Battery block and method of manufacturing the same
09799931 · 2017-10-24
Assignee
Inventors
- Hideaki Hamada (Hyoko, JP)
- YUKIO NISHIKAWA (Osaka, JP)
- Kazunori Kurumaya (Hyogo, JP)
- Oose Okutani (Hyogo, JP)
Cpc classification
B21C37/14
PERFORMING OPERATIONS; TRANSPORTING
Y02E60/10
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
H01M50/213
ELECTRICITY
H01M10/617
ELECTRICITY
Y02P70/50
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
Y10T29/49108
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
International classification
B21C37/14
PERFORMING OPERATIONS; TRANSPORTING
H01M10/617
ELECTRICITY
Abstract
A cell block including a metal case including a plurality of pipe-shaped members and a plurality of single cells housed in each of the pipe-shaped members. Each of the pipe-shaped members is joined at joining surfaces, and the pipe-shaped members are joined and integrated. A member for housing single cells is provided, and the housing member is molded with a high degree of accuracy and is capable of being manufactured at low cost and in a simple manner.
Claims
1. A battery block, comprising: a metallic case that includes a plurality of pipe-shaped members, each of the pipe-shaped members comprising a first brazed joint between mating faces of each of the pipe-shaped members; and a plurality of unit cells that are accommodated in the plurality of pipe-shaped members, wherein the plurality of pipe-shaped members are joined to each other with a plurality of second brazed joints and are integrated with each other, wherein each of the pipe-shaped members has a hollow interior and a protrusion at the mating faces, the protrusion protruding into the hollow interior of the pipe-shaped member, the protrusion extending continuously along the mating faces, wherein the first brazed joint extends from the outer periphery surface of the pipe-shaped member to the hollow interior and is formed integrally with the protrusion as a brazing material, and the protrusion is in contact with each of the plurality of unit cells.
2. The battery block according to claim 1, wherein each of the pipe-shaped members comprises a metallic plate including a core material and a brazing material layer.
3. The battery block according to claim 1, wherein each of the pipe-shaped members comprises aluminum, copper, brass, or stainless steel.
4. The battery block according to claim 1, wherein each of the pipe-shaped members is a circular pipe or a polygonal pipe.
5. The battery block according to claim 1, wherein each of the pipe-shaped members has a penetration slot or a notch portion.
6. The battery block according to claim 1, wherein a gap between the mating faces is 0.05 to 0.2 mm.
7. The battery block according to claim 1, wherein each protrusion suppresses vibration or rotation of the plurality of the unit cells accommodated in the plurality of the pipe-shaped members.
8. A method of manufacturing a battery block, the method comprising: a step of: forming a plurality of pipe-shaped metallic plates having a brazing material layer on an outer circumferential surface by bending a plurality of metallic plates including a core material and the brazing material layer to constitute a plurality of corresponding mating faces; forming an assembly of the plurality of pipe-shaped metallic plates by bringing the plurality of pipe-shaped metallic plates into contact with each other and fixing the plurality of pipe-shaped plates to each other; forming a battery case by heating the assembly of the plurality of pipe-shaped metallic plates, brazing the plurality of corresponding mating faces of each of the plurality of pipe-shaped metallic plates to form a plurality of pipe-shaped members, and brazing the plurality of pipe-shaped metallic plates to each other, wherein each of the pipe-shaped members has a hollow interior and a protrusion at the mating faces, the protrusion protruding into the hollow interior of the pipe-shaped member; and accommodating a unit cell in the hollow interior of each of the plurality of pipe-shaped members of the battery case such that the protrusion is in contact with the unit cell.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
(20) A battery block of the invention includes a metallic case and a plurality of unit cells. The metallic case includes a plurality of pipe-shaped members, and each of the unit cells is accommodated in a hollow portion of each of the pipe-shaped members. The unit cell that is included in the battery block has an electricity storage performance. Therefore, it is preferable that the battery block function as a high-capacity storage battery.
(21) Battery Block
(22) In
(23) Unit cells 40a, 40b, . . . , 40t are accommodated in corresponding pipe-shaped members 31a, 31b, . . . , 31t, respectively. Unit cells 40 that are accommodated are supported by holders 20 and 50. One electrode 41 of each of unit cells is connected to electrode plate 10 and the other electrode 42 is connected to electrode plate 60.
(24) As shown in
(25) It is preferable that the plurality of pipe-shaped members 31a, 31b, . . . , 31t, which constitute the metallic case, be joined to each other and be integrated to form an assembly. More specifically, respective side surfaces of the plurality of pipe-shaped members 31a, 31b, . . . , 31t are joined to each other to be integrated. Assembly 31 of the pipe-shaped members that is included in one battery case may be constructed by two or more pipe-shaped members, and the upper limit is not particularly limited. In addition, the metallic case may further include frame body 400 surrounding assembly 31 of the pipe-shaped members (refer to
(26) Pipe-shaped member 31 may be, for example, circular pipe 31-1 as shown in
(27) It is preferable that the plurality of pipe-shaped members 31a, 31b, . . . , 31t be integrated in such a manner that these come into contact with each other. An arrangement aspect of pipe-shaped members 31a, 31b, . . . , 31t is not particularly limited. For example, in a case where respective pipe-shaped members 31a, 31b, . . . , 31t are circular pipes, as shown in
(28) It is preferable that pipe-shaped member 31 be formed from a metal. It is preferable that a constituent metal of pipe-shaped member 31 be a metal having high heat conductivity. Specific examples include aluminum, copper, brass, stainless steel, an alloy thereof, and the like. Aluminum is preferable for realizing lightness of the pipe-shaped member.
(29) It is preferable that the thickness of the plate constituting pipe-shaped member 31 be 0.2 to 0.8 mm, and for example, approximately 0.4 mm. The smaller the thickness is, the further the metallic case becomes light. Accordingly, this is preferable. However, when the thickness is too small, the strength that is necessary for the case may not be obtained.
(30) A hollow size of pipe-shaped member 31 is set in accordance with the size of unit cell 40 that is accommodated therein. That is, it is preferable that a diameter of a hollow cross-section be slightly larger than a diameter of a cross-section of unit cell 40 that is accommodated in the hollow. This is because it is necessary to accommodate the unit cell in a hollow portion. It is preferable that a difference (clearance) between the diameter of the hollow cross-section of pipe-shaped member 31 and the diameter of the cross-section of unit cell 40 (including an insulating sheet in a case of covering the unit cell with the insulation sheet) that is accommodated therein be 0.01 to 0.38 mm. When the clearance is too large, the unit cell that is accommodated vibrates, and thus this is not preferable. When the clearance is too small, the unit cell may not be accommodated.
(31) As shown in
(32) As described above, pipe-shaped member 31 may be obtained by bending a metallic flat plate and joining the mating faces (refer to
(33) Relationship Between Joining Method and Protrusion
(34) As shown in
(35) 1) Case of Joining by Brazing
(36) Pipe-shaped member 31 may be obtained by disposing a brazing material on an outer circumferential surface of non-joined pipe-shaped member (pipe-shaped metallic plate) 30a having mating faces 35, and heating the brazing material to braze pipe-shaped member 30a. For example, non-joined pipe-shaped member 30a in which the brazing material is disposed on the outer circumferential surface thereof may be manufactured by the following methods a), b), or c). The “brazing material” represents an alloy having a melting point lower than that of a metal constituting a core material.
(37) a) As shown in
(38) b) As shown in
(39) c) As shown in
(40) In this manner, non-joined pipe-shaped member (pipe-shaped metallic plate) 30a in which the brazing material is disposed on the outer circumferential surface thereof is prepared. In addition, a method of manufacturing non-joined pipe-shaped member (pipe-shaped metallic plate) 30a is not particularly limited to the above-described method.
(41) At mating faces 35 of pipe-shaped metallic plate 30a having mating faces 35, it is preferable that ends of pipe-shaped metallic plate 30a in a lateral direction do not come into completely contact with each other, and a gap be provided between mating faces 35. In addition, pipe-shaped metallic plate 30a in which the brazing material is disposed on the outer circumferential surface thereof is heated to braze the mating faces. The brazing is performed by heating the pipe to a temperature higher than the melting point of the brazing material. In the brazing process, it is preferable that the brazing material flow into the gap between the mating faces, and the brazing material further leak to a hollow inner to form a protrusion. In this manner, the joining at mating faces 35, and formation of protrusion 38 that is formed from the remainder of the brazing material may be performed (refer to
(42) As shown in
(43) In addition, a shape of the gap between mating faces 35 may be adjusted to allow the brazing material to easily flow into the gap so as to reliably form the protrusion. For example, as shown in
(44) In addition, as shown in
(45) 2) Case of Joining by Adhesive
(46) Pipe-shaped member 31 may be obtained by applying an adhesive to mating faces 35 of pipe-shaped metallic plate 30a having mating faces 35 to bond mating faces 35 with each other. In this bonding, the applied adhesive leaks to the hollow inner surface to form a protrusion. That is, a protrusion formed from the remainder of the adhesive is formed.
(47) 3) Case of Joining by Welding
(48) Pipe-shaped member 31 may be obtained by metal-welding mating faces 35 of pipe-shaped metallic plate 30a having mating faces 35. Means for the metal welding is not particularly limited, and TIG welding, laser welding, or the like may be exemplified. In a ease of performing the metal welding, it is preferable to bring mating faces 35 of the metallic plate into close contact with each other. When mating faces 35, which are brought into close contact with each other, are welded by metal melting, a protrusion called “welding protrusion” may be formed. When this welding protrusion is positively formed, a protrusion protruding into the hollow is formed.
(49) 4) Case of Joining by Diffusion Joining
(50) Pipe-shaped member 31 may be obtained by diffusion-joining mating faces 35 of pipe-shaped metallic plate 30 having mating faces 35. The diffusion joining is performed by pressing and heating metal plates that overlap each other at mating faces 35. When the metal plates are pressed, a protrusion may be pressure-molded at the mating faces.
(51) It is preferable that the height of protrusion 38 (refer to
(52) As shown in
(53) As described above, the metallic case constituting the battery block includes the plurality of pipe-shaped members. The plurality of pipe-shaped members come into contact with each other and are integrated with each other. Specifically, the respective pipe-shaped members are joined to each other at a side surface of the respective pipe-shaped member and are integrated with each other.
(54) The joining between the pipe-shaped members is performed by brazing, bonding with an adhesive, metal welding, or the like, but the joining is preferably performed by brazing. For example, a plurality of pipe-shaped metallic plates, in which a brazing material is disposed on an outer circumferential surface thereof, are brought into contact with each other and are temporarily fixed to form an assembly, and the resultant assembly is heated to join the pipe-shaped members (pipe-shaped metallic plates) to each other.
(55) Each of the pipe-shaped members that are to be temporarily fixed to form the assembly may be a member after the joining at mating faces 35 or a member before the joining. In a case of temporarily fixing the plurality of pipe-shaped members (pipe-shaped metallic plates) having mating faces 35 before the joining to form the assembly, the joining at mating faces 35 and the joining between pipe-shaped metallic plates 30 that become pipe-shaped members 31 may be performed in the same process, and thus this case is preferable.
(56) As shown in
(57) When pipe-shaped metallic plates 30 (30a, 30b, . . . , 30e) are intended to be temporarily fixed, as shown in
(58) Frame body 400 is used as a jig during the brazing between the pipe-shaped members. Therefore, it may be preferable that a coefficient of linear expansion of frame body 400 be the same as that of the pipe-shaped members. This is in order for an assembly of the pipe-shaped members to be reliably maintained by the frame body during the heating of the brazed joints and in order for stress not to be applied to pipe-shaped metallic plates 30 (30a, 30b, . . . , 30e). Therefore, for example, as shown in
(59) As shown in
(60) On the other hand, the gap between the pipe-shaped members in the assembly may be left as is in a hollow state. This is because it is easy to heat or cool the battery block by allowing a coolant to flow through the gap or disposing a heater therein. For example, as shown in
(61) After the metallic case is obtained by heating assembly 30 of pipe-shaped metallic plates 30a, 30b, . . . to be brazed to each other, the unit cell is accommodated in each pipe-shaped member 31, and other members necessary for a battery are added thereto, whereby the battery block is obtained. The unit cell is commonly covered with a metallic case, but may be further covered with an insulation sheet. The insulation sheet is commonly a resin film, and the thickness thereof is 45 to 75 μm.
(62) Method of Manufacturing Battery Block
(63) Hereinafter, as an example, a method of manufacturing the battery block (metallic case) of the invention will be described with reference to
(64) (a) First, metallic plate 230 (refer to
(65) (b) The plurality of pipe-shaped metallic plates 30a, 30b, . . . , 30e are brought into contact with each other and are fixed to obtain assembly 30 of pipe-shaped metallic plates 30a, 30b, . . . , 30e. Specifically, pipe-shaped metallic plates 30a, 30b, . . . , 30e are brought into contact with each other and are temporarily fixed to obtain assembly 30. Then, as shown in
(66) (c) Assembly 30 of the pipe-shaped metallic plates is heated. Mating surfaces 35 of pipe-shaped metallic plates 30a, 30b, . . . , 30e are brazed to obtain assembly 31 of pipe-shaped members 31a, 31b, . . . , 31e. In addition, pipe-shaped metallic plates 30a, 30b, . . . , 30e are brazed to each other. According to this process, protrusion 38 formed from the brazing material as shown in
(67) (d) Furthermore, as shown in
(68) In this manner, a battery block is manufactured. In addition, unit cell 40 may be provided with insulation sheet 45 that covers the unit cell.
(69) Hereinbefore, the method of manufacturing the battery block was described, but the method of manufacturing the battery block is not limited to the above-described manufacturing method. For example, instead of the above-described process (a), as shown in
(70) Next, an operation effect of the method of manufacturing the battery block related to the invention will be described in comparison with a method of manufacturing a battery block in the related art.
(71) In the related art, when the pipe-shaped member is formed from a cast metal, since a raw material of a mold is sand, surface accuracy of the mold is poor, and surface accuracy of a pipe-shaped member that is a transcript of the mold also decreases. In addition, in a case of obtaining an aluminum pipe-shaped member, due to a variation in components of an aluminum molten metal or the like, a cavity may occur. Therefore, in addition to necessity of a secondary processing to increase the surface accuracy, it is difficult to remove the occurred cavity. In addition, it may be considered that the pipe-shaped member is obtained by a drawing processing. However, when it is intended to decrease the thickness of the pipe-shaped member, shaping accuracy may decrease, and shaping itself is difficult.
(72) Conversely, according to the method of manufacturing the battery block related to the invention, since the metallic plate is bent to obtain the pipe-shaped member, it is possible to simply increase shaping accuracy of a portion of the battery block, in which the unit cell is accommodated. Accordingly, in the battery block that is obtained by the method of manufacturing the battery block of the invention, since vibration of the unit cell that is accommodated may be suppressed, it is difficult for a performance as a battery block storage battery to deteriorate. In addition, this battery block is light and compact. Examples of use of the battery block utilizing this characteristic include a storage battery mounted in a vehicle.
(73) The disclosure of Japanese Patent Application No. 2011-120473, filed on May 30, 2011, including the specification, drawings and abstract, is incorporated herein by reference in its entirety.
INDUSTRIAL APPLICABILITY
(74) The battery block of the invention includes a plurality of unit cells and a metallic case that accommodates the unit cells, and shaping accuracy of the metallic case is high. Therefore, vibration of the unit cells that are accommodated is suppressed, and a function of each of the unit cells is appropriately exhibited. Furthermore, the metallic case may be simply manufactured at a lower cost.
REFERENCE SIGNS LIST
(75) 10 Electrode plate 20 Holder 30 Pipe-shaped metallic plate 31: Pipe-shaped member 30-1 Circular pipe 30-2 Polygonal pipe 32 Penetration slot 33 Notch 35 Mating face 38 Protrusion 40 Unit cell 41 Electrode 42 Electrode 45 Insulation sheet covering unit cell 50 Holder 60 Electrode plate 100 Battery block 200 Metallic flat plate 210 Core material 220 Brazing material layer 230 Metallic plate 240 Brazing sheet 250 Brazing paste 300 Half-pipe-shaped metallic plate 400 Frame body 400-1 Stainless steel plate 400-2 Aluminum frame 450 Metallic member 500 Coolant gas