Electrical battery assembly and method of manufacture

• US 20030091893A1
• Filed: 08/15/2002
• Published: 05/15/2003
• Est. Priority Date: 10/18/2001
• Status: Active Grant

• Current Assignee: Quallion, LLC (EnerSys)
• Original Assignee: Quallion, LLC (EnerSys)
• Inventors: Tsukamoto, Hisashi, Kishiyama, Clay, Szyszkowski, Andrew
• Granted Patent: US 7,070,881 B2
• Time in Patent Office: Days
• US Class Current: 429/94
• CPC Class Codes: A61N 1/378 Electrical supply
• CPC Class Codes: H01M 10/0431 Cells with wound or folded electrodes H01M10/045 takes precedence
• CPC Class Codes: H01M 4/661 Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/70 characterised by shape or form
• CPC Class Codes: H01M 50/119 Metals
• CPC Class Codes: H01M 50/176 for prismatic or rectangular cells H01M50/181 takes precedence
• CPC Class Codes: H01M 50/186 characterised by the disposition of the sealing members
• CPC Class Codes: H01M 50/191 Inorganic material
• CPC Class Codes: H01M 50/469 tubular or cylindrical
• CPC Class Codes: H01M 50/55 on the same side of the cell
• CPC Class Codes: H01M 50/553 Terminals adapted for prismatic, pouch or rectangular cells
• CPC Class Codes: H01M 50/562 characterised by the material
• 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 29/49114 including adhesively bonding

Abstract

The invention provides electrical storage battery assemblies and related methods for assembling such batteries. A battery assembly includes positive and negative electrode sheets and separator sheets sandwiched together and wrapped around a central mandrel to provide a spiral sandwich electrode assembly. The electrode assembly is housed inside a case that includes a case housing open at two ends and covers closing the two openings. The central mandrel of the electrode assembly is in electrical contact with one of the electrode sheets and a first battery terminal that passes through the case. A projecting member on the central mandrel provides the electrical connection between the electrode and the first battery terminal. The other electrode is in electrical contact with the case. A first insulator lies between the electrode assembly and the projecting member. A second insulator is positioned between the projecting member and the case.

Claims

1. An electrical storage battery comprising:

a case defining an internal volume therein, said case comprising a material chosen from the group consisting of stainless steel, titanium and alloys thereof;

an electrode assembly disposed inside said internal volume of said case, said electrode assembly comprising;

at least a first electrode member comprising;

an aluminum substrate; and

an active material coated on said substrate;

a tab electrically and mechanically attached to said first electrode member,

wherein said tab comprises a material chosen from the group consisting of stainless steel, titanium and alloys thereof;

at least a second electrode member of opposite polarity to said first electrode member;

a separator member physically separating the positive and negative electrode members from one another; and

an electrolyte;

wherein said tab is electrically and mechanically attached to said case.

2. The electrical storage battery of claim 1, wherein said first electrode member, said second electrode member, and said separator are disposed in a spiral configuration such that said electrode assembly is a jellyroll having said tab protruding from said jellyroll.

3. The electrical storage battery of claim 1, and further including a battery terminal pin, where said battery terminal pin is part of a plug, and wherein said plug seals and electrically couples with said case.

4. An electrical storage battery made by the steps of:

providing at least a first electrode member,

ultrasonically welding a tab to said first electrode member;

providing at least a second electrode member of opposite polarity from said first electrode member;

providing a separator;

assembling an electrode assembly by physically separating said first and second electrode members from one another with said separator but allowing electrical contact between said first and second electrode members through an electrolyte, wherein said tab protrudes from said electrode assembly;

enclosing said electrode assembly in a case;

welding said tab to said case after enclosing said electrode assembly in said case;

placing an electrolyte inside said case; and

sealing said case.

5. The electrical storage battery of claim 4 wherein said welding said tab to said case comprises resistance welding said tab to said case.

6. The electrical storage battery of claim 4 wherein said welding said tab to said case comprises laser welding said tab to said case.

7. The electrical storage battery of claim 4 wherein said first electrode member comprises a metal substrate of a different material from said tab.

8. The electrical storage battery of claim 4 wherein said first electrode member comprises a metal substrate, and wherein said substrate is thinner and has a lower resistivity than said case.

9. The electrical storage battery of claim 4, wherein said first electrode member comprises an aluminum substrate coated with an active material and wherein said tab material is chosen from the group consisting of stainless steel and titanium and alloys thereof.

10. The electrical storage battery of claim 4, wherein said first electrode member, said second electrode member, and said separator are disposed in a spiral configuration such that said electrode assembly is a jellyroll having said tab protruding from said jellyroll.

11. The electrical storage battery of claim 4 wherein said steps further include the step of sealing said case with a plug comprising a battery terminal pin, whereby said pin is electrically coupled to said case.

12. A method for making an electrical storage battery, comprising the steps of:

providing at least a first electrode member,

ultrasonically welding a tab to the first electrode member;

providing at least a second electrode member of opposite polarity from the first electrode member;

providing a separator;

assembling an electrode assembly by physically separating the first and second electrode members from one another with said separator but allowing electrical contact between the first and second electrode members through an electrolyte, wherein the tab protrudes from the electrode assembly;

enclosing the electrode assembly in a case;

welding the tab to the case after enclosing the electrode assembly in the case;

placing an electrolyte inside the case; and

sealing the case.

13. The method of claim 12 wherein said welding said tab to said case comprises resistance welding said tab to said case.

14. The method of claim 12 wherein said welding said tab to said case comprises laser welding said tab to said case.

15. The method of claim 12 wherein said step of providing a first electrode member comprises providing an electrode member comprising a metal substrate of a first material and wherein said step of ultrasonically welding a tab comprises ultrasonically welding a tab comprising a second material different from said first material.

16. The method of claim 12, wherein said step of providing a first electrode member comprises providing a first electrode member comprising metal substrate having a first resistivity, and wherein said step of ultrasonically welding a tab to the first electrode member comprises ultrasonically welding a tab having a second resistivity different from said first resistivity.

17. The method of claim 12, wherein said step of providing at least a first electrode member comprises providing an aluminum substrate coated with an active material and wherein said step of ultrasonically welding a tab to the first electrode member comprises ultrasonically welding a tab made from a material chosen from the group consisting of stainless steel and titanium and alloys thereof.

18. The method of claim 12, wherein said assembling step comprises disposing the first electrode member, the second electrode member, and the separator in a spiral configuration to form a jellyroll having the tab protruding from the jellyroll.

19. The method of claim 12, and further including the step of sealing the case with a plug comprising a battery terminal pin, whereby the pin is electrically coupled to the case.

20. An electrical storage battery comprising:

a case defining an internal volume therein;

a spiral sandwich member disposed inside the internal volume of the case, the spiral sandwich member comprising;

a positive electrode member;

a negative electrode member;

a separator member physically separating the positive and negative electrode members from one another;

an electrolyte; and

a central support member;

wherein the positive electrode, the negative electrode, and the separator are disposed in a spiral configuration around the central support member;

wherein one electrode of the positive and negative electrodes is electrically connected to said central support member and further including a battery terminal coupled to said central support member by a flexible projecting member attached to or integral with the central support member.

21. The electrical storage battery of claim 20, wherein said flexible projecting member includes a hole, and wherein said battery terminal comprises a pin extending through said hole.

22. The electrical storage battery of claim 20, wherein said flexible projecting member includes a tab, and wherein said battery terminal comprises a pin welded to said tab.

23. The electrical storage battery of claim 20, wherein said flexible projecting member includes a tab and a hole, and wherein said battery terminal comprises a pin extending through said hole and welded to said tab.

24. The electrical storage battery of claim 20, wherein the case comprises an electrically conductive case housing and an electrically conductive case cover, and further comprising:

a case-to-electrode insulator disposed between said electrode assembly and said case.

25. The electrical storage battery of claim 20, wherein the case comprises an electrically conductive case housing and an electrically conductive case cover, and further comprising:

a projecting member-to-electrode insulator disposed between said electrode assembly and said case cover wherein said electrically conductive projecting member extends through said second insulator.

26. The electrical storage battery of claim 20, wherein the case comprises an electrically conductive case housing and an electrically conductive case cover, and further comprising:

a case cover-to-projecting member insulator disposed between said flexible projecting member and said case cover;

wherein said battery terminal extends through said case cover-to-projecting member insulator.

27. The electrical storage battery of claim 25, wherein the case comprises an electrically conductive case housing and an electrically conductive case cover, and further comprising:

a case cover-to-projecting member insulator disposed between said flexible projecting member and said case cover;

wherein said battery terminal extends through said case cover-to-projecting member insulator.

28. An electrical storage battery made by the steps of:

providing a central support member;

assembling a spiral sandwich member around the central support member, wherein the spiral sandwich member comprises;

at least one positive electrode member;

at least one negative electrode member; and

a separator member physically separating the positive and negative electrode members from one another but allowing ionic contact between the positive and negative electrode members through an electrolyte;

enclosing the assembled spiral sandwich member in a case;

placing an electrolyte inside the case;

electrically connecting one electrode member of the positive and negative electrode members to a first battery terminal through structure on the central support member; and

sealing the case.

29. The electrical storage battery of claim 28, wherein said electrically connecting step comprises extending a pin of the battery terminal through a hole in the flexible projecting member.

30. The electrical storage battery of claim 28, wherein said electrically connecting step comprises welding a pin of the battery terminal to a tab portion of the flexible projecting member.

31. The electrical storage battery of claim 28, said electrically connecting step comprises extending a pin of the battery terminal through a hole in the flexible projecting member and welding the pin of the battery terminal to a tab portion of the flexible projecting member.

32. The electrical storage battery of claim 28, and wherein said steps further comprise:

providing a case-to-electrode insulator between said spiral sandwich member and said case.

33. The electrical storage battery of claim 28, and wherein said steps further comprise:

providing a projecting member-to-electrode insulator between said case cover and said electrode assembly.

34. The electrical storage battery of claim 28, and wherein said steps further comprise:

providing a case cover-to-projecting member insulator between said projecting member and said case cover.

35. The electrical storage battery of claim 33, and wherein said steps further comprise:

providing a case cover-to-projecting member insulator between said projecting member and said case cover.

36. A method for assembling an electrical storage battery, the method comprising:

providing a central support member;

assembling a spiral sandwich member comprising;

at least one positive electrode member;

at least one negative electrode member; and

a separator member physically separating the positive and negative electrode members from one another but allowing ionic contact between the positive and negative electrode members through an electrolyte;

enclosing the assembled spiral sandwich member in a case;

placing an electrolyte inside the case;

electrically connecting one electrode member of the positive and negative electrode members to a first battery terminal through a flexible projecting member on the central support member; and

sealing the case.

37. The method of claim 36, wherein said electrically connecting step comprises:

bending the flexible projecting member away from the electrode members;

welding the flexible projecting member to the first battery terminal; and

compressing the flexible projecting member into the case.

38. The method of claim 36, wherein said electrically connecting step comprises extending a pin of the battery terminal through a hole in the flexible projecting member.

39. The method of claim 36, wherein said electrically connecting step comprises welding a pin of the battery terminal to a tab portion of the flexible projecting member.

40. The method of claim 36, said electrically connecting step comprises extending a pin of the battery terminal through a hole in the flexible projecting member and welding the pin of the battery terminal to a tab portion of the flexible projecting member.

41. The method of claim 36, and further comprising:

providing a case-to-electrode insulator between the spiral sandwich member and the case.

42. The method of claim 36, and further comprising:

providing a projecting member-to-electrode insulator between the case cover and the electrode assembly.

43. The method of claim 36, and further comprising:

providing a case cover-to-projecting member insulator between the projecting member and the case cover.

44. The method of claim 42, and further comprising:

providing a case cover-to-projecting member insulator between the projecting member and the case cover.

45. An electrical storage battery comprising:

an electrically conductive case housing defining an internal volume inside said case housing and first and second openings into said case housing;

an electrode assembly disposed inside said internal volume of said case housing, said electrode assembly comprising;

at least one positive electrode member;

at least one negative electrode member;

at least one separator member physically separating said positive and negative electrode members from one another; and

an electrolyte;

an electrically conducting case bottom in electrical contact with said case housing and positioned to cover said first opening;

a first insulator disposed between said first case housing opening and said electrode assembly;

a second insulator disposed between said electrode assembly and said second case housing opening;

an electrically conductive projecting member electrically coupled to one of said positive and negative electrode members of said electrode assembly and extending through said second insulator;

a battery terminal electrically connected to said projecting member;

an electrically conducting case cover in electrical contact with said case housing and positioned to cover said second opening in said case housing;

a third insulator disposed between said projecting member and said case cover; and

a central support member, wherein said positive electrode, said negative electrode, and said separator are disposed in a spiral configuration around said central support member, and wherein said electrically conductive projecting member is electrically coupled to said one of said positive and negative electrode members of said electrode assembly via said central support member;

wherein said first battery terminal extends through an opening in said case cover.

46. The electrical storage battery of claim 45, wherein the other of said positive and negative electrode members is electrically coupled to said case housing.

47. The electrical storage battery of claim 46, and further comprising a second battery terminal in electrical contact with said case cover.

48. The electrical storage battery of claim 47, wherein said second battery terminal is part of a plug that seals said opening in said case cover.

49. An electrical storage battery made by the steps of:

providing an electrode assembly comprising;

at least one positive electrode member;

at least one negative electrode member; and

at least one separator member physically separating the positive and negative electrode members from one another but allowing electrical contact between the positive and negative electrode members through an electrolyte;

enclosing the electrode assembly in an electrically conductive case;

connecting one of the positive and negative electrode members to a first battery terminal through an electrically conductive member connected between the electrode member and the first battery terminal;

providing a first insulator between the electrode assembly and the electrically conductive member connected between the electrode member and the first battery terminal;

providing a second insulator between the case and the electrically conductive member connected between the electrode member and the first battery terminal;

placing an electrolyte inside the case; and

sealing the case.

50. The electrical storage battery of claim 49, wherein said step of providing an electrode assembly comprises providing said positive electrode, said negative electrode, and said separator disposed in a spiral configuration.

51. The electrical storage battery of claim 49, and wherein said steps further comprise:

providing a central support member;

wherein said step of providing an electrode assembly comprises providing said positive electrode, said negative electrode, and said separator in a spiral configuration around said central support member; and

wherein said step of connecting one of the positive and negative electrode members to a first battery terminal comprises connecting an electrically conductive projecting member to said one of said positive and negative electrode members and to said central support member.

52. The electrical storage battery of claim 49, and wherein said steps further comprise:

providing a second battery terminal; and

electrically connecting the second battery terminal to the case.

53. The electrical storage battery of claim 52, wherein said step of placing an electrolyte inside the case comprises placing said electrolyte through a filling hole in said case, and wherein said step of providing the second battery terminal includes providing a fill plug physically attached to the second battery terminal, and wherein sealing the case includes installing the fill plug into said filling hole.

54. The electrical storage battery of claim 49, wherein said step of sealing the case includes:

installing a case cover onto a case housing; and

installing a plug into an opening in the case cover.

55. A method for assembling an electrical storage battery, the method comprising:

providing an electrode assembly comprising;

at least one positive electrode member;

at least one negative electrode member; and

at least one separator member physically separating the positive and negative electrode members from one another but allowing electrical contact between the positive and negative electrode members through an electrolyte;

enclosing the electrode assembly in an electrically conductive case;

electrically connecting one of the positive and negative electrode members to the case;

electrically isolating a first battery terminal from the case;

connecting the other of the positive and negative electrode members to the first battery terminal through an electrically conductive member connected between the electrode member and the first battery terminal;

providing a first insulator between the electrode assembly and the electrically conductive member connected between the electrode member and the first battery terminal;

providing a second insulator between the case and the electrically conductive member connected between the electrode member and the first battery terminal;

placing an electrolyte inside the case; and

sealing the case.

56. The electrical storage battery of claim 55, wherein said step of providing an electrode assembly comprises providing the positive electrode, negative electrode, and separator disposed in a spiral configuration.

57. The electrical storage battery of claim 55, and wherein said steps further comprise providing a central support member;

wherein said step of providing an electrode assembly comprises providing the positive electrode, negative electrode, and separator in a spiral configuration around the central support member; and

wherein said step of connecting one of the positive and negative electrode members to a first battery terminal comprises connecting an electrically conductive projecting member to one of the positive and negative electrode members and to the central support member.

58. The method of claim 55, and further comprising:

providing a second battery terminal; and

electrically connecting the second battery terminal to the case.

59. The method of claim 58, wherein placing an electrolyte inside the case comprises placing an electrolyte through a filling hole in the case, and wherein providing the second battery terminal includes providing a fill plug physically attached to the second battery terminal, and wherein sealing the case includes installing the fill plug into the filling hole.

60. The method of claim 55, wherein sealing the case includes:

installing a case cover onto a case housing; and

installing a plug into an opening in the case cover.

61. An electrical storage battery made by the steps of:

providing an electrode assembly comprising at least one positive electrode, at least one negative electrode, and at least one separator between the electrodes;

installing the electrode assembly inside a case housing open at two ends;

closing a first end of the case housing with a first cover, wherein an insulator isolates at least one of the electrodes from the first cover;

electrically coupling one of the positive and negative electrodes with the case housing;

electrically coupling the other of the positive and negative electrodes to a first battery terminal;

electrically insulating the first battery terminal from the case housing;

closing the second end of the case housing with a second cover having an electrolyte filling hole;

placing an electrolyte inside the case through the electrolyte filling hole;

sealing the electrolyte filling hole with a plug member in electrical contact with the case housing, wherein the plug member includes a battery terminal pin.

62. The electrical storage battery of claim 61, wherein said sealing step comprises sealing the electrolyte filling hole with a tapered plug member.

63. The electrical storage battery of claim 61, wherein said steps further include:

providing a central member; and

wrapping an electrode assembly comprising said at least one positive electrode, at least one negative electrode, and at least one separator around the central member.

64. A method for assembling an electrical storage battery, the method comprising:

providing an electrode assembly comprising at least one positive electrode, at least one negative electrode, and at least one separator between the electrodes;

installing the electrode assembly inside a case housing open at two ends;

closing a first end of the case housing with a first cover, wherein an insulator isolates at least one of the electrodes from the first cover;

electrically coupling one of the positive and negative electrodes to the case housing;

electrically coupling the other of the positive and negative electrodes to a first battery terminal;

electrically insulating the first battery terminal from the case housing;

closing the second end of the case housing with a second cover member having an electrolyte filling hole;

placing an electrolyte inside the case through the electrolyte filling hole;

sealing the electrolyte filling hole with a plug member in electrical contact with the case housing, wherein the plug member includes a battery terminal pin.

65. The method of claim 64, wherein said sealing step comprises sealing the electrolyte filling hole with a tapered plug member.

66. The method of claim 64, and further including the steps of:

providing a central member; and

wrapping an electrode assembly comprising the at least one positive electrode, at least one negative electrode, and at least one separator around the central member.

67. A method for producing a battery case comprising:

providing a block of Ti-6A1-4V;

removing material to form an outer shape having two opposing ends;

hollowing out the shaped block from one end partway through to the other end;

hollowing out the shaped block from the other end to form a through hole with the first hollowed out end.

68. The method as in claim 67 wherein said removing step comprises machining.

69. The method as in claim 67 wherein said removing step comprises EDM.

70. The method as in claim 67 wherein said hollowing steps comprise machining.

71. The method as in claim 67 wherein said hollowing steps comprise EDM.

72. The method as in claim 67 wherein said removing step comprises forming a noncylindrical outer shape.