Electrochemical accumulator with packaging comprising at least one polyaryletherketone (paek) sheet, sheet and associated manufacturing methods

Abstract

The invention concerns a new flexible or rigid packaging for an electrochemical accumulator (A). The packaging contains at least one polyaryletherketone (PAEK) sheet, notably a polyetheretherketone (PEEK™) sheet. According to a preferred embodiment, a polyaryletherketone (PAEK) sheet incorporates within it at least one metal stud constituting one of the poles of the accumulator. The packaging is useful for the packaging of lithium-ion accumulators.

1 : An electrochemical accumulator comprising an electrochemical cell comprising an anode and a cathode on opposite sides of an electrolyte, a first current collector comprising a first strip, which is connected to the anode, and a second current collector comprising a second strip, which is connected to the cathode, and a packaging, which contains the electrochemical cell in a sealed fashion, whilst being traversed by a proportion of the first and second strips forming poles which extend in the plane of the electrochemical cell,
 wherein the packaging comprises multiple polyaryletherketone (PAEK) sheets attached to one another at their periphery.   
     
     
         2 : An electrochemical accumulator, comprising an electrochemical cell comprising an anode and a cathode on opposite sides of an electrolyte, a first current collector, which is connected to the anode, a second current collector, which is connected to the cathode, and a packaging, which contains the electrochemical cell in a sealed fashion, whilst being traversed by a proportion of the first and second current collectors forming poles,
 wherein the packaging comprises a polyaryletherketone (PAEK) sheet comprising a metal stud, which constitutes one of the poles of the accumulator, and   wherein the metal stud is welded to a portion of a current collector contained within the packaging.   
     
     
         3 : The electrochemical accumulator of  claim 1 , wherein the packaging comprises a single polyaryletherketone (PAEK) sheet comprising two metal studs, which constitute the two poles of the accumulator, and
 wherein the single sheet is folded into two portions which are attached to one another at their periphery, and each of the two studs is welded to the portion of a current collector contained within the packaging.   
     
     
         4 : The electrochemical accumulator of  claim 1 , wherein the packaging comprises a single polyaryletherketone (PAEK) sheet comprising two metal studs, which constitute the two poles of the accumulator, and a polyaryletherketone (PAEK) sheet without metal studs, and attached at its periphery to the PAEK sheet, incorporating both metal studs, wherein each of the two metal studs is welded to the portion of a current collector contained within the packaging. 
     
     
         5 : The electrochemical accumulator of  claim 2 , wherein the packaging comprises two polyaryletherketone (PAEK) sheets, each comprising a metal stud constituting one of the poles of the accumulator, wherein each of the two studs is welded to the portion of a current collector contained within the packaging. 
     
     
         6 : The electrochemical accumulator (A) according to  claim 4 , wherein both polyaryletherketone (PAEK) sheets have a unit thickness such that they are rigid, wherein one of the sheets is machined to constitute a base of a case to contain the electrochemical cell, and the other sheet comprises the metal studs constituting a cover of the case. 
     
     
         7 : A method for manufacturing a polyaryletherketone (PAEK) sheet comprising a metal stud, the method comprising:
 A) forming an opening within a polyaryletherketone (PAEK) sheet;   B) freezing a metal bar to reduce a straight section of the metal bar to dimensions smaller than those of the opening in the sheet,   C) introducing the frozen bar into the opening of the sheet;   D) holding the frozen bar in the opening of the sheet at ambient temperature until the metal bar is adjusted whilst tightening; and then   E) cutting the metal bar along the straight section, once the metal bar has expanded and adjusted whilst tightening in the opening of the sheet, to obtain the metal stud.   
     
     
         8 : The method according to  claim 7 , wherein the sheet is a polyetheretherketone (PEEK™). 
     
     
         9 : The method according to  claim 7 , wherein the hole in A) is formed in a single sheet having a thickness such that it is rigid. 
     
     
         10 : The method according to  claim 7 , comprising:
 C′) during C), introducing the frozen bar into the opening of the rigid sheet until a connection is made with a portion of a current collector positioned on a side of the rigid sheet opposite the side that the bar was introduced;   D′) during D), holding the connection of the metal bar with the current collector;   E′) during E), cutting the metal bar only on the side of the rigid sheet through which the bar was introduced, wherein the stud incorporated in the rigid sheet is also permanently connected with the portion of the current collector.   
     
     
         11 : The method according to  claim 7 , wherein the hole in A) is formed in a stack of sheets having unit thickness such that they are flexible, and comprising a rigid divider interposed between two flexible sheets in the stack. 
     
     
         12 : A method for manufacturing a polyaryletherketone (PAEK) sheet comprising a metal stud, the method comprising:
 A) forming a first piece of polyaryletherketone (PAEK) sheet;   B) bonding a second piece of polyaryletherketone (PAEK) sheet around a perimeter of a metal sheet;   C) superimposing the first piece on the metal sheet such that the first and second pieces of polyaryletherketone (PAEK) sheet overlap;   D) ultrasonic bonding the overlapping pieces of polyaryletherketone (PAEK) sheet.