STARWHEEL-ENABLED ASSEMBLING OF LONG-LIFE BATTERIES

Abstract

system and method for assembling tong-life cylindrical batteries. Assembly comprises use of jelly rolls of battery materials comprised of fold over tabs at end plate periphery, said tabs useful to maintaining relatively short electron paths and to maintaining electrical connections, to benefit of long useful life of battery. In a preferred embodiment, at least one starwheel enables movement and positioning of cylindrical battery cases during assembly. In a preferred embodiment, such correct positioning of battery cases enables them to receive placement of jelly roll of battery materials and to receive battery caps. Assembly comprises use of jelly rolls of battery materials comprising end plates configured of extensions of electrode in face-to-face shingle-style overlaps. Said tight overlaps, held in place by tabs, enable secure electrical connections to be maintained over long life of battery, and comprise mitigation against overheating of battery during rapid charge or discharge, thus reducing likelihood of fire.

Claims

1-20. (canceled)

21. A system for assembling finished batteries from battery parts, said system comprising at least one mechanism at least consistent with derivation/adaptation from automated industrial bottling systems and mechanisms, said at least one derived/adapted battery assembling mechanism of list: capping chuck automatically positioned to automatically cap battery case; at least one capping chuck coordinated in timing to correct cap-receiving position of battery case; automated feeding of battery parts into at least one battery assembly line; computer control of at least one of gears, motorized drives, and automated mechanisms for battery assembly; automatic movement of at least one battery case into desired position for assembly, said moving comprising rotary motion of at least one starwheel; at least one battery case coordinated to automatic receipt of insertion of jelly roll of battery materials; continuous motion assembly sequence automated for at least one battery case, during which sequence case moves to enable automatic attachment of battery cap; at least a first battery part induced to mutual coordinated motion to align with at least a second battery part in enabling automatic assembly; battery cap automatically induced to attachment to battery case, such attachment enabled by one of list: adhesive, pressure/snap-on motion, swivel/twist-on motion, receiving groove; battery parts in automated transit during battery assembly, said transit comprising sensor control; sensors verifying automated steps during battery assembly; multiple lines of battery parts supply configured and arranged in automated assembly, comprising computer control of battery caps, and battery cases; coordination mechanism for enabling placement of jelly rolls of battery materials into battery cases, said mechanism of coordination comprising at least one mechanism derivable from liquid filling line mechanisms of bottling industry; coordination mechanism for enabling capping of battery cases, said mechanism of coordination derivable from bottle-capping mechanism in bottling industry; battery parts automated motion comprising use of interacting starwheels.

22. The system of claim 21, further comprising at least one said derived/adapted mechanism of list: battery case in correct position to enable insertion of jelly roll of battery materials, battery case in correct position to enable capping, functions of filling, and capping coordinated to progressive movement of battery cases. finished batteries delivery to collecting point, accomplishment of filling of battery cases as line of battery cases continues to move, in-line capping mechanism for rendering capping of battery cases, feed of part coordinated with in-line mechanisms of assembly of batteries, in-line mechanisms serving jelly roll filling and cap-attaching actions, said mechanisms movable in coordination to movement of cases within moving line, moving line of battery cases aligned to an in-line filler mechanism dispensing jelly rolls, moving line of battery cases aligned to in-line capping mechanism.

23. The system of claim 22, further comprising at least one of battery assembly mechanism at least consistent with adaptation/derivation from bottle industry filling system mechanism, and at least one battery assembly mechanism at least consistent with adaptation/derivation from bottle industry capping system mechanism.

24. The system of claim 23, further comprising use in personal device of at least one finished battery of instant invention assembly line production.

25. The system of claim 24, further comprising said personal device use applied to at least one of energy storage use and home use.

26. The system of claim 23, further comprising at least one jelly roll of battery materials wound by motorized bobbin.

27. The system of claim 23, further comprising at least one supplier to said finished battery assembling from battery parts system, said supplier providing at least one support item of list: operations support for assembling batteries from parts, management support for assembling batteries from parts, logistical support for assembling batteries from parts, parts supply support for assembling batteries from parts, financial support for battery assembly from parts, construction support for assembling batteries from parts, marketing support for assembling batteries from parts.

28. A method for assembling finished batteries from battery parts, said method comprising at least one step at least consistent with step derivation/adaptation from method/step used in bottling industry, said at least one derived/adapted step for battery assembly of list: positioning at least one battery case correctly for capping under capping chuck; causing at least one capping chuck to correctly place battery cap on positioned battery case; using reservoirs, bins and feeding chutes to enable timely feeding of battery parts into battery assembly line; using gears, motorized drives, and control mechanisms for battery assembly under computer control; using rotary motion of at least one starwheel to move battery case after battery case into position for respective filling; moving continuously at least one battery case during assembly line sequence wherein case receives insertion of jelly roll of battery materials; moving continuously at least one battery case during assembly line sequence wherein case receives attachment of battery cap; maneuvering a battery cap in mutual coordination to automated positioning of battery case it will cap; comprising battery cap placement of use of at least one of list: adhesive, pressure/snap-on motion, swivel/twist-on motion, receiving groove; moving battery parts during battery assembly, said moving comprising sensor-related control; using sensors to verify automated steps during battery assembly; configuring and arranging multiple lines of battery parts supply comprising at least battery caps, and battery cases, the functioning of such supply lines comprising use of at least one computer; coordinating placing jelly rolls of battery materials into battery cases, comprising at least one coordinating mechanism derivable from at least one filling-associated coordinating mechanism comprised in at least one bottling industry automated assembly line; coordinating capping of battery cases during battery assembly, comprising at least one coordinating mechanism derivable from at least one capping-associated coordinating mechanism comprised in at least one bottling industry automated assembly line; moving battery parts comprising use of interacting starwheels; moving battery cases to progressively align said cases for each being filled with a jelly roll of battery materials; moving battery cases, each containing a jelly roll of battery materials, to progressively align for capping.

29. The method of claim 28, further comprising at least one step of list: positioning battery case after battery case into correct position to enable insertion of jelly roll, aligning case with jelly roll filling position, aligning case with capping position, filling, and capping occurs in coordination to progressive movement of battery cases; delivering finished batteries to collecting point, filling and capping of battery cases, accomplished as line of battery cases continues to move, arranging assembly line for case filling and capping by use of in-line filling mechanism and in-line capping mechanism, feeding of battery part coordinated with in-line motion of partially assembled batteries, completing filling with jelly roll of battery materials and capping with caps of moving battery cases, said moving towards the collection point, affixing of caps onto battery cases accomplished comprising a moving line of battery cases aligned to in-line capping mechanism.

30. The method of claim 29, further comprising a step of using at least one of bottling industry filling method derived/adapted to use for battery assembly, and at least one bottling industry capping method derived/adapted to use for battery assembly.

31. The method of claim 30, further comprising a step of using in personal device at least one finished battery of instant invention assembly line production.

32. The method of claim 31, further comprising a step wherein said personal device use comprises at least one of use for energy storage and home use.

33. The method of claim 30, further comprising a step of winding at least one jelly roll of battery materials, said winding comprising use of motorized bobbin.

34. The method of claim 30, further comprising a step of supplying support for said battery assembly, said supplying comprising at least one of list: operations support for said assembling batteries from parts, management support for said assembling batteries from parts, logistical support for said assembling batteries from parts, parts supply support for said assembling batteries from parts, financial support for said assembling batteries from parts, construction support for said assembling batteries from parts, marketing support for said assembling batteries from parts.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0026] Other features and advantages of the present invention will become apparent when the following detailed description is read in conjunction with the accompanying drawings, in which:

[0027] FIG. 1 is a schematic illustrating details of a preferred embodiment.

[0028] FIG. 2 is a schematic illustrating details of a preferred embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0029] In FIG. 1, a schematic illustrates a preferred embodiment of instant invention wherein elements of, and coordination of, assembly line for assembling long-life batteries are schematically represented. First representation, at top left of drawing, comprises a stack of four representative jelly rolls of battery materials 109. Said four rolls represent the reservoir of this element feeding the assembly process, i.e. a line of jelly rolls rendered into alignment, such as one at a time, to be inserted into battery cases by the insertion mechanism, here represented by plunger 107. It is understood that the supporting structures, such as frame of metal scaffolding and bins and feeding chutes, and the like, are present and configured to purpose as is well-known in the art. It is understood that gears and motorized drives are also present, along with control mechanisms and optionally with computer control, as is well-known in the bottling industry and herein modified to purpose of battery assembly.

[0030] Each jelly roll comprises at least one end plate. Each end plate comprises extensions of electrode, here viewed in end on perspective schematic, in format representing compact face-to-face shingle style overlap of said extensions. End plate also comprises plurality of folded over tabs at periphery (see FIG. 2 for details of end plate).

[0031] The stack of jelly rolls is aligned to permit lowest roll of stack to be acted upon by plunger 107, which plunger represents one of several well-known inserting mechanisms useful (not shown) within instant invention assembly lines, wherein a first element (jelly roll) is propelled at proper time and inserted into a second element (battery case). Insertion is timed in relation to stop and go motion of starwheel 101.

[0032] Said starwheel 101 comprises machined plastic wheel on axis, enabled by system control to perform timed counterclockwise rotary stop and go motion. Starwheel 101 comprises notches 103 and 102, suitable to hold battery cases 105 and 104, respectively. The starwheel's rotary motion in a stop and go movement is understood to move case after case into position for filling and capping.

[0033] In this illustration, starwheel 101 is in a stop position wherein the battery case 105 is positioned to receive insertion of jelly roll from stack 109, and the battery case 104 having jelly roll inside, is positioned to receive attachment of battery cap 106. Said stop position of starwheel 101 was reached after the previous go motion of wheel rotated counterclockwise one notch-worth of rotary motion. Said one notch-worth of rotary motion positioned the notch 103 occupant battery case 105 to be in position to receive a jelly roll. Said same one notch-worth of starwheel counterclockwise rotation also positioned the notch 102 occupant battery case 104 to be in position to receive a cap.

[0034] Thus, it is understood that the stop and go one-notch at a time rotary motion of preferred embodiment starwheel 101, said motion positions battery case after battery case into correct position to enable said insertion of jelly roll and then said capping to occur to each battery case in turn. Plunger 107 represents the mechanism of inserting. Plunger 108 represents the mechanism of capping.

[0035] Battery cap 106 represents the reservoir of battery caps and the mechanism of positioning cap to enable capping mechanism to attach it to case. The position illustrated for battery cap 106, i.e. over case 104 located in notch 102, this coordinated positioning represents the timing of cap reservoir and feed mechanism to position a cap in coordination to starwheel 101 rotary motion. Thus, it is understood that a cap, rendered into position for capping case 104, such action is timed to occur as the starwheel rotary motion counterclockwise renders battery case 104 into stopped position suitable to receive said cap 106.

[0036] Battery cap attachment represented is understood to be accomplished and secured in place by one of a variety of well-known in the art means of attaching. For example, said attachment can comprise use of adhesive, or a mechanism of ‘snap-on’ type wherein cap secures to snap-receiving mechanism at the battery case, or a twist-on mechanism wherein plunger grips and swivels the cap onto a receiving groove of the battery case, or spot welding mechanism (not shown). It is understood that the cap attaching step can be a separate notch position step from the cap placing.

[0037] The control mechanism for timing, and the power supply which enable the mechanisms herein illustrated, these are accomplished by means well-known in the art (not shown). For example, the power supply is typically electric grid supply, and the movements are enabled by computer control of gears and the use of sensors to verify steps.

[0038] As starwheel rotates a further notch-worth from the position illustrated in FIG. 1, it is understood that case 105 next stops at capping position, and receives a cap. It is understood that case 104 moves in radial movement within notch 102 until said case 104 reaches the exit point for movement of case off starwheel 101 and on to next part of assembly sequence. Said next part of sequence can be as a second interacting starwheel which removes case 104 from its notch in starwheel 101 and takes it into notch of said second starwheel. Such second starwheel can transfer, via its radial moving of case 104, said case to higher elevation wherein case 104 is guided to roll along track with guard rails to collection point of finished batteries.

[0039] In a preferred embodiment, movements of battery cases within system thus comprise at least one of list: stop and go, radial, rolling along track, moving from one starwheel's notch position to a second interacting starwheel's notch position, movement aligning case with jelly roll filling position, movement aligning case with capping position. Radial movement is defined as motion at a right angle to an axis of rotation. Essentially, radial motion is the movement around a shaft rather than along its length.

[0040] It is understood that instant invention assembly lines can be comprised in a variety of configurations, each within scope of instant invention. In a preferred embodiment, such configurations and arrangements typically comprise mechanisms which can be thought of as three lines of parts supply and configuring. Jelly rolls of battery materials comprised of end plates as disclosed herein, battery caps, and battery cases, these are each supplied and rendered into correct position for assembly simultaneously. Actions follow, by which filling, and capping occur in coordination to progressive movement of battery cases. Finished batteries are delivered to collecting point.

[0041] Although the illustration in FIG. 1 is of filling and capping performed when starwheel is stopped, in a preferred embodiment the filling and/or capping is accomplished as line of battery cases continues to move. Such moving line filling and/or capping is rendered by in-line filling mechanism and/or in-line capping mechanism, as are well-known in the art of bottling, and modified for battery assembly use herein. For example, a line/reservoir of stacked rolls, and a line/reservoir of stacked caps, each feed and coordinate with in-line mechanisms of motion coordination, to accomplish assembly of batteries. Such in-line mechanisms complete the filling and attaching actions while moving parts of said filling and attaching mechanism also move in coordination to the moving receiving line of battery cases (not shown). Such moving line placement typically enables greater throughput of finished batteries as compared to stop and go motion assembly.

[0042] In a preferred embodiment, moving insertion of jelly rolls of battery materials into battery cases, is accomplished comprising a moving line of battery cases aligned to an in-line filler mechanism dispensing jelly rolls. In a preferred embodiment, affixing of caps onto battery cases, is accomplished comprising a moving line of battery cases aligned to in-line capping mechanism.

[0043] In FIG. 2, a preferred embodiment is illustrated in schematic form, said schematic illustrating an end plate of jelly roll of battery materials of instant invention's long-life battery. Said end plate 201 comprises a compact assembly of overlapped extensions of an electrode of said battery. At 203 is illustrated a representation of five compactly assembled overlapped extensions typical of overlapped extensions of instant invention. The schematic illustrates 4 such groups of 5 extensions as examples across the expanse of the end plate. These represent what are typically dozens, and up to a hundred or more extensions in tight overlap across the full expanse of the typical end plate. Visible in this perspective view, as ends of extensions in tight overlap, such 4 groups of 5 tightly overlapped extensions have a face-to-face shingle type of overlap. Please see details in non-provisional application Ser. No. 17/102,226 filed 23 Nov. 2020 by instant inventor, entitled ‘Configuring and maintaining shingled overlaps of electrode extensions at end plate of jelly roll of battery materials.’

[0044] It is understood that the full expanse of the typical end plate of instant invention's long-life battery is comprised of overlapping extensions of electrode. The schematic conveys this by illustrating groups. For the actual end plate, a surface appearance would be comprised of ends of extensions visible as overlapping and compacted across the expanse. The typical overlap format is illustrated by schematic of a group at 204.

[0045] To convey the said full expanse nature of these overlaps across the full end plate in typical end plate, four groups of five tightly compacted extensions 203 are schematically illustrated. These ends of extensions are meant n illustration, to reflect the result of winding of the jelly roll. Such winding of parallel extensions renders them in compact overlap. It is understood that said extensions are viewed in FIG. 2 in perspective view in which the top edges of said extensions are seen, as opposed to faces which are not seen but understood to be overlapped face-to-face with other extensions within the full end plate.

[0046] The tight compactness of overlapped extensions is represented by the closeness of the top edges of the 5 extensions in each of the 4 groups. Such compactness, tightness, and closeness of application of said extensions across the end plate, i.e. the face-to-face shingle-style overlapping, is important to be maintained in place during the working life of the battery. Such maintaining enables long life of the battery. To accomplish such maintaining, tabs 202 assist in such maintaining of compactness of end plate, as is further described below. The tabs typically are aligned around the entire end plate periphery but are schematically represented here by 4 tabs. Each tab is folded over the periphery of the end plate and snuggly onto it, to preserve the overlap of the extensions.

[0047] The extensions on end view are seen to have each a typical slightly curved configuration, as illustrated, for example, at 204. Such slightly curved nature enables the tight overlaps of extensions, which tightness serves to enable the electrical connections between and among the extensions. Such electrical connections enable multiple electron paths, which enables heat mitigation for the battery. By preserving said plurality of electrical connections, the battery is enabled to maintain short average electron path length. Thus, the battery is enabled to longer useful life. The tabs preserve this arrangement of extensions, by securing the end plate from unraveling.

[0048] In a preferred embodiment, fold-over tabs 202 are illustrated here as four tabs. Such illustration is understood to be representative of a dozen tabs or more per typical end plate. Such illustration is understood to be representative of folded down tabs around the full periphery of the typical end plate. Said tabs are typically comprised of durable material, such as metal. Such tabs secure the end plate and its function, as discussed herein.

[0049] Although the invention has been described in considerable detail in language specific to structural features, and or method acts, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as exemplary preferred forms of implementing the claimed invention. Stated otherwise, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting. Therefore, while exemplary illustrative embodiments of the invention have been described, numerous variations and alternative embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated and can be made without departing from the spirit and scope of the invention.

[0050] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reassembly by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.