Welding techniques for polymerized lithium ion battery cells and modules

• US 9,537,185 B2
• Filed: 12/27/2013
• Issued: 01/03/2017
• Est. Priority Date: 12/28/2012
• Status: Active Grant

• Current Assignee: CPS Technology Holdings, LLC
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Tyler, Matthew R., Obasih, Kem M.
• Primary Examiner(s): RYAN, PATRICK J
• Assistant Examiner(s): McConnell, Wyatt
• Application Number:
  US14/142,058
• Publication Number:
  US 20140186683A1
• Time in Patent Office: 1,103 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/1635 at least passing through one of the parts to be joined, i.e. laser transmission welding
• CPC Class Codes: B29C 66/1222 comprising at least a lapped joint-segment
• CPC Class Codes: B29C 66/1224 comprising at least a butt joint-segment
• CPC Class Codes: B29C 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• CPC Class Codes: B29L 2031/7146 Battery-cases
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/647 Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/655 Solid structures for heat exchange or heat conduction
• CPC Class Codes: H01M 10/6551 Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6554 Rods or plates
• CPC Class Codes: H01M 50/103 prismatic or rectangular H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/107 having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H01M 50/112 Monobloc comprising multiple compartments
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/121 Organic material
• CPC Class Codes: H01M 50/124 : having a layered structure
• CPC Class Codes: H01M 50/128 : with two or more layers of only inorganic material
• CPC Class Codes: H01M 50/141 : for protecting against humidity
• CPC Class Codes: H01M 50/16 : Organic material
• CPC Class Codes: H01M 50/169 : by welding, brazing or soldering
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/26 : Assemblies sealed to each other in a non-detachable manner
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 29/4911 : including sealing
• CPC Class Codes: Y10T 29/49115 : including coating or impregnating

Abstract

A lithium ion (Li-ion) battery cell includes a housing. The housing includes side walls coupled to and extending from a first portion of the housing to form an opening in the housing opposite the first portion of the housing. The housing includes an electrically nonconductive polymeric (e.g., plastic) material. An electrochemical cell element is disposed in the housing and immersed in electrolyte that is also disposed in the housing. The Li-ion battery cell also includes a cover including an electrically nonconductive polymeric material. The cover is disposed over the opening in the housing and sealed to the housing via a seal. The seal is configured to resist or prevent ingress of moisture into the housing and to resist or prevent egress of the electrolyte from the housing.

Claims

1. A method for manufacturing a lithium ion (Li-ion) battery cell, comprising:

disposing a Li-ion electrochemical cell element into a housing through an opening in a bottom of the housing opposite to terminal openings in a top of the housing, wherein the housing comprises a side wall coupled to and extending from the top of the housing to form the opening in the bottom of the housing, wherein the housing comprises an electrically nonconductive polymeric material;

disposing a cover over the opening in the bottom of the housing such that a first ridge extending along the side wall of the housing contacts a plurality of second ridges oriented substantially perpendicular to the first ridge and disposed on the cover, wherein the cover comprises an electrically nonconductive polymeric material; and

sealing the cover to the housing via a weld, wherein the weld is configured to resist or prevent ingress of moisture into the housing and to resist or prevent egress of electrolyte from the housing.

2. The method of claim 1, wherein sealing the cover to the housing via the weld comprises laser welding the cover to the housing, wherein the cover comprises a transmissive material configured to allow light from a laser to pass therethrough, and wherein the housing comprises an absorptive material configured to absorb the light transmitted through the transmissive material of the cover such that the cover melts into the housing to form the weld.

3. The method of claim 1, wherein sealing the cover to the housing via the weld comprises laser welding the cover to the housing, wherein the housing comprises a transmissive material configured to allow light and heat from a laser to pass therethrough, and wherein the cover comprises an absorptive material configured to absorb the light and heat transmitted through the transmissive material of the housing such that the housing melts into the cover to form the weld.

4. The method of claim 1, wherein sealing the cover to the housing via a weld comprises ultra-sonic welding.