Battery pack

Abstract

A battery pack is provided with: one or more secondary battery cells having positive and negative electrodes; a metal terminal portion electrically connected to the electrodes of the one or more secondary battery cells; a terminal holder integrally formed with the terminal portion; and an exterior case that houses the one or more secondary battery cells and is provided with a holder housing space that houses the terminal holder. The exterior housing forms a recess at a position facing the terminal portion in a portion of the holder housing space.

Description

Technical Field

[0001] The present disclosure relates to battery packs. Background Art

[0002] In electrical equipment using rechargeable secondary batteries such as lithium-ion secondary batteries, a battery pack containing a plurality of secondary battery cells is used to replace the secondary batteries (e.g., Patent Document 1). The battery pack is charged while connected to the electrical equipment or while removed from the battery equipment and placed in a dedicated charger.

[0003] In such a battery pack, an electric contact point is required between the battery pack body and a charger for charging the battery pack. In order to obtain stable electrical contact at the electric contact point, elasticity is often given to the connection terminal on the battery pack side or the charger side.

[0004] Here, it is considered to give elasticity to the connection terminal on the battery pack side. When such a connection terminal having elasticity is installed in the battery pack, first, the connection terminal is set on the terminal bracket, and after assembling the bracket fitting, the bracket fitting is assembled to the battery pack housing.

[0005] However, in conventional battery packs, there is a problem that when the mounting position of the connection terminal relative to the terminal holder is misaligned during assembly of the holder fitting, the terminal holder cannot be assembled to the battery pack housing at a correct position.

[0006] Prior Art Literature

[0007] Patent Literature

[0008] Patent Document 1: Japanese Patent Application Laid-Open No. 6-333547 Summary of the invention

[0009] One of the objects of the present disclosure is to provide a battery pack that can be assembled even when there is a deviation in the mounting position of a terminal portion relative to a terminal holder.

[0010] A battery pack according to one embodiment of the present invention comprises: one or more secondary battery cells having positive and negative electrodes; a metal terminal portion electrically connected to the electrodes of the one or more secondary battery cells; a terminal bracket integrally formed with the terminal portion; and an outer shell that accommodates the one or more secondary battery cells and has a bracket storage space for accommodating the terminal bracket, the outer shell forming a recessed portion at a position opposite to the terminal portion in a portion of the bracket storage space.

[0011] In a method for manufacturing a battery pack according to another aspect of the present invention, the battery pack comprises: one or more secondary battery cells having positive and negative electrodes; a metal terminal portion electrically connected to the electrodes of the one or more secondary battery cells; a terminal bracket comprising a resin member and a metal sheet protruding from the surface of the resin member and integrally formed with the terminal portion; and an outer shell that accommodates the one or more secondary battery cells and is provided with a bracket storage space for accommodating the terminal bracket. The method for manufacturing the battery pack includes the following steps: joining the terminal portion and the metal sheet by spot welding; and arranging the terminal bracket in the bracket storage space in a posture such that a portion of the terminal portion is opposed to a recessed portion formed in a portion of the bracket storage space of the outer shell.

[0012] According to a battery pack involved in one form of the present invention, when the terminal part and the terminal bracket are integrated, even if there is a deviation in the installation position of the terminal part relative to the terminal bracket, the deviation can be absorbed by the terminal part entering a part of the recessed portion formed at a position opposite to the terminal part, thereby storing the terminal bracket in the bracket storage space. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a perspective view of the battery pack according to the first embodiment of the present invention.

[0014] Figure 2 yes Figure 1 Vertical cross-sectional view at line II-II.

[0015] Figure 3 yes Figure 2 An enlarged cross-sectional view of the main part.

[0016] Figure 4 Yes means Figure 3 Cross-sectional view of the terminal bracket.

[0017] Figure 5 Yes means insert the terminal bracket into Figure 3 An enlarged cross-sectional view of the state of the outer casing.

[0018] Figure 6 This is a three-dimensional view of the terminal bracket.

[0019] Figure 7 This is an exploded perspective view of the terminal bracket.

[0020] Figure 8 It is an enlarged cross-sectional view of a main part of a battery pack according to a comparative example.

[0021] Fig. 9 Yes means Figure 4 A cross-sectional view showing that the connection position between the terminal holder and the terminal portion is deviated to the left.

[0022] Fig.10 Yes means Figure 4 A cross-sectional view showing that the connection position between the terminal holder and the terminal portion is deviated to the right.

[0023] Fig.11 It means that Fig. 9 An enlarged cross-sectional view of a state where the terminal holder is inserted into the outer housing.

[0024] Fig.12 It means that Fig.10 An enlarged cross-sectional view of a state where the terminal holder is inserted into the outer housing.

[0025] Fig.13 It is a three-dimensional diagram of an insulating board.

[0026] Fig.14 It is an exploded perspective view showing a state where an insulating plate is arranged on a wall portion.

[0027] Fig.15 It is an enlarged cross-sectional view showing a state where an insulating plate is arranged on a wall portion.

[0028] Fig.16 This is an enlarged cross-sectional view of a main part of a battery pack according to a second embodiment of the present invention.

[0029] Fig.17 This is an enlarged cross-sectional view of a main part of a battery pack according to a second embodiment of the present invention. DETAILED DESCRIPTION

[0030] The aspects of the present invention can be identified by the following structures and features.

[0031] In a battery pack according to another aspect of the present invention, in any of the above aspects, a convex portion may be formed around the concave portion, and the terminal portion may be in contact with the convex portion.

[0032] In addition, the battery pack according to another aspect of the present invention may further include an insulating plate having insulating properties disposed on the wall surface of the bracket storage space in any of the above aspects, and the recess is formed on the insulating plate. According to the above structure, by adding another member provided with a recess to the outer casing, the recess can be easily formed in the bracket storage space of the outer casing.

[0033] Furthermore, in a battery pack according to another aspect of the present invention, in any of the above aspects, the insulating plate may be formed by laminating a plurality of sheets of paper.

[0034] Furthermore, in a battery pack according to another aspect of the present invention, in any of the above aspects, the insulating plate may include: a first surface forming the recess; and a second surface bent from the first surface.

[0035] Furthermore, in the battery pack according to other aspects of the present invention, in any of the above aspects, the terminal holder may include: a resin member; and a metal sheet protruding from a surface of the resin member, and the terminal portion is joined to the metal sheet to form an integral body with the terminal holder.

[0036] Furthermore, in a battery pack according to another aspect of the present invention, in any of the above aspects, the terminal portion and the metal sheet may be joined by spot welding.

[0037] Furthermore, in a battery pack according to another aspect of the present invention, in any of the above aspects, the terminal portion may be bent in an L-shape to form a connection terminal to the outside with one end joined to the metal sheet and the other end bent in a V-shape.

[0038] Hereinafter, the embodiments of the present invention will be described based on the accompanying drawings. Among them, the embodiments shown below are examples for concretizing the technical ideas of the present invention, and the present invention is not specific to the following. In addition, this specification is by no means specific to the components shown in the claims as components of the embodiments. In particular, the size, material, shape, relative configuration, etc. of the structural parts recorded in the embodiments, as long as there is no special specific record, do not mean to limit the scope of the present invention to only this, but are simply illustrative examples. In addition, the size, positional relationship, etc. of the components shown in the various drawings are sometimes exaggerated in order to make the description clear. Furthermore, in the following description, with respect to the same name, figure mark, representing the same or homogeneous components, detailed description is appropriately omitted. Furthermore, the various elements constituting the present invention can be set to be composed of multiple elements by the same component to use multiple elements as one component, and vice versa, the function of realizing a component can also be shared by multiple components.

[0039] The battery pack of the present invention can be used as a power source for portable electrical equipment such as a wireless device, an electric vacuum cleaner, and an electric tool, or can be used as a backup power source for a server, a power source for home use, a business office use, or a factory use by using static power storage, and can be used as a driving power source for power-assisted bicycles, an electric scooter, an electric cart, or a driving power source for vehicles such as a hybrid car and an electric car. Hereinafter, as one embodiment of the present invention, a battery pack used as a power source for a portable wireless device is described.

[0040] [Implementation Method 1]

[0041] exist Figure 1 to Figure 3 1 and 2 show a battery pack 100 according to Embodiment 1 of the present invention. In these figures, respectively, Figure 1 A perspective view showing a battery pack 100 according to Embodiment 1 of the present invention is shown. Figure 2express Figure 1 The vertical cross-section diagram at line II-II, Figure 3 express Figure 2 The battery pack 100 shown in these figures includes: one or more secondary battery cells 1; a terminal portion 20; a terminal holder 30 connected to the terminal portion 20; and an outer case 10.

[0042] (External casing 10)

[0043] The outer casing 10 accommodates one or more secondary battery cells 1 and a battery holder. Figure 1 As shown in FIG. 1 , the outer casing 10 is formed into a box shape. The outer casing 10 is divided into two parts, for example, an upper casing 12 and a lower casing 11. The outer casing 10 is made of a member with excellent insulation properties, for example, a resin such as polycarbonate or PC-ABS alloy. Figure 2 , Figure 3 As shown in the cross-sectional view of FIG. 1 , a holder storage space 15 for storing the terminal holder 30 is provided. The holder storage space 15 is defined between a wall portion 13 formed in the lower case 11 of the outer case 10 and an inner block 14 in the outer case 10 .

[0044] (Secondary battery cell 1)

[0045] One or more secondary battery cells 1 can be used as square or cylindrical secondary battery cells. Figure 2 In the example shown, two square secondary battery cells 1 are arranged for use. In addition, the number and configuration of the secondary battery cells 1 are not limited to this example, and any number and configuration can be appropriately adopted. Each secondary battery cell 1 has a positive and negative electrode. The positive and negative electrodes are preferably provided on one end surface of the secondary battery cell 1. The secondary battery cell 1 can appropriately utilize a known secondary battery such as a lithium-ion secondary battery, a nickel-hydrogen battery, a nickel-cadmium battery, etc.

[0046] (Terminal bracket 30)

[0047] Terminal support 30 Figure 3 As shown in the cross-sectional view of FIG. , it is integrally formed with the terminal portion 20. Figure 4 A cross-sectional view of the terminal support 30 is shown. Figure 5 The terminal holder 30 is shown inserted into the outer casing 10. Figure 6 A perspective view of the terminal support 30 is shown. Figure 7 As shown in these figures, the terminal holder 30 includes a resin member 31 and a metal sheet 32. The resin member 31 is Figure 7 As shown in FIG. Figure 4 , Figure 7As shown, insert molding is performed so that the metal piece 32 protrudes from the surface of the plate-shaped resin member 31.

[0048] (Terminal portion 20)

[0049] On the other hand, Figure 2 As shown in FIG. 1 , the terminal portion 20 electrically connects one end to one or more electrodes of the secondary battery cell 1 and exposes the other end to the outside, thereby serving as a connection terminal 21 to the outside. The terminal portion 20 is composed of a conductive and elastic member. Figure 7 The terminal portion 20 is bent into an L shape as shown in the figure, and the bending makes it easier to exert elasticity. In addition, one end is connected to the metal sheet 32 ​​of the terminal holder 30, and the other end is bent into a V shape. The terminal portion 20 of this structure constitutes a connection terminal 21 in which the valley portion of the V shape abuts. In addition, the outer casing 10 is as shown in the figure. Figure 3 As shown in the cross-sectional view of FIG. 1 , the opening window 16 is formed so that a portion of the connection terminal 21 in the terminal portion 20 is exposed to the outside.

[0050] The terminal portion 20 is formed by bending a metal plate. Figure 6 , Figure 7 In the example, two terminal portions 20 corresponding to the positive and negative electrodes are joined to two metal sheets 32 protruding from the terminal holder 30. In this way, the metal terminal portion 20 is joined to the metal sheet 32 ​​made of the same metal and is integrally formed with the terminal holder 30. The joining of the terminal portion 20 and the metal sheet 32 ​​is preferably performed by welding. Thus, the metals can be easily joined to each other. More preferably, the joining is performed by spot welding using a laser or the like. In this way, the terminal holder 30 formed by integrally joining the terminal portion 20 is as shown in FIG. Figure 5 It is stored in the bracket storage space 15 as shown by the dotted line.

[0051] Here, when welding the terminal portion 20 and the metal sheet 32, if the welding position deviates from the designed position, a situation occurs where the terminal portion 20 and the metal sheet 32 ​​can no longer be accommodated in the bracket storage space 15. Figure 8 As shown in the cross-sectional view of the battery pack 800 involved in the comparative example shown, the bracket storage space 815 is divided between the wall portion 813 formed in the outer shell 810 and the inner block 814 in the outer shell 810. If a gap is generated between the outside of the terminal bracket 830 and the inner surface of the bracket storage space 815 when the terminal bracket 830 is stored in the bracket storage space 815, the terminal bracket 830 will shake, which may damage the stability of the connection between the connection terminal 821 and the terminal of the charger or the electrical device. For this reason, the inner shape of the bracket storage space 815 is designed to be consistent with the outer shape of the terminal bracket 830, that is, so that shaking does not occur.

[0052] Here, if Fig. 9As shown by the arrow in the middle, if the connection position of the metal sheet 32 ​​and the terminal portion 20 deviates further to the left than the original design position, the horizontal width of the terminal bracket 30 after the terminal portion 20 is joined will be greater than the design value, and as a result, it may no longer be accommodated in the bracket storage space 15. However, if the connection position of the metal sheet 32 ​​and the terminal portion 20 is adjusted for safety reasons, the result is Fig.10 If the position of the connection terminal 21 of the terminal portion 20 deviates too much to the right compared to the original design position as shown by the arrow, the position of the connection terminal 21 of the terminal portion 20 will deviate from the original position, which is not preferred from the perspective of the stability of the electrical connection. However, due to the problem of crossover in manufacturing, it is difficult to improve the accuracy of the connection position between the metal sheet 32 ​​and the terminal portion 20, the yield rate will be reduced, etc., which is also disadvantageous in terms of manufacturing cost.

[0053] For this purpose, in the battery pack 100 according to the present embodiment, a recess 41 is formed in a portion of the holder storage space 15 of the outer case 10 at a position facing the terminal portion 20. Figure 3 In the example shown in the cross-sectional view of FIG. 1 , a recess 41 is formed in a part of the inner surface of the wall portion 13. By setting such a structure, even if it is assumed that Fig. 9 In the case where the lateral width of the terminal bracket 30 joined with the terminal portion 20 is larger than the designed value and thus cannot be accommodated in the bracket accommodation space 15, the same Fig.11 As shown, a portion of the terminal portion 20 enters the recess 41, so that the terminal bracket 30 can be accommodated in the bracket storage space 15. In this way, even if there is a deviation in the position where the terminal portion 20 is fixed to the terminal bracket 30, the recess 41 can absorb the deviation, thereby even such a terminal bracket 30 can be accommodated in the bracket storage space 15.

[0054] In addition, even if Fig.10 In the case where the lateral width of the terminal support 30 joined to the terminal portion 20 is smaller than the designed value, the Fig.12 As shown, the terminal holder 30 is accommodated in the holder accommodation space 15 .

[0055] The size of the recess 41 is formed to be at least wider than the lateral width of the terminal portion 20. Figure 6 As shown in the figure, when there are two terminals 20, one for the positive electrode and the other for the negative electrode, the width is set to be sufficient so that both of the two terminals 20 can be inserted. As a result, the advantage of being easy to form the recess 41 as one can be obtained. In addition, when there are a plurality of terminal portions 20, the recesses 41 can be formed at positions corresponding to the respective terminal portions 20 in the insulating plate 40 described later. In this way, by forming a plurality of small recesses 41 corresponding to the size of each terminal portion 20, the strength of the insulating plate 40 can be maintained compared to a structure in which a large recess 41 is formed.

[0056] In addition, Fig.11 When the lateral width of the terminal holder 30 to which the terminal portion 20 is joined is larger than the design value as shown, the longitudinal length of the recess 41 is set to a sufficient size to hold a portion of the terminal portion 20 in the recess 41. In addition, the design is also made in relation to the thickness of the convex portion 42 described later, so that when a portion of the terminal portion 20 is received in the recess 41, the angle of the connecting terminal 21 at the front end of the terminal portion 20 is not significantly changed. That is, if the longitudinal length of the recess 41 is too small, the angle of inclination of the terminal portion 20 abutting against the convex portion 42 becomes larger, and the position of the connecting terminal 21 will deviate significantly. For example, the longitudinal length of the recess 41 and the thickness of the convex portion 42 are designed so that when the terminal portion 20 is received in the recess 41, the angle θ at which the terminal portion 20 is inclined from the vertical direction is less than 5°.

[0057] (Protrusion 42)

[0058] As a result of providing the recessed portion 41 in a part of the inner surface of the wall portion 13, a convex portion 42 is formed around the recessed portion 41. The convex portion 42 is brought into contact with the terminal portion 20 for guidance, and the connection terminal 21 is kept exposed from the opening window 16. In other words, by providing the recessed portion 41 in the wall portion 13, the contact area with the terminal portion 20 is reduced, and a gap is formed between the terminal portion 20 and a part of the inner surface of the wall portion 13, which results in a loss of stability. This is suppressed by bringing the terminal portion 20 into contact with the convex portion 42.

[0059] (Insulation plate 40)

[0060] In order to facilitate the formation of the recessed portion 41 in the wall portion 13 of the bracket storage space 15, the battery pack 100 according to the first embodiment is additionally provided with an insulating plate 40. Fig.13 As shown in the perspective view of FIG. 1 , the insulating plate 40 is formed in a flat plate shape as a whole, and a concave portion 41 is formed in the middle. Fig.14 The inner surface of the wall portion 13 disposed on the bracket storage space 15 can be Fig.15 As shown in the figure, the recess 41 is easily formed in the outer case 10. In addition, the thickness of the wall 13 of the outer case 10 is designed so that it is thinned in advance by the thickness of the insulating plate 40. In this way, the recess 41 can be formed without changing the inner diameter of the bracket storage space 15. In addition, an adhesive or a double-sided tape can be used to fix the insulating plate 40 to the wall 13. In this case, the thickness of the wall 13 is also designed in consideration of the thickness of the adhesive, the double-sided tape, etc.

[0061] The insulating plate 40 is made of an insulating material, which can prevent unexpected conduction, short circuit, etc. while allowing the metal terminal portion 20 to abut. In addition, the insulating plate 40 can be composed of a laminate. Thus, by laminating a sheet with an opening formed in advance on a flat sheet, the recess 41 can be easily formed. As the material of the laminated sheet, paper, talc, and resin can be used. In particular, paper is preferred from the perspectives of less environmental burden, ease of acquisition, and recyclability. In addition, the insulating plate 40 provided with the recess 41 can also be formed by resin molding.

[0062] The insulating plate 40 may be formed in a flat plate shape or in a Fig.13 As shown in FIG. 4 , in addition to the first surface 43 on which the recessed portion 41 is formed, a second surface 44 is provided which is bent from the first surface 43. Figure 3 As shown in the figures, the insulating plate 40 can be easily made self-standing and can be easily handled.

[0063] [Implementation Method 2]

[0064] In addition, Figure 3 , Fig.13 In the example of the embodiment 2, the first surface 43 of the insulating plate 40 is recessed to form the recess 41, but the present invention is not limited to this structure, and the insulating plate 40 may be opened to form the recess 41. Fig.16 . In this figure, the same reference numerals are given to the same components as those in the first embodiment, and detailed description thereof is omitted. The insulating plate 40B shown in this figure is formed by hollowing out a portion corresponding to the recess 41B to form an opening, and is arranged on the wall 13 of the outer case 10, thereby forming the recess 41B on the wall surface of the bracket storage space 15. According to this structure, the advantage of being able to easily form an opening in the insulating plate 40B can be obtained.

[0065] [Implementation method 3]

[0066] In addition, the method of forming the recessed portion 41 in the wall portion 13 of the outer casing 10 may be to process the wall portion 13 itself in addition to providing other members such as the above-mentioned insulating plate 40. Fig.17 In this figure, the same reference numerals are given to the same components as those in the above-mentioned embodiment 1, and detailed descriptions are omitted. Fig.17 The outer casing 10 shown is resin molded so that the recess 41C is formed integrally with the wall portion 13C in advance. In this case, although demolding becomes complicated, it can be realized by using a sliding mold or the like. According to this structure, since it is not necessary to prepare other components such as an insulating plate, the advantage of being able to simplify the manufacturing process can be obtained. As a disadvantage, the mold cost becomes high.

[0067] [Battery Pack Manufacturing Method]

[0068] The following describes an assembly method for the above-mentioned battery pack 100. First, the terminal portion 20 and the metal sheet 32 ​​are joined by spot welding. Next, the terminal bracket 30 is arranged in the bracket storage space 15 in a posture in which a portion of the terminal portion 20 is opposed to a recess 41 formed in a portion of the bracket storage space 15 of the outer shell 10. Thus, when the terminal portion 20 and the terminal bracket 30 are integrated, even if there is a deviation in the installation position of the terminal portion 20 relative to the terminal bracket 30, the deviation can be absorbed by the terminal portion 20 entering the recess 41 formed at a position opposite to the terminal portion 20, so that the terminal bracket 30 can be stored in the bracket storage space 15.

[0069] Industrial Applicability

[0070] The battery pack of the present invention can be suitably used as a power source for a wireless device, a power source for portable electrical equipment such as an electric vacuum cleaner and an electric tool, and can also be suitably used in applications such as a power source device for mobile bodies such as power-assisted bicycles and electric carts.

[0071] Description of Reference Numerals

[0072] 100, 200, 300, 800…battery pack

[0073] 1…Secondary battery cell

[0074] 10…External housing

[0075] 11…Lower housing

[0076] 12…Upper housing

[0077] 13, 13C…Wall

[0078] 14…Internal Block

[0079] 15…Stand storage space

[0080] 16…Opening window

[0081] 20…Terminal part

[0082] 21…Connection terminals

[0083] 30…Terminal bracket

[0084] 31…Resin components

[0085] 32…Metal sheet

[0086] 40, 40B…Insulation board

[0087] 41, 41B, 41C… concave portion

[0088] 42…Convex part

[0089] 43…Front page

[0090] 44...Second side.

Claims

1. A battery pack comprising: One or more secondary battery cells having positive and negative electrodes; a metal terminal portion electrically connected to the electrode of the one or more secondary battery cells; a terminal support integrally formed with the terminal portion; and an outer casing that accommodates the one or more secondary battery cells and is provided with a holder accommodating space for accommodating the terminal holder, The outer case has a recessed portion formed in a portion of the holder housing space at a position facing the terminal portion.

2. The battery pack according to claim 1, wherein: A convex portion is formed around the concave portion, The terminal portion is configured to abut against the convex portion.

3. The battery pack according to claim 1, wherein: The battery pack shown also features: An insulating plate having insulating properties is disposed on a wall surface of the bracket storage space.

4. The battery pack according to claim 3, wherein: The insulating board is formed by laminating a plurality of sheets of paper.

5. The battery pack according to claim 3, wherein: The insulating plate comprises: a first surface forming the recess; and A second surface is bent from the first surface.

6. The battery pack according to any one of claims 1 to 5, wherein: The terminal support comprises: a resin member; and a metal piece protruding from a surface of the resin member, The terminal portion is joined to the metal sheet to be integrally formed with the terminal holder.

7. The battery pack according to claim 6, wherein: The terminal portion and the metal sheet are joined by spot welding.

8. The battery pack according to claim 6, wherein: The terminal portion is bent in an L-shape, one end of which is joined to the metal sheet and the other end of which is bent in a V-shape to form a connection terminal to the outside.

9. A method for manufacturing a battery pack, the battery pack comprising: One or more secondary battery cells having positive and negative electrodes; a metal terminal portion electrically connected to the electrode of the one or more secondary battery cells; a terminal holder including a resin member and a metal piece protruding from a surface of the resin member and integrally formed with the terminal portion; and an outer casing for accommodating the one or more secondary battery cells and provided with a holder for accommodating the terminal holder, The manufacturing method of the battery pack comprises the following steps: joining the terminal portion and the metal sheet by spot welding; and The terminal holder is arranged in the holder accommodating space in a posture in which a part of the terminal portion faces a recessed portion formed in a part of the holder accommodating space of the outer case.

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