Method for manufacturing energy storage modules and apparatus for manufacturing energy storage modules

Abstract

To provide a method for manufacturing an energy storage module and an apparatus for manufacturing an energy storage module that can suppress the ingress of foreign matter into the energy storage module caused by wear particles generated when the insert mold slides against the mold during the process of attaching the insert mold to the mold used for resin molding. [Solution] The method for manufacturing the energy storage module 10 includes an attachment step of inserting an insertion part 142 of a nesting mold 140, in which the tip of a communication hole forming part 141 is positioned in a first communication hole 21h of a first resin part 21 formed in an electrode laminate 11, into an insertion hole 131 formed in a mold 130, and a molding step of forming a second resin part by resin molding using the mold 130 to which the nesting mold 140 has been attached in the attachment step, wherein the attachment step includes a suction step of sucking the inside of the mold 130 through the suction hole 132 when inserting the insertion part 142 into the insertion hole 131.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a power storage module and a manufacturing apparatus for the power storage module.

Background Art

[0002] Conventionally, as a power storage module, a bipolar battery including a bipolar electrode in which a positive electrode active material layer is formed on one surface of an electrode plate and a negative electrode active material layer is formed on the other surface is known. For example, Patent Document 1 discloses a method for manufacturing a power storage module and a manufacturing apparatus for the power storage module, which include an electrode laminate including a plurality of electrodes laminated in a first direction and a seal member surrounding the electrode laminate as viewed from the first direction.

[0003] The plurality of electrodes in this power storage module include a bipolar electrode. Further, the seal member in this power storage module includes a first resin portion forming a first communication hole communicating with an internal space provided between adjacent electrodes, and a second resin portion forming a second communication hole communicating with the first communication hole.

[0004] The manufacturing method described in Patent Document 1 includes a first molding step of attaching a first nested mold having a first communication hole forming portion for forming a first communication hole to a mold and forming a first resin portion by resin molding using the mold, and a second molding step of attaching a second nested mold having a second communication hole forming portion for forming a second communication hole to the mold and forming a second resin portion by resin molding using the mold. In the second molding step, the second communication hole forming portion is inserted into the first communication hole up to a position that does not penetrate the first communication hole, and resin molding of the second resin portion is performed.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] However, in the technology described in Patent Document 1, when inserting the insertion part of the insert mold into the insertion hole formed in the mold to attach the insert mold to the mold, the insert mold may wear down due to sliding against the mold. Furthermore, if the wear particles generated during wear adhere to the vicinity of the first and second communication holes of the energy storage module obtained after resin molding, there is a risk that they may be mixed into the inside of the energy storage module as foreign matter. If metallic foreign matter is mixed into the inside of the energy storage module, the foreign matter may precipitate and cause an internal short circuit.

[0007] This disclosure is made to solve such problems and aims to provide a method for manufacturing an energy storage module and an apparatus for manufacturing an energy storage module that can suppress the ingress of foreign matter into the energy storage module caused by wear particles generated when the insert mold slides against the mold during the attachment of the insert mold to the mold used for resin molding. [Means for solving the problem]

[0008] A method for manufacturing an energy storage module according to one embodiment is a method for manufacturing an energy storage module, wherein the energy storage module comprises an electrode stack, a first resin part having a first communication hole that communicates with an internal space provided inside the electrode stack, and a second resin part having a second communication hole that communicates with the first communication hole, and is formed by resin molding using a mold to which an insert mold is attached, the mold having an insertion hole formed to communicate with the inside of the mold and a suction hole formed to communicate with the insertion hole, the insert mold having a communication hole forming part for forming the second communication hole and an insertion part that is inserted into the insertion hole, the manufacturing method comprising an attachment step of inserting the insertion part of an insert mold, in which the tip of the communication hole forming part is positioned in the first communication hole of the first resin part formed in the electrode stack, and a molding step of forming the second resin part by resin molding using a mold to which the insert mold is attached by the attachment step, the attachment step having a suction step of sucking the inside of the mold through the suction hole when inserting the insertion part into the insertion hole.

[0009] A manufacturing apparatus for an energy storage module according to one embodiment is a manufacturing apparatus for an energy storage module, the energy storage module having an electrode stack, a first resin part having a first communication hole that communicates with an internal space provided inside the electrode stack, and a second resin part having a second communication hole that communicates with the first communication hole and formed by resin molding using a mold to which an insert mold is attached, the mold having an insertion hole formed to communicate with the inside of the mold and a suction hole formed to communicate with the insertion hole, the insert mold having a communication hole forming part for forming the second communication hole and an insertion part that is inserted into the insertion hole, and the manufacturing apparatus having a mold, an insert mold, and a suction device that sucks the inside of the mold through the suction hole when inserting the insertion part of the insert mold, whose tip is positioned in the first communication hole of the first resin part formed in the electrode stack, into the insertion hole. [Effects of the Invention]

[0010] This disclosure provides a method for manufacturing an energy storage module and an apparatus for manufacturing an energy storage module that can suppress the ingress of foreign matter into the energy storage module caused by wear particles generated when the insert mold slides against the mold during the installation of the insert mold into the mold used for resin molding. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic cross-sectional view showing the configuration of a storage module manufactured by the storage module manufacturing method according to Embodiment 1. [Figure 2] This is a schematic cross-sectional view showing the configuration of the manufacturing apparatus for the energy storage module according to Embodiment 1. [Figure 3] This is a flowchart showing the method for manufacturing an energy storage module according to Embodiment 1. [Figure 4] This is a schematic cross-sectional view illustrating the installation process. [Figure 5] This is a schematic cross-sectional view illustrating the molding process and the demolding process. [Modes for carrying out the invention]

[0012] Embodiment 1 Embodiments of this disclosure will be described below with reference to the drawings. However, the present invention is not limited to the following embodiments. Also, for clarity of explanation, the following description and drawings have been simplified as appropriate. What is shown in the drawings is only a part of the whole, and in reality, many other components not shown are included. In the following description, the same or equivalent elements are denoted by the same reference numerals, and redundant explanations are omitted.

[0013] Figure 1 is a schematic cross-sectional view showing the configuration of a power storage module manufactured by the power storage module manufacturing method according to Embodiment 1. The power storage module 10 shown in Figure 1 is a power storage module used in batteries of various vehicles such as forklifts, hybrid vehicles, and electric vehicles.

[0014] The energy storage module 10 is, for example, a bipolar battery equipped with bipolar electrodes, as described later. The energy storage module 10 is a secondary battery such as a nickel-metal hydride secondary battery or a lithium-ion secondary battery. The energy storage module 10 may also be an electric double-layer capacitor or an all-solid-state battery. In the following description, the case in which the energy storage module 10 is a nickel-metal hydride secondary battery is used as an example.

[0015] As shown in Figure 1, the energy storage module 10 includes an electrode stack 11 and a resin sealing member 12 that seals the electrode stack 11.

[0016] The electrode stack 11 includes a plurality of stacked electrodes. The plurality of electrodes are stacked in a first direction D1 via a separator 13. The first direction D1 is the direction in which the electrodes are stacked. The energy storage module 10 has a rectangular shape when viewed from the first direction D1. The plurality of electrodes include a plurality of bipolar electrodes 14, a negative terminal electrode 18, and a positive terminal electrode 19.

[0017] The bipolar electrode 14 has an electrode plate 15, a positive electrode active material layer 16 provided on one surface 15a of the electrode plate 15, and a negative electrode active material layer 17 provided on the other surface 15b of the electrode plate 15. The positive electrode active material layer 16 is formed by applying a positive electrode slurry containing a positive electrode active material. The negative electrode active material layer 17 is formed by applying a negative electrode slurry containing a negative electrode active material. In the electrode laminate 11, the positive electrode active material layer 16 of one bipolar electrode 14 faces the negative electrode active material layer 17 of one bipolar electrode 14 adjacent in the first direction D1 with the separator 13 interposed therebetween. In the electrode laminate 11, the negative electrode active material layer 17 of one bipolar electrode 14 faces the positive electrode active material layer 16 of the other bipolar electrode 14 adjacent in the first direction D1 with the separator 13 interposed therebetween.

[0018] In the electrode laminate 11, a negative terminal electrode 〈0000087〉 is disposed at one end in the first direction D1, and a positive terminal electrode 〈0000088〉 is disposed at the other end in the first direction D1. The negative terminal electrode 〈0000089〉 includes the electrode plate 15 and the negative electrode active material layer 17 provided on the other surface 15b of the electrode plate 15. The negative electrode active material layer 17 of the negative terminal electrode 〈0000087〉 faces the positive electrode active material layer 16 of the bipolar electrode 14 at one end in the first direction D1 through the separator 13.

[0019] The positive terminal electrode 〈0000090〉 includes the electrode plate 15 and the positive electrode active material layer 16 provided on one surface 15a of the electrode plate 15. The positive electrode active material layer 16 of the positive terminal electrode 〈0000091〉 faces the negative electrode active material layer 17 of the bipolar electrode 14 at the other end in the first direction D1 through the separator 13.

[0020] The electrode plate 15 is formed, for example, in a rectangular sheet shape. The material of the electrode plate 15 is, for example, a metal material, a conductive resin material, or a conductive inorganic material. Examples of the conductive resin material include a conductive polymer material or a resin obtained by adding a conductive filler to a non-conductive polymer material as needed. The electrode plate 15 may include a plurality of layers. In this case, each layer of the electrode plate 15 may include the above metal material and / or conductive resin material.

[0021] A coating layer may be formed on the surface of the electrode plate 15. The coating layer may be formed by a known method such as plating or spray coating. The electrode plate 15 may have, for example, a plate shape, a foil shape (e.g., a metal foil), a film shape, or a mesh shape. Examples of the metal foil include aluminum foil, copper foil, nickel foil, titanium foil, or stainless steel foil. The electrode plate 15 may be an alloy foil of the above metals or a foil formed by integrating a plurality of metal foils. The outer edge portion 15c of the electrode plate 15 forms a rectangular frame shape and is an uncoated area where the positive electrode active material and the negative electrode active material are not coated. In the present embodiment, the outer edge portion 15c of the electrode plate 15 is the outer edge portion of the electrode and the outer edge portion of the electrode laminate 11.

[0022] Examples of the positive electrode active material constituting the positive electrode active material layer 16 include nickel hydroxide. Examples of the negative electrode active material constituting the negative electrode active material layer 17 include a hydrogen storage alloy. The positive electrode active material layer 16 and the negative electrode active material layer 17 are rectangular when viewed from the first direction D1. In the present embodiment, the formation region of the negative electrode active material layer 17 on the other surface 15b of the electrode plate 15 is slightly larger than the formation region of the positive electrode active material layer 16 on one surface 15a of the electrode plate 15.

[0023] The separator 13 is formed, for example, in a sheet shape. Examples of the separator 13 include a porous film made of a polyolefin resin such as polyethylene (PE) or polypropylene (PP), a woven fabric or a non-woven fabric made of polypropylene, methyl cellulose, or the like. The separator 13 may be reinforced with a vinylidene fluoride resin compound. Note that the separator 13 is not limited to a sheet shape, and a bag-shaped one may be used.

[0024] A plurality of internal spaces V are provided inside the electrode laminate 11. The internal spaces V are provided between electrodes (electrode plates 15) adjacent in the first direction. And an electrolytic solution (not shown) containing an alkaline solution such as an aqueous potassium hydroxide solution is accommodated in each internal space V. The electrolytic solution is impregnated in the separator 13, the positive electrode active material layer 16, and the negative electrode active material layer 17.

[0025] The sealing member 12 is a member for forming an internal space V between adjacent electrodes in the first direction D1 and for sealing the internal space V. In this embodiment, the sealing member 12 seals the spaces between adjacent bipolar electrodes 14 along the first direction D1, between adjacent negative terminal electrodes 18 and bipolar electrodes 14 along the first direction D1, and between adjacent positive terminal electrodes 19 and bipolar electrodes 14 along the first direction D1.

[0026] The sealing member 12 has a first resin portion 21 formed on the electrode laminate 11 and a second resin portion 31 formed on the first resin portion 21.

[0027] The first resin portion 21 is formed in a rectangular cylindrical shape overall. The first resin portion 21 is provided on the side surface 11s of the electrode stack 11 that extends in the first direction D1, surrounding the electrode stack 11 when viewed from the first direction D1. The first resin portion 21 holds the outer edge portion 15c on the side surface 11s. The first resin portion 21 can be joined to at least one of the one side 15a and the other side 15b of the electrode plate 15 at each outer edge portion 15c of the electrode plate 15.

[0028] The first resin portion 21 includes a plurality of sealing materials 22, a plurality of spacers 23, and a welded end portion 24. The sealing materials 22 are provided on each of the electrode plates 15. Therefore, the sealing materials 22 are stacked on top of each other along the first direction D1. The sealing materials 22 are formed in a frame shape on the outer edge portion 15c of the electrode plate 15. The sealing materials 22 are provided so as to extend from one side 15a of the electrode plate 15 through the side to the other side 15b, covering the outer edge portion 15c. The sealing materials 22 are joined to at least one of the one side 15a and the other side 15b of the electrode plate 15 at each outer edge portion 15c of the electrode plate 15 by welding or the like.

[0029] The spacer 23 is positioned between adjacent sealing materials 22 in the first direction D1. This allows the spacer 23 to maintain space between adjacent sealing materials 22, i.e., between adjacent electrode plates 15. The spacer 23 is frame-shaped and positioned on the outer edge 15c of the electrode plate 15 when viewed from the first direction D1.

[0030] The welded end 24 is formed by welding together the ends of multiple sealing materials 22 and multiple spacers 23 that are opposite to the internal space V, thereby integrating them. The welded end 24 is formed in the shape of a rectangular frame surrounding the electrode stack 11 when viewed from the first direction D1. The welded end 24 is formed by welding together the ends of each sealing material 22 and each spacer 23 that are located outside the outer peripheral edge of the electrode plate 15 when viewed from the first direction D1. The side surface of the welded end 24 opposite to the internal space V extends along the first direction D1 and constitutes the side surface 21s of the first resin part 21.

[0031] The second resin portion 31 is located outside the electrode stack 11 and the first resin portion 21, and is provided outside the unit stack U (see Figure 4) which includes the electrode stack 11 and the first resin portion 21. The second resin portion 31 is provided on the side surface 21s of the first resin portion 21 that extends in the first direction D1. In this embodiment, the second resin portion 31 is provided on the side surface 21s of one side portion 21a that constitutes the first resin portion 21. The side portion 21a extends in a second direction D2 that intersects (in this case, perpendicular to) the first direction D1 of the electrode stack 11.

[0032] The second resin portion 31 is formed, for example, by resin injection molding. The second resin portion 31 extends along the entire length of the electrode laminate 11 in the first direction D1. The second resin portion 31 covers at least the region of the first resin portion 21 in which a plurality of first communication holes 21h, described later, are formed. In this embodiment, the second resin portion 31 is formed in a plate shape that covers both end faces and the side surface 21s of the side portion 21a in the first direction D1. The second resin portion 31 is welded to the outer edge of the side portion 21a by the heat during injection molding.

[0033] The second sealing portion has overhang portions 32 at both ends in the first direction D1. One overhang portion 32 protrudes toward the inner edge of the first resin portion 21 at one end in the first direction D1 and is bonded to a sealing material 22 welded to one side 15a of the electrode plate 15 constituting the negative electrode terminal electrode 18. The other overhang portion 32 protrudes toward the inner edge of the first resin portion 21 at the other end in the first direction D1 and is bonded to a sealing material 22 welded to the other side 15b of the electrode plate 15 constituting the positive electrode terminal electrode 19.

[0034] The first resin part 21 and the second resin part 31 are formed of, for example, an insulating resin. In this embodiment, since the electrolyte is strongly alkaline, the first resin part 21 and the second resin part 31 are made of an insulating resin material that has strong alkali resistance.

[0035] Examples of resin materials constituting the first resin part 21 and the second resin part 31 include polypropylene (PP), polyethylene (PE), polyphenylene sulfide (PPS), or modified polyphenylene ether (modified PPE). The resin materials constituting the first resin part 21 and the resin materials constituting the second resin part 31 are mutually compatible. As a result, the first resin part 21 and the second resin part 31 can be directly bonded to each other. The first resin part 21 is made of polypropylene (PP), for example, and the second resin part 31 is made of modified polyphenylene ether (modified PPE), for example.

[0036] The first resin portion 21 has a first communication hole 21h that communicates with the internal space V. In this embodiment, the first communication hole 21h extends in a third direction D3 that intersects (in this case, perpendicular to) the first direction D1 and the second direction D2, passing through the spacer 23 and the welded end portion 24, so as to connect the internal space V and the second communication hole 31h.

[0037] The second resin portion 31 has a second communication hole 31h that communicates with the first communication hole 21h. The second communication hole 31h communicates with the internal space V via the first communication hole 21h. In this embodiment, the second communication hole 31h extends through the second resin portion 31 in a third direction D3 so as to connect the first communication hole 21h and the opening 34 described later. The width of the first communication hole 21h (length of the first communication hole 21h in the first direction D1) and the width of the second communication hole 31h (length of the second communication hole 31h in the first direction D1) are, for example, the same.

[0038] The first communication hole 21h and the second communication hole 31h are preferably injection holes for injecting electrolyte into the internal space V. After the electrolyte has been injected, the first communication hole 21h and the second communication hole 31h can become passages through which gas generated in the internal space V flows.

[0039] The number of first communication holes 21h is the same as the number of internal spaces V. Each first communication hole 21h communicates with a different internal space V. The number of second communication holes 31h is also the same as the number of internal spaces V. Each second communication hole 31h communicates with a different first communication hole 21h. In addition to the two first communication holes 21h and two second communication holes 31h shown in Figure 1, the sealing member 12 has a plurality of first communication holes 21h and a plurality of second communication holes 31h not shown on the front and back sides of Figure 1.

[0040] The second resin portion 31 has a plurality of protrusions 33 that project in a third direction D3 from the side surface 31s extending in a first direction D1 of the second resin portion 31. The protrusions 33 have a frame shape that forms a plurality of openings 34. When the electrolyte is injected into the internal space V, the protrusions 33 guide the electrolyte into the second communication hole 31h and suppress leakage of the electrolyte to the outside. In addition, the protrusions 33 can function as connecting protrusions for connecting a pressure regulating valve or the like.

[0041] Viewed from the third direction D3, the projections 33 are arranged to surround each second communication hole 31h. The second communication holes 31h communicate with the openings 34 formed by the projections 33. The width of the opening 34, which is the length of the opening 34 in the first direction D1, is greater than the width of the second communication hole 31h, which is the length of the second communication hole 31h in the first direction D1.

[0042] The energy storage module 10 described above can be manufactured using the energy storage module manufacturing apparatus 100 shown in Figure 2. Therefore, Figure 2 is a schematic cross-sectional view showing the configuration of the energy storage module manufacturing apparatus according to Embodiment 1.

[0043] The manufacturing apparatus 100 shown in Figure 2 includes molds 110, 120, and 130, an insert mold 140, and a suction machine 150. Molds 110, 120, and 130 are used to form the second resin part 31 by injection molding. Molds 110, 120, and 130 are, for example, metal molds.

[0044] The molds 110 and 120 face each other along a first direction D1. The molds 110 and 120 are positioned to sandwich the unit laminate U from both sides in the first direction D1. The unit laminate U positioned between the molds 110 and 120 has, for example, the outer edge of its side portion 21a protruding outside the molds 110 and 120.

[0045] The mold 130 has a shape that corresponds to the outer shape of the second resin part 31. The mold 130 is configured to move back and forth along the second direction D2. The mold 130 is positioned to surround the outer edge of the side part 21a. A nesting mold 140 is attached to the mold 130.

[0046] The mold 130 has an insertion hole 131 formed to communicate with the inside of the mold 130, and a suction hole 132 formed to communicate with the insertion hole 131. The insertion portion 142 of the nesting mold 140, which will be described later, is inserted into the insertion hole 131. The insertion hole 131 and the suction hole 132 extend through the mold 130 in a third direction D3, for example, to connect the inside and outside of the mold 130. The suction hole 132 communicates with the inside of the mold 130 via the insertion hole 131. Each suction hole 132 is connected to a suction machine 150, which will be described later, by piping or the like.

[0047] The nesting mold 140 has a shape that corresponds to the shape of the first communication hole 21h and the shape of the second communication hole 31h. The nesting mold 140 is used to form the second communication hole 31h in the second resin part 31. Therefore, the number of nesting molds 140 is the same as the number of second communication holes 31h. In addition to the two nesting molds 140 shown in Figure 2, the manufacturing apparatus 100 has several other nesting molds 140, not shown, on the front and back sides of Figure 2.

[0048] The nesting mold 140 is, for example, a metal plate. The nesting mold 140 has a communication hole forming section 141 for forming the second communication hole 31h and an insertion section 142 that is inserted into the insertion hole 131. The nesting mold 140 is attached to the mold 130 by inserting the insertion section 142 into the insertion hole 131 before the injection molding of the second resin section 31. The nesting mold 140 is removed from the second resin section 31 and the unit laminate U after injection molding, thereby forming the second communication hole 31h while preventing the first communication hole 21h from becoming blocked.

[0049] The suction device 150 is located outside the mold 130. The suction device 150 is connected to each suction hole 132. The suction device 150 sucks the inside of the mold 130 through the suction holes 132 when inserting the insertion part 142 of the nesting mold 140, in which the tip of the communication hole forming part 141 is positioned in the first communication hole 21h of the first resin part 21 formed in the electrode laminate 11, into the insertion hole 131.

[0050] Here, when inserting the insertion part 142 into the insertion hole 131, the insert mold 140 (specifically, the insertion part 142) may slide against the mold 130 (specifically, the insertion hole 131), causing wear and generating wear particles. If these wear particles, generated during wear, adhere to the vicinity of the first communication hole 21h and the second communication hole 31h of the energy storage module 10 obtained after injection molding, there is a risk that they may become foreign matter and enter the inside of the energy storage module 10.

[0051] Therefore, the suction device 150 sucks up the wear particles along with the gas inside the mold 130. As the suction device 150, a dust collector that sucks up and collects the wear particles along with the gas inside the mold 130 can be used.

[0052] As described above, the manufacturing apparatus 100 for the energy storage module 10 according to this embodiment includes a mold 130, an insert mold 140, and a suction device 150. In this manufacturing apparatus 100, when the insertion portion 142 of the insert mold 140 is inserted into the insertion hole 131 formed in the mold 130, wear particles generated by the sliding of the insert mold 140 against the mold 130 are sucked out from inside the mold 130 along with gas by the suction device 150. Therefore, the adhesion of wear particles near the first communication hole 21h and the second communication hole 31h of the energy storage module 10 obtained after resin molding is suppressed.

[0053] The manufacturing apparatus 100 described above can be used in the manufacturing method of the energy storage module 10 shown in Figure 3. Therefore, the manufacturing method of the energy storage module according to Embodiment 1 will be described with reference to Figure 3. Figure 3 is a flowchart showing the manufacturing method of the energy storage module according to Embodiment 1.

[0054] As shown in Figure 3, the manufacturing method of the energy storage module 10 has five steps, for example: a preparation step (step S1), an installation step (step S2), a molding step (step S3), a demolding step (step S4), and an injection step (step S5).

[0055] The details of each process will be explained below with reference to Figures 4 and 5. Figure 4 is a schematic cross-sectional view illustrating the mounting process. Figure 5 is a schematic cross-sectional view illustrating the molding process and the demolding process. The positions and directions of the cross-sections shown in Figures 4 and 5 are the same as those of the cross-sections in Figures 1 and 2. In addition, the specific structures of the electrode laminate 11 and the first resin part 21 are omitted in Figures 4 and 5 as appropriate, and the molds 110 and 120 are not shown.

[0056] [Preparation process (Step S1)] Step S1 is a preparation step for preparing the unit laminate U. The unit laminate U shown in Figure 4 includes an electrode laminate 11 and a first resin portion 21 formed in the electrode laminate 11. The first resin portion 21 of the unit laminate U has a first communication hole 21h formed therein that communicates with an internal space V provided inside the electrode laminate 11. The tip of the communication hole forming portion 141 of the corresponding nesting type 140 is positioned in each first communication hole 21h of the unit laminate U.

[0057] [Installation process (Step S2)] Step S2 is an installation step in which the insertion part 142 of the nested type 140, in which the tip of the communication hole forming part 141 is positioned in the first communication hole 21h of the first resin part 21 of the unit laminate U, which is the electrode laminate 11, is inserted into the insertion hole 131.

[0058] In the installation process, for example, 110 and 120 are positioned so as to sandwich the unit laminate U, in which the nesting mold 140 has been placed in the preparation process. Next, as shown in S2-1 of Figure 4, the mold 130 is positioned such that the inside of the mold 130 faces the side surface 21s of the first resin part 21, and the insertion hole 131 faces the insertion part 142 of the corresponding nesting mold 140.

[0059] Next, as shown in S2-2 of Figure 4, the insertion part 142 is inserted into the corresponding insertion hole 131 by moving the mold 130 toward the side surface 21s of the first resin part 21 along the second direction D2. The white arrow shown in S2-2 of Figure 4 indicates the direction of movement of the mold 130 during the mounting process. By inserting the insertion part 142 into the insertion hole 131, the nesting mold 140 can be placed inside the molds 110, 120, and 130 together with the unit laminate U.

[0060] Here, the installation process includes a suction step in which the inside of the mold 130 is sucked through the suction hole 132 when the insertion part 142 is inserted into the insertion hole 131. In the suction step, when the insertion part 142 is inserted into the insertion hole 131, the inside of the mold 130 is sucked by a suction device 150 connected to the suction hole 132. As a result, wear particles generated by the sliding of the insert mold 140 against the mold 130 when the insertion part 142 is inserted into the insertion hole 131 are sucked out of the mold 130 along with the gas.

[0061] Then, as shown in S2-3 of Figure 4, in the mold closed state after the insertion part 142 is inserted into the insertion hole 131, a molding space C is formed surrounded by the molds 110, 120, 130, the nesting mold 140, and the unit laminate U. The molding space C is a cavity space filled with molten resin material, which is the material for forming the second resin part 31, and has a shape corresponding to the shape of the second resin part 31. In this embodiment, molds 110 and 120 are fixed molds and mold 130 is a movable mold, but mold 130 may be a fixed mold and molds 110 and 120 may be movable.

[0062] [Molding process (Step S3)] Step S3 is a molding step in which the second resin part 31 is formed by resin molding using the mold 130 to which the insert mold 140 has been attached in the mounting step. As shown in S3 of Figure 5, in the molding step, for example, the second resin part 31 is formed in the first resin part 21 of the unit laminate U by injection molding.

[0063] Specifically, in the molding process, for example, molten resin material is injected into the molding space C at a predetermined injection pressure from a gate (not shown) provided in the mold 130. By cooling and solidifying the resin material, a second resin part 31 having a shape corresponding to the molding space C is formed. In the molding process, the communication hole forming part 141 of the insert mold 140 prevents the first communication hole 21h from being blocked during the formation of the second resin part 31, while forming a second communication hole 31h that communicates with the first communication hole 21h in the second resin part 31.

[0064] [Release process (Step S4)] Step S4 is a demolding step in which the mold 130 and the insert mold 140 are released from the second resin part 31 and the unit laminate U formed by the molding process. In the demolding step, for example, the mold 130 is removed from the second resin part 31 and the unit laminate U by moving the mold 130 away from the side surface 31s of the second resin part 31 along the second direction D2. The white arrow shown in S4-1 of Figure 5 indicates the direction of movement of the mold 130 in the demolding step.

[0065] Next, the insert mold 140 is moved away from the second resin part 31 and the unit laminate U along the second direction D2, thereby removing the insert mold 140 from the second resin part 31 and the unit laminate U. This creates a second communication hole 31h in the second resin part 31 that communicates with the internal space V via the first communication hole 21h. The white arrow shown in S4-2 of Figure 5 indicates the direction of movement of the insert mold 140 during the demolding process. Next, the molds 110 and 120 are separated from each other, and the unit laminate U with the second resin part 31 formed on it is removed from the molds 110 and 120.

[0066] [Injection process (Step S5)] Step S5 is an injection step in which the electrolyte is injected into the internal space V through the second communication hole 31h and the first communication hole 21h of the sealing member 12. If the first communication hole 21h and the second communication hole 31h are injection holes, the electrolyte is injected into each of the internal spaces V during the injection step. After the electrolyte is injected, the first communication hole 21h and the second communication hole 31h are sealed by connecting a pressure regulating valve or the like to the projection 33. In this way, the energy storage module 10 is manufactured.

[0067] As described above, the manufacturing method of the energy storage module 10 according to this embodiment includes an attachment step of inserting the insertion portion 142 of a nesting mold 140, in which the tip of the communication hole forming portion 141 is positioned, into the insertion hole 131 of the first communication hole 21h of the first resin portion 21 formed in the electrode laminate 11, and a molding step of forming the second resin portion 31 by resin molding using the mold 130 to which the nesting mold 140 has been attached in the attachment step.

[0068] In this manufacturing method, when the insertion portion 142 of the insert mold 140 is inserted into the insertion hole 131 formed in the mold 130, wear particles generated by the sliding of the insert mold 140 against the mold 130 are sucked out from inside the mold 130 along with gas during the suction process. As a result, the adhesion of wear particles near the first communication hole 21h and the second communication hole 31h of the energy storage module 10 obtained after resin molding is suppressed.

[0069] Therefore, according to this embodiment, when attaching the insert mold 140 to the mold 130 used for resin molding, it is possible to suppress the ingress of foreign matter into the energy storage module 10 caused by wear particles generated by the wear of the insert mold 140 due to sliding against the mold 130.

[0070] This disclosure is not limited to the embodiments described above, and may be modified as appropriate without departing from its intent. [Explanation of symbols]

[0071] 10 Energy storage modules 11 Electrode stack 11s Side view 12 sealing member 13 separator 14 bipolar electrode 15 Electrode plate 15a One side 15b Other side 15c Outer edge 16 Positive electrode active material layer 17 Negative electrode active material layer 18 Negative terminal electrode 19 Positive terminal electrode 21 First resin part 21a Side part 21h First communication hole 21s Side 22 Sealing material 23 Spacer 24 Welded end 31 2nd resin part 31h 2nd communication hole 31s Side 32 Overhang portion 33 Protrusion 34 Opening 100 Manufacturing equipment Models 110, 120, and 130 131 Insertion port 132 Suction port 140 Nesting type 141 Communication hole forming part 142 Insertion part 150 Suction machine C: Molding space U: Unit laminate V: Internal space

Claims

1. A method for manufacturing an energy storage module, The aforementioned energy storage module is Electrode stack and, A first resin portion having a first communication hole formed therein that communicates with an internal space provided inside the electrode laminate, A second resin part is formed by resin molding using a mold to which an insert mold is attached, and a second communication hole is formed that communicates with the first communication hole. The aforementioned type is, An insertion hole formed to communicate with the inside of the mold, A suction hole formed to communicate with the aforementioned insertion hole, The aforementioned nested type is, A communication hole forming section for forming the second communication hole, It has an insertion portion that is inserted into the aforementioned insertion hole, The aforementioned manufacturing method is An installation step of inserting the nested insertion part, in which the tip of the communication hole forming part is positioned, into the first communication hole of the first resin part formed in the electrode laminate, The process includes a molding step of forming the second resin part by resin molding using the mold to which the insert mold has been attached by the mounting step, The aforementioned mounting process is, A method for manufacturing an energy storage module, comprising a suction step of sucking the inside of the mold through the suction hole when inserting the insertion portion into the insertion hole.

2. The method for manufacturing an energy storage module according to claim 1, wherein the first and second communication holes are injection holes for injecting an electrolyte into the internal space.

3. A manufacturing apparatus for energy storage modules, The aforementioned energy storage module is Electrode stack and, A first resin portion having a first communication hole formed therein that communicates with an internal space provided inside the electrode laminate, A second resin part is formed by resin molding using a mold to which an insert mold is attached, and a second communication hole is formed that communicates with the first communication hole. The aforementioned type is, An insertion hole formed to communicate with the inside of the mold, A suction hole formed to communicate with the aforementioned insertion hole, The aforementioned nested type is, A communication hole forming section for forming the second communication hole, It has an insertion portion that is inserted into the aforementioned insertion hole, The aforementioned manufacturing apparatus, The above type and, The aforementioned nested type, A manufacturing apparatus for an energy storage module, comprising: a suction machine that sucks the inside of the mold through the suction hole when inserting the nested insertion part, in which the tip of the communication hole forming part is positioned into the first communication hole of the first resin part formed in the electrode laminate, into the insertion hole.

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