意图；
图14为实施例4中筒体结构示意图；
图中附图标记为：
01、子管路；02、中间连接管；03、下盖板；
1、外壳；2、单体电池；4、筒体；5、第一盖板；6、第二盖板；7、电解液共享腔室；8、第二通孔；9、第三通孔；10、气体腔室；11、加强筋；13、传热连接件；14、中空箱体；15、隔板；
具体实施方式
为使本申请的上述目的、特征和优点能够更加明显易懂，下面结合说明书附图对本申请的具体实施方式做详细的说明，显然所描述的实施例是本申请的一部分实施例，而不是全部实施例。基于本申请中的实施例，本领域普通人员在没有做出创造性劳动前提下所获得的所有其他实施例，都应当属于本申请的保护的范围。
在下面的描述中阐述了很多具体细节以便于充分理解本申请，但是本申请还可以采用其他不同于在此描述的其它方式来实施，本领域技术人员可以在不违背本申请内涵的情况下做类似推广，因此本申请不受下面公开的具体实施例的限制。
在本申请的描述中，需要说明的是，术语中的“顶、底”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本申请和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本申请的限制。此外，术语“第一、第二、第三、第四”仅用于描述目的，而不能理解为指示或暗示相对重要性。
本申请所涉及的大容量电池，包括外壳及排布在外壳内的多个并联的单体电池；此处所述的单体电池可以为方壳电池，也可以为市售的多个并联的软包电池。各个单体电池内腔包括电解液区和气体区。
以下实施例主要以方壳电池作为单体电池进行详述。外壳结构以及各个单体电池在外壳内的具体排布方式可以根据具体需求设置，如当选用方壳电池作为单体电池时，外壳可以为方形壳体，各个单体电池可以沿外壳的长度 方向依次排布；外壳还可以为圆柱形中空壳体，各个单体电池可以沿外壳的周向排布，但是相对于方形壳体，方壳电池在圆柱形中空壳体内的稳定性较难保证，另外，由此类大容量电池形成的储能设备能量密度一般，但是该结构的大容量电池具有较好的散热性能。
从结构稳定性以及能量密度方面考虑，本申请优选方形壳体作为外壳。
本申请外壳可以采用以下几种结构形式，以矩形外壳为例：
一、外壳为分体结构，包括顶部和底部均敞口的筒体、第一盖板和第二盖板；
此类筒体结构可通过铝挤压方式成型：
首先采用铝挤压方式成型顶部和底部均敞口的筒体，之后加工具有电解液共享腔室的第一盖板，将第一盖板固定在筒体底部敞口端。
需要说明的是，在将单体电池置于筒体后，通过第二盖板密封筒体顶部敞口端(需要使得各个单体电池极柱伸出盖板)，以保证电解液不与外界接触。
筒体与第一盖板也可以为一体件，通常可采用铸造工艺一体成型；
二、外壳为分体结构，包括顶部和底部均敞口的筒体、第二盖板以及可以作为电解液共享腔室的中空箱体；
与第一种方案类似，此类筒体结构可通过铝挤压方式成型：
首先采用铝挤压方式成型顶部和底部均敞口的筒体，之后将中空箱体覆盖在筒体底部敞口端，并与该敞口端密封连接。
将单体电池置于筒体后，中空箱体内腔与各个单体电池内腔的电解液区连通，通过第二盖板密封筒体顶部敞口端(需要使得各个单体电池极柱伸出盖板)，以保证电解液不与外界接触。
三、与上述两种结构不同的是，该方案筒体采用四块矩形板焊接成型筒体，但是，由于焊缝较多，使得筒体的整体强度以及密封性相对较差。
以下结合附图及具体实施例对本申请做进一步地描述。
为了便于描述，以下实施例中将外壳长度方向定义为x方向，外壳宽度方向定义为y方向，外壳高度方向定义为z方向。
实施例1
如图2及图3所示，本实施例大容量电池，包括9个并联的单体电池2， 其他实施例中数量可根据实际需求进行调整。结合图4，该单体电池2为方壳电池，方壳电池包括上盖板、下盖板、筒体和电芯组件；此处所述电芯组件也可以称之为电极组件，由正极、隔膜、负极顺序排列，采用叠片或卷绕工艺装配而成。上盖板、筒体、下盖板组成了单体电池壳体，电芯组件设置在单体电池壳体内。
结合图5，本实施例外壳1为矩形外壳，包括顶部和底部为敞口端的截面为矩形的筒体4以及覆盖筒体4底部敞口端的第一盖板5及覆盖顶部敞口端的第二盖板6。第一盖板5上设有电解液共享腔室7。
第一盖板5可以采用不同的结构形式，但是需要保证将其覆盖筒体4底部敞口端时，其与筒体4底部敞口端连接部位的密封性，同时需要保证设置在第一盖板5上电解液共享腔室7的内腔和各个单体电池2内腔贯通。本实施例选用与筒体4底部敞口端形状相适配的平板作为第一盖板5，通过将第一盖板5与筒体4底部敞口端边沿焊接，确保二者之间的密封性。本实施例中为矩形筒体4，因此该平板为矩形平板，面积可以略大于筒体4底部敞口端面积，通过熔焊的方式将其固定在筒体4底部敞口端；面积也可以略小于筒体4底部敞口端面积，通过嵌焊的方式将其固定在筒体4底部敞口端。通过在各个单体电池2壳体底部开设贯通其内腔的第一通孔，确保电解液共享腔室7的内腔和各个单体电池2内腔贯通。
本实施例第一盖板5和电解液共享腔室7的结构可以为图5及图6所示结构，在第一盖板5上开设沿第一盖板5长度方向延伸的第一通道作为电解液共享腔室7。也可以采用折弯或铝挤压工艺，直接在第一盖板5成型第一通道，将第一盖板5内表面向远离第一盖板5内表面的方向凸起形成。
如图7所示，图5、图6和图7中的第一通道均向远离筒体顶部的方向凸起。需要说明的是，图7中电解液共享腔室7两端敞口需密封。
本实施例第一盖板5及电解液共享腔室7的结构还可以为图8所示结构，电解液共享腔室7为中空管，截面可以为矩形，也可以为圆形。与第一盖板5为一体件，与筒体4一样可以也采用铝挤压工艺成型该一体件。采用中空管作为电解液共享腔室7时，需要在管壁和第一盖板5上开设贯通电解液共享腔室7内腔的第二通孔8，使得电解液共享腔室7的内腔和各个单体电池2内 腔贯通。此处需要注意的是，第二通孔8可以为多个，且数量与各个单体电池2相等，各个第二通孔8与第一通孔一一对应且贯通；也可以直接在第一盖板5和电解液共享腔室7开设一个沿电解液共享腔室7长度方向延伸的长条状的第二通孔8，该第二通孔8的尺寸需要确保，当将第一盖板5焊接在筒体4底部敞口端时，使得该第二通孔8与所有单体电池2的第一通孔贯通。
本实施例还可以在电解液共享腔室7设有注液口，当各个单体电池2内腔和电解液共享腔室连通后，可以通过该注液口向各个单体电池2内腔和电解液共享腔室内再次注入电解液，以保证电解液的连续性，后期还可以通过该注液口实现换液。
需要说明的是，在不注液的情况，需要通过堵头对该注液口进行密封。
本实施例第二盖板6的结构如图9所示，第二盖板6上开设能够使各个单体电池2极柱伸出的第三通孔9；第二盖板6覆盖在所述筒体4顶部敞口端，并与该敞口端密封连接；优选第二盖板6的形状与筒体4顶部敞口端形状相适配，本实施例中为矩形筒体4，因此该平板为矩形平板，面积可以略大于筒体4顶部敞口端面积，通过熔焊的方式将其固定在筒体4顶部敞口端；面积也可以略小于筒体4顶部敞口端面积，通过嵌焊的方式将其固定在筒体4顶部敞口端。
本实施例的大容量电池可通过以下过程制备：
步骤一、加工外壳1，包括筒体4、带有电解液共享腔室7的第一盖板5、第二盖板6。
步骤二、将带有电解液共享腔室7的第一盖板5密封焊接在筒体4底部敞口端。
步骤三、分容分选，筛选满足要求的多个单体电池；在单体电池壳体底部开设第一通孔后利用密封组件密封；将多个第一通孔处具有密封组件的单体电池排布在步骤二的筒体4内；
若电解液共享腔室7为图5、图6及图7所示结构，则需使得具有密封组件的第一通孔与第一通道对应，确保利用外力或者电解液自身打开密封组件后，各个单体电池内腔电解液区和电解液共享腔室7贯通；
若电解液共享腔室7为管状的结构形式(图8所示结构)，则需使得密封 组件与第二通孔8对应，确保利用外力或者电解液自身打开密封组件后，各个单体电池内腔电解液区和电解液共享腔室7贯通；
密封组件可以采用中国专利CN218525645U、CN218525614U公开的密封组件。
步骤四、将第二盖板6密封焊接在筒体4顶部敞口端，各个单体电池2极柱伸出第三通孔9后，第三通孔9对应的外壳区域与单体电池2壳体固定密封，可以将第三通孔9边沿与极柱周边区域的单体电池壳体焊接实现密封；
若各个单体电池2沿z方向的尺寸不完全相等，部分z方向尺寸较小的单体电池2的壳体与大容量电池外壳可能存在虚焊甚至无法焊接的问题，而难以保证第三通孔9与单体电池壳体密封性。
为了克服此类问题，可以在第三通孔9的周边区域设置薄弱部，在焊接过程中，通过薄弱部的变形，补偿各个单体电池在z方向的尺寸差，使得所有单体电池2的极柱伸出第三通孔9。本实施例中的薄弱部可以为以第三通孔9中心为中心点，沿第三通孔9周边区域开设的环形凹槽。其他实施例中，薄弱部还可以为开设在第三通孔9周边区域的长条形凹槽。在其他实施例中，若存在类似的问题，即所有单体电池2极柱不能同时完全伸出第三通孔9，均可采用在第三通孔9周边区域增设薄弱部的方案来解决。
也可以在第三通孔9和极柱之间增设密封连接件，该密封连接件包括中空构件；该中空构件的底部用于和单体电池的第一区域密封连接，中空构件的顶部与所述第二盖板的第二区域密封连接；第一区域为位于所述任一单体电池的上盖板中任一极柱周边的区域；所述第二区域为位于第二盖板上任一一个第三通孔对应的区域。第三通孔对应的区域为第二盖板外表面上对应任一一个第三通孔的周边区域；或者第三通孔对应的区域为第三通孔孔壁。其中，极柱周边的区域即为极柱上绝缘密封垫周边的区域。该绝缘密封垫为单体电池上用于使极柱和上盖板之间绝缘的零件。
在其他实施例中，第一盖板5、第二盖板6与筒体4敞口端还可以采用粘接或者螺钉连接方式实现固定，但是相对于焊接的方式，密封性或连接可靠性相对较弱。
步骤五、利用外力或者电解液自身打开密封组件，电解液共享腔室7内 腔和各个单体电池内腔的电解液区贯通。
在各个单体电池2内腔和电解液共享腔室7贯通后，各个单体电池2内腔的电解液均通过电解液共享腔室7连通，为了防止出现电解液中断的现象，可以在各个单体电池2内腔和电解液共享腔室7贯通后，向电解液共享腔室7注入电解液来保证电解液的连续性。
之后将所有单体电池2并联。在其他实施例中，可以在步骤四和步骤五之间，将各个单体电池2并联。
具体可以采用图10和图11所示的传热连接件13将所有单体电池2并联，传热连接件13为一根细长构件，该细长构件用于和各个单体电池2的正极或负极连接；且，细长构件上沿着轴向方向设置有用于安装传热管的装夹部。通过传热连接件13将多个单体电池2的正极或负极连接起来，并且在传热连接件13上装夹传热管，可以对每个单体电池2上极柱局部温度的控制，大大降低极柱温度过高而导致热失控现象的发生。
为了形成了更完整的SEI膜,使大容量电池具有更稳定的循环能力，通过电解液共享腔室7向各个单体电池2内腔注入电解液后，对整个大容量电池进行化成。
实施例2
与实施例1不同的是，本实施例通过在第二盖板6上增设气体腔室10，作为气体共享腔室或者泄爆通道。
本实施例第二盖板6的结构与实施例1中第一盖板5的结构类似，气体腔室10可以为成型在第二盖板6上的第二通道，第二通道向远离筒体底部的方向凸起。该第二通道也可以采用折弯或铝挤压工艺与第二盖板6一体成型。
气体腔室10也可以为设置在第二盖板6上的中空管，可以与第二盖板6采用铝挤压工艺一体成型，其结构如图12所示。其他实施例中，第二盖板6与管状气体腔室10可以为分体结构，但是加工较为复杂。
气体腔室10作为气体共享腔室时，需要在各个单体电池2壳体顶部开设贯通单体电池2内腔的第五通孔；
当选用第二通道结构形式的气体腔室10时，将第二盖板6固定在筒体4顶部敞口端后，第二通道直接通过第五通孔与各个单体电池内腔的气体区连 通。
当选用中空管作为气体腔室10时，需要在管壁和第二盖板6上开设贯通气体腔室10内腔的第四通孔。将第二盖板6固定在筒体4顶部敞口端后，气体腔室10通过第四通孔和第五通孔与各个单体电池2内腔的气体区连通。此处需要注意的是，第四通孔可以为多个，且数量与各个单体电池2相等，各个第四通孔与第五通孔一一对应且贯通；也可以直接在第二盖板6和气体腔室10开设一个沿气体腔室10长度方向延伸的长条状的第四通孔，该第四通孔的尺寸需要确保，当将第二盖板6焊接在筒体4顶部敞口端时，使得该第四通孔与所有单体电池2的第五通孔贯通。
气体腔室10作为气体共享腔室时，可以在气体腔室10上设置排气阀和泄爆膜，或只设置排气阀；排气阀可手动或自动开启，定期开启排气阀，各单体电池2中气体区内的气体可经气体腔室10及排气阀后排出；当设置泄爆膜时，排气阀和泄爆膜位于气体腔室10的两端，泄爆膜用于在任意单体电池2发生热失控时，热失控烟气冲破泄爆膜排出中空构件，使得此类大容量电池具有较高的安全性能。
可通过以下过程制备：
需要在实施例1制备过程的基础上，在各个单体电池顶部开设第五通孔后利用密封组件密封；将多个第五通孔处具有密封组件的单体电池排布在筒体4内；将第二盖板6密封焊接在筒体4顶部敞口端，使得具有密封组件的第五通孔与第四通孔对应，确保利用外力或者电解液自身打开密封组件后，第五通孔与第四通孔贯通；密封组件可以采用中国专利CN218525645U、CN218525614U公开的密封组件，焊接第三通孔9边沿与极柱周边区域的单体电池2壳体部位，实现密封。最后利用外力或者电解液自身打开密封组件，气体腔室10内腔和各个单体电池内腔的气体区连通。
当气体腔室10作为泄爆通道时，气体腔室10覆盖各个单体电池2顶部泄爆部，当任一单体电池2泄爆部被内腔烟气冲破时，该单体电池2内腔的气体区和气体腔室10内腔连通。
可通过以下过程制备：
需要在实施例1制备过程的基础上，将第二盖板6密封焊接在筒体4顶 部敞口端，使得各个单体电池的泄爆部与气体腔室10对应，确保泄爆部被内腔烟气冲破后，该单体电池2内腔的气体区和气体腔室10内腔连通；焊接第三通孔9边沿与极柱周边区域的单体电池2壳体部位，实现密封。
需要说明的是，本实施例所述的泄爆部包括设置在单体电池2顶部的具有泄爆膜的泄爆口或防爆口，或设有泄爆阀的泄爆口等。
实施例3
与上述实施例不同的是，本实施例外壳1选用上述第二种结构形式，其结构如图13所示，包括筒体4、第二盖板6和作为电解液共享腔室的中空箱体14。
其中筒体4和第二盖板6的结构及成型方法与实施例1或实施例2相同，此处不在赘述；
中空箱体14覆盖在筒体4底部敞口端，其顶部与筒体4底部敞口端密封连接；可采用焊接方式连接，也可采用胶粘等连接方式，但是焊接相对密封性以及连接可靠性均较高，因此本实施例采用焊接的方式。
中空箱体14，为截面是矩形的中空箱体14，其顶部开设有与第一通孔贯通的第二通孔8，中空箱体14内腔通过第一通孔及第二通孔8与各个单体电池2内腔的电解液区连通；同上，第二通孔8可以为多个，且数量与各个单体电池2相等，各个第二通孔8与第一通孔一一对应且贯通；也可以直接在中空箱体14顶部开设一个沿中空箱体14长度方向延伸的长条状的第二通孔8，该第二通孔8的尺寸需要确保，当将中空箱体14焊接在筒体4底部敞口端时，使得该第二通孔8与所有单体电池2的第一通孔贯通。
其制备过程和上述实施例基本一致，此处不在赘述。
实施例4
本实施例在筒体4内腔设有多个隔板15，将筒体4内腔分割为多个单体电池2安装腔。
具体结构如图14所示，每个单体电池2安装腔内固定有一个单体电池2，靠近中间部位的每个单体电池2，其两侧的侧壁均和隔板15接触，靠近最外侧的两个单体电池2，其中一个侧壁和隔板15接触，另一侧壁和筒体4侧壁接触，第一方面可提高各个单体电池2在壳体内的安装稳定性；第二方面， 可以防止各个单体电池2鼓胀，而导致大容量电池循环性能降低的问题出现；第三方面，各个单体电池2充放电过程中产生的热量可以通过隔板15传输至外部，降低热失控发生的风险；第四方面还可以增强筒体4强度。
每个单体电池2安装腔内也可以固定有两个或两个以上的单体电池2。
隔板15和矩形筒体4可以一体挤压成型，当矩形筒体4沿x方向的长度较长、难以通过一次挤压完成时，可以先挤压两个或两个以上的子矩形筒体4，然后将各个子矩形筒体4拼接后焊接连接形成所需尺寸的矩形筒体4。针对实施例1中的大容量电池，可以挤压两个能够容纳五个单体电池2的子矩形筒体4，其中多出的一个单体电池2安装腔可以作为电解液储液仓使用。电解液储液仓与电解液共享腔室连通，用于给此类大容量电池内加注电解液。
为了确保外壳1的承重，可以从第二盖板6上方将第二盖板6与隔板15再次焊接。还可以在筒体4侧壁设有沿其高度方向延伸，长度方向排布的多条加强筋11，从图中可以看出，各个加强筋11位于单体电池2安装腔侧壁的中间位置。
另外，当设有隔板15时，可以取消不包括气体腔室的第二盖板6，将各个单体电池2上盖板边沿与各个单体电池2安装腔顶部敞口端密封焊接，使得筒体4顶部敞口端密封即可。

Claims (7)

  1. 一种大容量电池的制备工艺，其特征在于，包括以下步骤：
    加工外壳：
    加工半成品外壳，该半成品外壳包括相对两端敞口的筒体以及固定在筒体任一敞口端的第一盖板，第一盖板设有电解液共享腔室；
    加工用于固定在筒体另一敞口端的第二盖板，并在第二盖板加工与各个单体电池极柱对应的第三通孔；
    单体电池装入半成品外壳：
    将多个单体电池排布在半成品外壳内；
    密封：
    将第二盖板密封焊接在筒体另一敞口端，各个单体电池极柱伸出第二盖板上对应第三通孔后，将第三通孔对应的第二盖板区域与单体电池壳体固定密封；
    开包：
    利用外力或者电解液自身，在单体电池壳体开孔，使电解液共享腔室内腔和各个单体电池内腔的电解液区贯通。
  2. 根据权利要求1所述的大容量电池的制备工艺，其特征在于：
    加工第二盖板的步骤中，还包括：
    在第二盖板加工气体腔室；
    开包步骤中还包括：
    利用外力或者电解液自身，在单体电池壳体开孔，使气体腔室内腔和各个单体电池内腔的气体区贯通。
  3. 根据权利要求1或2所述的大容量电池的制备工艺，其特征在于：加工半成品外壳步骤中，采用铝挤压工艺一体成型相对两端敞口的筒体，采用铝挤压工艺或铸造工艺一体成型第一盖板，之后将第一盖板密封固定在筒体任一敞口端。
  4. 根据权利要求1或2所述的大容量电池的制备工艺，其特征在于：采用铸造工艺一体成型半成品外壳。
  5. 根据权利要求1或2所述的大容量电池的制备工艺，其特征在于：开包过程中，利用外力或电解液自身，在单体电池壳体开孔，电解液共享腔室内腔和各个单体电池内腔的电解液区贯通后，还包括通过电解液共享腔室向各个单 体电池内腔注入电解液，对整个大容量电池进行化成的步骤。
  6. 根据权利要求1或2所述的大容量电池的制备工艺，其特征在于，单体电池装入半成品外壳步骤中采用的多个单体电池为执行过分容分选后的单体电池。
  7. 根据权利要求1或2所述的大容量电池的制备工艺，其特征在于：密封步骤中，在第三通孔和极柱之间增设密封连接件，利用密封连接件将第三通孔对应的外壳区域与单体电池壳体固定密封；
    密封步骤具体为：
    将作为密封连接件中空构件的底部和单体电池的第一区域密封连接，第一区域为位于所述任一单体电池的上盖板中任一极柱周边的区域；
    将第二盖板密封焊接在筒体顶部敞口端，各个单体电池极柱以及中空构件伸出第二盖板上对应第三通孔后，将中空构件的顶部与所述第二盖板的第二区域密封连接；所述第二区域为位于第二盖板上任一一个第三通孔对应的区域。
PCT/CN2024/096988 2023-06-06 2024-06-03 一种大容量电池的制备工艺 Ceased WO2024251064A1 (zh)

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