Battery unit and method for manufacturing the battery unit

Abstract

To integrate a secondary battery and a panel structure together.SOLUTION: A battery unit comprises: a plate-like core member that has a plurality of protrusions provided on at least one surface; a plate-like face plate that is arranged on the plurality of protrusions; batteries that are arranged respectively in spaces between the core member and the face plate; and joints that are selectively formed between the face plate and the plurality of protrusions and that connects the core member and the face plate together.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a battery unit and a method for manufacturing a battery unit. [Background technology]

[0002] Battery cases having a highly rigid sandwich panel structure are used for installation in automobiles, trains, and other mobility products (for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-110003 A Summary of the Invention [Problem to be solved by the invention]

[0004] Current electric mobility mainly uses lithium-ion batteries that use liquid. Lithium-ion batteries have safety concerns such as spontaneous combustion, so strict safety requirements are imposed on them. There is an increasing need for lightweight structures in mobility products in general to extend the driving range. There is a demand for technology that is lightweight and can effectively utilize the limited space in mobility products.

[0005] An object of the present disclosure is to provide a battery unit in which a battery and a panel structure are integrated, and a method for manufacturing the battery unit. [Means for solving the problem]

[0006] A battery unit according to one embodiment of the present disclosure comprises a plate-shaped core member having a plurality of protrusions on at least one surface, a plate-shaped face plate arranged on the plurality of protrusions, a battery arranged in the space between the core member and the face plate, and a joint selectively formed between the face plate and the plurality of protrusions to connect the core member and the face plate.

[0007] A manufacturing method for a battery unit according to one aspect of the present disclosure includes forming a convex portion on at least one surface of a core member, placing a battery on the core member, and joining a face plate to the convex portion.

[0008] A method for manufacturing a battery unit according to one aspect of the present disclosure includes forming a convex portion on at least one surface of a core member, joining a face plate to the convex portion, and inserting a battery into the space between the core member and the face plate.

[0009] A method for manufacturing a battery unit according to one embodiment of the present disclosure includes the steps of forming a convex portion on at least one surface of a core member, shaping the core member and a face plate fused to the convex portion into a three-dimensional shape, shaping a battery into a three-dimensional shape, placing the battery on the core member, and joining the face plate to the convex portion. Effect of the Invention

[0010] According to the present disclosure, the battery and the panel structure can be integrated. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic cross-sectional view of a battery unit according to a first embodiment. [Diagram 2] FIG. 2 is a diagram illustrating a core member according to the first embodiment. [Diagram 3]FIG. 3 is a diagram illustrating an example of the shape of the battery according to the first embodiment. [Figure 4] FIG. 4 is a diagram illustrating an example of the shape of the battery according to the first embodiment. [Diagram 5] FIG. 5 is a diagram illustrating an example of the shape of the battery according to the first embodiment. [Figure 6] FIG. 6 is a flowchart showing the flow of a first example manufacturing method of the battery unit according to the first embodiment. [Figure 7] FIG. 7 is a flowchart showing the flow of the second example manufacturing method of the battery unit according to the first embodiment. [Figure 8] FIG. 8 is a flowchart showing the flow of the third example of a manufacturing method for the battery unit according to the first embodiment. [Figure 9] FIG. 9 is a schematic cross-sectional view of a battery unit according to the second embodiment. [Figure 10] FIG. 10 is a diagram illustrating a core member according to the second embodiment. [Figure 11] FIG. 11 is a schematic cross-sectional view of a battery unit according to a modified example of the second embodiment. [Figure 12] FIG. 12 is a schematic cross-sectional view of a battery unit according to a third embodiment. [Figure 13] FIG. 13 is a schematic cross-sectional view of a battery unit according to a modified example of the third embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, an embodiment of the present invention will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited to this embodiment, and when there are multiple embodiments, the present invention also includes a configuration in which each embodiment is combined. In the following embodiments, the same parts are given the same reference numerals, and duplicated explanations will be omitted.

[0013] [First embodiment] The configuration of the battery unit according to the first embodiment will be described with reference to Fig. 1 and Fig. 2. Fig. 1 is a schematic diagram showing a cross section of the battery unit according to the first embodiment. Fig. 2 is a schematic diagram showing a core member according to the first embodiment. The battery unit of the present disclosure can be applied to, for example, automobiles, trains, other mobility products, buildings, and the like.

[0014] As shown in FIG. 1, the battery unit 10 includes a core member 12 , a face plate 14 , a joint portion 16 , a protrusion portion 18 , and a battery 20 .

[0015] The core member 12 has, for example, thermoplasticity. The core member 12 is formed in a plate shape from a thermoplastic resin. Examples of the thermoplastic resin include, but are not limited to, polyamide resin, polypropylene resin, ABS resin, polyether ether ketone, polyether ketone ketone, and polyphenylene sulfide. The thermoplastic resin is preferably a thermoplastic fiber reinforced plastic (FRP: Fiber Reinforced Plastics) containing reinforcing fibers. The fiber reinforced plastic is preferably, for example, a glass fiber reinforced plastic (GFRP: Glass Fiber Reinforced Plastics) and a carbon fiber reinforced plastic (CFRP: Carbon Fiber Reinforced Plastics). The fiber reinforced plastic is not limited to these. The core member 12 has a plurality of convex portions 18 on one surface. The core member 12 has a concave portion 22 on the other surface at a position corresponding to the convex portion 18. As shown in FIG. 2, a plurality of convex portions 18 are formed on one surface of the core member 12.

[0016] The face plate 14 is disposed on one surface of the core member 12. The face plate 14 is disposed on the convex portion 18 on one surface of the core member 12. The face plate 14 has thermoplastic properties. The face plate 14 is formed in a plate shape from a thermoplastic resin. Examples of the thermoplastic resin include, but are not limited to, polyamide resin, polypropylene resin, ABS resin, polyether ether ketone, polyether ketone ketone, and polyphenylene sulfide. The thermoplastic resin is preferably a thermoplastic reinforced fiber plastic containing reinforcing fibers. The reinforced fiber plastic is preferably, for example, a glass fiber reinforced plastic and a carbon fiber reinforced plastic. The reinforced fiber plastic is not limited to these. The core member 12 and the face plate 14 may be formed from the same material or from different materials. For example, in this embodiment, the core member 12 may be formed from a normal thermoplastic resin, and the face plate 14 may be formed from a reinforced fiber plastic having thermoplastic properties. Also, the core member 12 may be formed from a reinforced fiber plastic having thermoplastic properties, and the face plate 14 may be formed from a normal thermoplastic resin. Furthermore, the core member 12 and the face plate 14 may be formed of different types of thermoplastic resins. For example, in this embodiment, the core member 12 may be formed of polyamide resin, and the face plate 14 may be formed of polypropylene resin. The core member 12 and the face plate 14 may be formed of thermosetting resin. A charging port for the battery 20 may be provided on the outer surface of the face plate 14. The charging port for the battery 20 may be provided on the outer surface of the core member 12.

[0017] The joint 16 connects the core member 12 and the face plate 14. The joint 16 is formed between the top of the protrusion 18 and one surface of the face plate 14. The joint 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14. The joint 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14, for example, depending on the shapeability, rigidity, and impact resistance characteristics required for the battery unit 10. The joint 16 is a fusion part formed by heating and melting the joint between the top of the protrusion 18 and the face plate 14, and then disposing the face plate 14 and cooling it. The heating may be performed using, for example, a heat source such as a heater or an electric heating wire, ultrasonic vibration, electromagnetic induction by a magnetic field, or a laser, but is not limited to these methods. The joint 16 may be, for example, an adhesive part where an adhesive that bonds the top of the protrusion 18 and the face plate 14 has dried.

[0018] The battery 20 is a secondary battery. The battery 20 is, for example, a battery with relatively low explosion-proof requirements and high degree of freedom in shape. The battery 20 may be, for example, a lithium ion battery. The battery 20 may be, for example, an all-solid-state battery using a solid electrolyte. The battery 20 may be another type of battery.

[0019] The battery 20 is disposed on the core member 12. For example, the battery 20 is disposed between the convex portions 18 on the core member 12. For example, the battery 20 is formed in a straight line so as to be disposed in an area on the core member 12 where the convex portions 18 are not formed. Note that in the example shown in FIG. 1, the battery 20 is disposed on the core member 12, but the present disclosure is not limited thereto. For example, the battery 20 may be disposed below the core member 12 in a usage form. For example, the battery 20 may be disposed so that the long side shown in FIG. 1 is perpendicular to the plane of the core member 12.

[0020] For example, the battery 20 may contact the side surface of the protrusion 18 on the core member 12 and be fixed in position by the protrusion 18. In other words, the protrusion 18 may have a function of fixing the position of the battery 20. The protrusion 18 may be processed to improve frictional force, for example, by roughening the surface. In addition, the inner surfaces of the core member 12 and the face plate 14 may be roughened so that the core member 12 and the face plate 14 as a whole have a function of fixing the position of the battery 20. In addition, the core member 12 and the face plate 14 may have a double curved surface shape, and the battery 20 may have a double curved surface shape that conforms to the core member 12.

[0021] The battery 20 can be charged and discharged, for example, through a charging / discharging port (not shown) provided on the outer surface of the faceplate 14 or the outer surface of the core member 12. When multiple batteries 20 are arranged on the core member 12, the multiple batteries 20 can be connected in series or in parallel to provide a single charging / discharging port on the outer surface of the faceplate 14. Even when multiple batteries 20 are connected in series or in parallel, the number of charging / discharging ports provided on the outer surface of the faceplate 14 may be multiple.

[0022] When using a plurality of battery units 10 each equipped with a battery 20, each battery unit 10 may be provided with an attachment or the like that allows the plurality of battery units 10 to be electrically connected in series or in parallel. This allows the use of a plurality of battery units 10 to be treated as a single battery system.

[0023] It is desirable that the contact portion between the battery 20 and the core member 12 and the face plate 14 is insulated. For example, an insulating sheet is preferably arranged at the contact portion between the battery 20 and the core member 12 and the face plate 14. By arranging an insulating sheet (not shown) at the contact portion between the battery 20 and the core member 12 and the face plate 14, insulation can be maintained. The insulating sheet is formed of, for example, resin. By maintaining insulation between the battery 20 and other components inside the battery unit 10, safety can be improved. Note that, on the outer surface of the battery 20, an insulating sheet may be arranged at least at the contact portion between the core member 12 and the face plate 14. An insulating sheet may be arranged on each of the core member 12, the face plate 14, and the battery 20.

[0024] [Battery shape] The shape of the battery according to the first embodiment will be described with reference to Fig. 3, Fig. 4, and Fig. 5. Fig. 3, Fig. 4, and Fig. 5 are diagrams that diagrammatically show an example of the shape of the battery according to the first embodiment.

[0025] 3, the battery 20A may be configured in a plate shape. The battery 20A has a plurality of holes 20a, which are, for example, through holes. The plurality of holes 20a are formed so that the protrusions 18 of the core member 12 can be inserted into the holes 20a. The battery 20A is configured to cover the upper surface of the core member 12 while avoiding the protrusions 18 by inserting the protrusions 18 into the holes 20a from the top of the core member 12.

[0026] 4, the battery 20B may be divided into a first battery 20B1, a second battery 20B2, and a third battery 20B3. The first battery 20B1, the second battery 20B2, and the third battery 20B3 are each configured in a plate shape. The first battery 20B1, the second battery 20B2, and the third battery 20B3 are each configured to cover the upper surface of the core member 12 by being disposed between the protrusions 18.

[0027] As shown in Fig. 4, the battery 20C may be divided into a first battery 20C1, a second battery 20C2, and a third battery 20C3. The first battery 20C1, the second battery 20C2, and the third battery 20C3 each have a plurality of cutouts 20c. The plurality of cutouts 20c are formed to follow the periphery of the protrusion 18. The first battery 20C1, the second battery 20C2, and the third battery 20C3 are configured to cover the upper surface of the core member 12 while avoiding the protrusion 18 by arranging the cutouts 20c to follow the periphery of the protrusion 18.

[0028] 3, 4, and 5, the battery 20A, the battery 20B, and the battery 20C can be disposed on the entire surface of the core member 12 while avoiding the protruding portion 18. Since the battery 20A and the battery 20C are configured so as to be disposed so as to avoid the protruding portion 18, the area can be made larger, making it easier to ensure the battery capacity.

[0029] Return to FIG. 1. The arrow shown in FIG. 1 indicates the shaping direction of the battery unit 10. The shaping direction shown in FIG. 1 is an example and does not limit the shaping direction according to the present disclosure. For example, the shaping direction may be the opposite direction to the direction shown in FIG. 1. When the core member 12 and the face plate 14 are made of a thermoplastic resin, the core member 12 and the face plate 14 are heated within the heat resistance temperature of the battery 20 to soften them. After the core member 12 and the face plate 14 are heated, a bending load is applied within the load capacity of the battery 20, thereby obtaining a battery unit 10 having an integral structure of the core member 12, the face plate 14, and the battery 20 without damaging the battery 20. In this embodiment, the more the shape freedom and load capacity of the battery 20 are excellent, the higher the shape freedom of the battery unit 10 is.

[0030] [Manufacturing method] (First example) A first example of a manufacturing method for the battery unit according to the first embodiment will be described with reference to Fig. 6. Fig. 6 is a flow chart showing the flow of the first example of a manufacturing method for the battery unit according to the first embodiment.

[0031] The surface of the thermoplastic resin is shaped into an uneven shape to form the core member 12 (step S10). The uneven shape may include a one-sided convex type in which a plurality of convex portions 18 are formed on only one side, and a double-sided convex type in which a plurality of convex portions 18 are formed on both sides. Then, the process proceeds to step S12.

[0032] The battery 20 is placed on the core member 12 (step S12). Specifically, the battery 20 is placed on the core member 12 so as to avoid the protruding portion 18. Then, the process proceeds to step S14.

[0033] The core member 12 and the face plate 14 are joined together (step S14). Specifically, the face plate 14 and the multiple protrusions 18 are selectively fused or bonded together to join the core member 12 and the face plate 14. Then, the process proceeds to step S16.

[0034] The core member 12, the face plate 14, and the battery 20 are shaped into a desired three-dimensional shape (step S16). Specifically, the core member 12, the face plate 14, and the battery 20 are shaped into a desired three-dimensional shape by applying heat to the core member 12, the face plate 14, and the battery 20 to a predetermined temperature while applying a bending load. This results in the battery unit 10. Note that step S16 may be omitted depending on the location and application of the battery unit 10.

[0035] (Second example) A second example of a manufacturing method for the battery unit according to the first embodiment will be described with reference to Fig. 7. Fig. 7 is a flowchart showing the flow of the second example of a manufacturing method for the battery unit according to the first embodiment.

[0036] Step S20 is the same as step S10 shown in FIG. 6, and therefore a description thereof will be omitted.

[0037] The core member 12 and the face plate 14 are joined together (step S22). Specifically, the face plate 14 is selectively fused to the plurality of protrusions 18 to join the core member 12 and the face plate 14. That is, in the second example manufacturing method for the battery unit 10 according to the first embodiment, the core member 12 and the face plate 14 are joined together before the battery 20 is placed on the core member 12. Then, the process proceeds to step S24.

[0038] The battery 20 is inserted into the space between the core member 12 and the face plate 14 (step S24). Specifically, the battery 20 is inserted into the space between the core member 12 and the face plate 14 so as to avoid the protrusions 18. Therefore, in the manufacturing method of the second example, it is preferable that the battery 20 has a linear shape without any cutouts or the like. Then, the process proceeds to step S26.

[0039] Step S26 is the same as step S16 shown in Fig. 6, and therefore a description thereof will be omitted. Note that step S26 may be omitted depending on the location and application of the battery unit 10.

[0040] As shown in the second example manufacturing method, the battery unit 10 can also be obtained by joining the core member 12 and the face plate 14 together and then inserting the battery 20 therein.

[0041] (Third example) A third example of a manufacturing method for the battery unit according to the first embodiment will be described with reference to Fig. 8. Fig. 8 is a flowchart showing the flow of the third example of a manufacturing method for the battery unit according to the first embodiment.

[0042] Step S30 is the same as step S10 shown in FIG. 6, and therefore a description thereof will be omitted.

[0043] The core member 12 is shaped into a desired three-dimensional shape (step S32). The face plate 14 is shaped into a desired three-dimensional shape (step S34). The battery 20 is shaped into a desired three-dimensional shape (step S36). That is, in the third example manufacturing method of the battery unit 10 according to the first embodiment, the core member 12, the face plate 14, and the battery 20 are each shaped into a three-dimensional shape independently. Therefore, in the third example manufacturing method of the battery unit 10 according to the first embodiment, the core member 12 and the face plate 14 may be formed of a thermosetting resin or the like. When the core member 12 and the face plate 14 are formed of a thermosetting resin or the like, step S30 and step S32 are the same process.

[0044] The battery 20 formed into a three-dimensional shape is placed on the core member 12 formed into a three-dimensional shape (step S38). Specifically, the battery 20 formed into a three-dimensional shape is placed on the core member 12 so as to avoid the protruding portion 18. Then, the process proceeds to step S40.

[0045] The core member 12 formed into a three-dimensional shape and the face plate 14 formed into a three-dimensional shape are joined together (step S40). Specifically, the core member 12 and the face plate 14 are joined by selectively fusing or adhering the formed face plate 14 and the multiple protrusions 18. This results in the battery unit 10. In the manufacturing method of the third example of the battery unit 10 according to the first embodiment, the core member 12, the face plate 14, and the battery 20 are formed independently. Therefore, the temperature and bending load when forming the core member 12 and the face plate 14 into a three-dimensional shape can be increased without considering the heat resistance temperature and load resistance of the battery 20. This allows the selection range of materials that can be used for the core member 12 and the face plate 14 to be expanded.

[0046] In step S36, the battery 20 may be prepared in advance in a desired three-dimensional shape. This eliminates the need to consider the temperature and bending load when forming the battery 20 into a three-dimensional shape, and therefore the range of available batteries 20 can be expanded.

[0047] In the first embodiment, the battery unit 10 has a three-dimensional structure in which the core member 12, the face plate 14, and the battery 20 are integrated together. Therefore, for example, by applying the battery unit 10 to the body of a drone or the like, space can be saved.

[0048] In the first embodiment, the battery unit 10 can be shaped into a curved structure that takes into account air resistance by taking advantage of the three-dimensional structure, for example. This makes it possible to easily expand the range of application of the battery unit 10 in the first embodiment.

[0049] In the first embodiment, the battery 20 is a secondary battery with low explosion-proof requirements, so that the structural members with explosion-proof requirements, i.e., the core member 12 and the face plate 14, can be made of fiber-reinforced plastic such as carbon fiber-reinforced plastic, instead of steel plate. This allows the battery unit 10 to be made lighter. For this reason, by applying the battery unit 10 to, for example, an automobile door, the fuel efficiency of the automobile can be improved. In addition, by applying the battery unit 10 to, for example, an automobile, the battery 20 can be arranged on a plate-shaped part such as a door, so that in addition to a conventional battery, the battery 20 can be installed in a portion that was not previously installed, thereby increasing the cruising distance.

[0050] In the first embodiment, the battery unit 10 can be quickly shaped into a shape appropriate for the application by storing the core member 12, face plate 14, and battery 20 in an integrated state without being shaped in advance. This allows the present embodiment to handle a wide variety of products and shorten the delivery time.

[0051] [Second embodiment] The configuration of the battery unit according to the second embodiment will be described with reference to Fig. 9 and Fig. 10. Fig. 9 is a schematic cross-sectional view of the battery unit according to the second embodiment. Fig. 10 is a schematic view of a core member according to the second embodiment.

[0052] 9, the battery unit 10A includes a core member 12A, face plates 14a and 14b, a joint 16, a battery 20, a temperature sensor 24, and a flow path 26. The battery unit 10A includes face plates on both sides of the core member 12A. The battery unit 10A has a sandwich structure in which the core member 12A is sandwiched between the face plates 14a and 14b.

[0053] 1 in that the core member 12A has protrusions 18 on both sides. The core member 12A has recesses 22 on both sides at positions corresponding to the protrusions 18. As shown in Figures 9 and 10, the core member 12A has a plurality of protrusions 18 and a plurality of recesses 22 on both sides.

[0054] The faceplate 14a is disposed on one surface of the core member 12A. The faceplate 14a is disposed on a protruding portion 18 on one surface of the core member 12A. The faceplate 14b is disposed on the other surface of the core member 12A. The faceplate 14b is disposed on the other surface of the core member 12A. The faceplate 14b is disposed on a protruding portion 18 on the other surface of the core member 12A. The battery unit 10A has an air layer between the core member 12A and the faceplate 14a. The battery unit 10A has an air layer between the core member 12A and the faceplate 14b.

[0055] The joint 16 connects the core member 12A and the face plate 14a on one surface of the core member 12A. The joint 16 is formed between the top of the protrusion 18 and one surface of the face plate 14a. The joint 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14a. The joint 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14a, for example, according to the rigidity and impact resistance characteristics required for the battery unit 10A. The joint 16 is a fusion part formed by heating and melting the joint between the top of the protrusion 18 and the face plate 14a, and then disposing and cooling the face plate 14a. The joint 16 may be, for example, an adhesive part where the adhesive that bonds the top of the protrusion 18 and the face plate 14a has dried.

[0056] The joint 16 connects the core member 12A and the face plate 14b on the other surface of the core member 12A. The joint 16 is formed between the top of the protrusion 18 and one surface of the face plate 14b. The joint 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14b. The joint 16 is selectively formed between the top of the plurality of protrusions 18 and one surface of the face plate 14b, for example, according to the rigidity and impact resistance characteristics required for the battery unit 10A. The joint 16 is a fusion part formed by heating and melting the joint between the top of the protrusion 18 and the face plate 14b, and then disposing and cooling the face plate 14b. The joint 16 may be, for example, an adhesive part where the adhesive that bonds the top of the protrusion 18 and the face plate 14b has dried.

[0057] The battery 20 is disposed in a space between the core member 12A and the face plate 14b. The battery 20 is disposed on the face plate 14b in the space between the core member 12A and the face plate 14b. In the example shown in FIG. 9, the battery 20 is disposed on the face plate 14b, but the present disclosure is not limited thereto. For example, the battery 20 may be disposed below the face plate 14b in a usage form. For example, the battery 20 may be disposed so that the long side shown in FIG. 1 is perpendicular to the plane of the face plate 14b. In addition, the core member 12A, the face plate 14a, and the face plate 14b may have a double curved surface shape, and the battery 20 may have a double curved surface shape along at least one of the core member 12A and the face plate 14b.

[0058] The temperature sensor 24 is disposed in the space between the core member 12A and the face plate 14a. The temperature sensor 24 is disposed on the core member 12A in the space between the core member 12A and the face plate 14a. The temperature sensor 24 detects, for example, the temperature of the space between the face plate 14a and the face plate 14b. The temperature sensor 24 detects, for example, a change in temperature of the space between the face plate 14a and the face plate 14b due to heat generation by the battery 20.

[0059] The flow passage 26 is disposed in a space between the core member 12A and the face plate 14a. The flow passage 26 is a space through which a fluid such as a gas or a liquid flows. The flow passage 26 exchanges heat between the fluid passing through the inside and the air between the face plate 14a and the face plate 14b.

[0060] In the second embodiment, for example, the temperature detection result by the temperature sensor 24 is monitored, and a fluid is caused to flow through the flow path 26 in accordance with the temperature detection result of the temperature sensor 24, thereby making it possible to keep the temperature between the face plates 14a and 14b constant. By making the temperature sensor 24, for example, an IoT (Internet of Things) sensor, it is possible to monitor the temperature detection result by the temperature sensor 24 by an external device. In this way, the temperature sensor 24 and the flow path 26 configure a temperature adjustment system that adjusts the temperature inside the face plates 14a and 14b.

[0061] A filler may be disposed between the core member 12A and the face plate 14a. Examples of the filler include, but are not limited to, explosion-proof materials, heat insulating materials, sound absorbing materials, fire extinguishing agents, and latent heat storage materials. Well-known materials may be used as the explosion-proof materials, heat insulating materials, fire extinguishing agents, and latent heat storage materials.

[0062] By disposing an explosion-proof material between the core member 12A and the face plate 14a, the explosion-proof characteristics of the battery unit 10A can be improved. By disposing a heat insulating material between the core member 12A and the face plate 14a, the heat insulating properties of the battery unit 10A can be improved. By disposing a fire extinguishing agent between the core member 12A and the face plate 14a, a fire extinguishing function can be added in which the fire extinguishing agent is released when the core member 12A and the face plate 14a melt when a fire or the like occurs. By disposing a fire extinguishing agent between the core member 12A and the face plate 14a, safety can be improved. By disposing a latent heat storage material between the core member 12A and the face plate 14a, the temperature of the battery 20 can be kept constant. By disposing a latent heat storage material between the core member 12A and the face plate 14a, the temperature adjustment characteristics can be further improved.

[0063] In the second embodiment, the battery unit 10A has a sandwich structure, which can further improve its rigidity.

[0064] In the second embodiment, a sandwich structure is adopted for the battery unit 10A to form a space inside, and a temperature adjustment function including the temperature sensor 24 and the flow path 26 can be configured in the space. That is, in the second embodiment, the temperature adjustment function of the battery 20 can be integrated into the battery unit 10A. This allows the second embodiment to achieve further space saving.

[0065] In the second embodiment, a sandwich structure is adopted for the battery unit 10A to form a space inside, in which explosion-proof materials, heat insulating materials, sound absorbing materials, fire extinguishing agents, latent heat storage materials, etc. can be placed. This allows the second embodiment to impart desired functions to the battery unit 10A. This allows the second embodiment to achieve further space saving.

[0066] In the second embodiment, for example, by manufacturing the battery unit 10A by the method shown in Fig. 8, the temperature of the battery 20 can be appropriately controlled, allowing the battery to be used even in an environment where the surface temperatures of the faceplates 14a and 14b are high. This is because the heat resistance temperatures of the faceplates 14a and 14b and the heat resistance temperature of the battery 20 can be determined independently, making it possible to set the heat resistance temperatures of the faceplates 14a and 14b high.

[0067] [Modification of the second embodiment] The configuration of a battery unit according to a modification of the second embodiment will be described with reference to Fig. 11. Fig. 11 is a schematic cross-sectional view of a battery unit according to a modification of the second embodiment.

[0068] As shown in FIG. 11, the battery unit 10Aa differs from the battery unit 10 shown in FIG. 9 in that the batteries 20 are arranged in the space between the core member 12A and the face plate 14b, and in the space between the core member 12A and the face plate 14a.

[0069] The battery 20 may be disposed in at least one of the space between the core member 12A and the face plate 14a and the space between the core member 12A and the face plate 14b. The battery 20 is disposed on the face plate 14a in the space between the core member 12A and the face plate 14a, but the present disclosure is not limited thereto. In addition, the core member 12A, the face plate 14a, and the face plate 14b may have a double curved surface shape, and the battery 20 may have a double curved surface shape along at least one of the core member 12A, the face plate 14a, and the face plate 14b.

[0070] The number of batteries 20 arranged on the faceplate 14a side and the number of batteries 20 arranged on the faceplate 14b side may be the same or different. The shape of the batteries 20 arranged on the faceplate 14a side and the shape of the batteries 20 arranged on the faceplate 14b side may be the same or different. The type of the batteries 20 arranged on the faceplate 14a side and the type of the batteries 20 arranged on the faceplate 14b side may be the same or different.

[0071] In the modified example of the second embodiment, the battery 20 can be disposed on at least one of the face plate 14a and the face plate 14b. This allows the modified example of the second embodiment to improve the degree of freedom in design.

[0072] In the modified example of the second embodiment, the battery 20 can be disposed on both the face plate 14a and the face plate 14b. This allows the modified example of the second embodiment to improve the amount of power supply.

[0073] [Third embodiment] The configuration of the battery unit according to the third embodiment will be described with reference to Fig. 12. Fig. 12 is a schematic cross-sectional view of the battery unit according to the third embodiment.

[0074] As shown in Fig. 11, the battery unit 10B includes a core member 12, a face plate 14, a joint 16, a battery 20, and a solar cell 28. The battery unit 10B differs from the battery unit 10 shown in Fig. 1 in that it includes the solar cell 28.

[0075] The solar cell 28 is provided on the outer surface of the face plate 14. The solar cell 28 has flexibility that allows it to be bent, for example, in the shaping direction indicated by the arrow in Fig. 11. The battery unit 10B is a battery unit in which a power generation function and a power storage function are integrated.

[0076] In the third embodiment, the battery unit 10B is integrated with a power generation function and a power storage function, thereby realizing a battery unit that is lightweight, has improved strength and rigidity, and has a power generation function and a power storage function integrated therein.

[0077] The third embodiment can be applied to mobility such as drones, which have weight and space constraints on the payload, to reduce weight with a shape that takes air resistance into consideration, and can also provide power storage and power generation functions. As a result, when the third embodiment is applied to drones, it can improve flight performance and continuous flight distance, and reduce weight by reducing the amount of wiring.

[0078] [Modification of the third embodiment] The configuration of a battery unit according to a modification of the third embodiment will be described with reference to Fig. 13. Fig. 13 is a schematic cross-sectional view of a battery unit according to a modification of the third embodiment.

[0079] 13, the battery unit 10Ba includes a core member 12A, a face plate 14a, a face plate 14b, a joint 16, a battery 20, a temperature sensor 24, a flow path 26, and a solar cell 28. The battery unit 10Ba differs from the battery unit 10A in that the battery unit 10Ba includes the solar cell 28.

[0080] The solar cell 28 is provided on the outer surface of the faceplate 14a. The solar cell 28 may be provided on the outer surface of the faceplate 14b, for example. The solar cell 28 may be provided on at least one of the outer surface of the faceplate 14a and the outer surface of the faceplate 14b, for example.

[0081] The battery 20 may be disposed in at least one of the space between the core member 12A and the face plate 14a and the space between the core member 12A and the face plate 14b, as in the case described in the modified example of the second embodiment. In the modified example of the third embodiment, the specific arrangement of the battery 20 is similar to that in the modified example of the second embodiment, and therefore will not be described.

[0082] In the modified example of the third embodiment, the battery unit 10Ba is integrated with a power generation function and a power storage function, thereby realizing a battery unit that is lightweight and has improved strength and rigidity, in which the power generation function, the power storage function, and the temperature adjustment function are integrated.

[0083] [effect] The battery unit described in the embodiment can be understood, for example, as follows.

[0084] The battery unit of the first embodiment includes a plate-shaped core member 12 having a plurality of protrusions 18 on at least one surface, a plate-shaped face plate 14 arranged on the plurality of protrusions 18, a battery 20 arranged in the space between the core member 12 and the face plate 14, and a joint 16 selectively formed between the face plate and the plurality of protrusions 18 to join the core member 12 and the face plate 14. This provides a battery unit in which the battery 20 and the panel structure are integrated.

[0085] In the battery unit of the second aspect, the battery 20 is a secondary battery, which allows the battery unit of the second aspect to be applied to mobility products.

[0086] In the battery unit of the third aspect, the secondary battery is a lithium ion battery or an all-solid-state battery, which allows the battery unit of the third aspect to have lower explosion-proof requirements and thus to be lighter in weight.

[0087] In the battery unit of the fourth embodiment, the core member 12 and the face plate 14 are made of a thermoplastic resin. This allows the core member 12, the face plate 14, and the battery 20 to be easily shaped into a desired three-dimensional shape in a state in which the battery 20 is assembled in the battery unit of the fourth embodiment.

[0088] The battery unit of the fifth embodiment has an insulating sheet provided at the contact portion between the battery 20 and the core member 12 and the face plate 14. This allows the battery unit of the fifth embodiment to insulate the battery 20 from the core member 12 and the face plate 14, thereby improving safety.

[0089] In the battery unit of the sixth embodiment, an insulating sheet is provided on the battery, which allows the battery unit of the sixth embodiment to insulate the battery 20 from the core member 12 and the face plate 14, thereby improving safety.

[0090] In the battery unit of the seventh embodiment, the face plate 14 has a charging port for the battery 20 on the outer surface. This makes it easy to charge and discharge the battery 20 when the battery 20 is incorporated in the battery unit 10.

[0091] In the battery unit of the eighth aspect, the face plate 14 is provided with a solar cell 28 on the outer surface. This allows the power generation function to be integrated, so that by applying the battery unit of the eighth aspect to a mobility product, the cruising distance can be increased.

[0092] In the battery unit of the ninth embodiment, the protrusions 18 are formed on both sides of the core member 12. A face plate 14a is disposed on one side of the core member 12. A face plate 14b is disposed on the other side of the core member 12. The battery 20 is disposed in the space between the core member 12 and the face plate 14b. This allows the rigidity of the battery unit of the ninth embodiment to be improved.

[0093] The battery unit of the tenth embodiment includes a temperature adjustment system between the multiple core members 12 and the face plate 14a, which allows the battery unit of the tenth embodiment to maintain a constant internal temperature.

[0094] In the battery unit of the eleventh embodiment, the temperature adjustment system includes a flow path 26 through which a fluid flows, and a temperature sensor 24 that detects the temperature between the face plates 14a and 14b. As a result, the battery unit of the eleventh embodiment can keep the internal temperature constant by causing a fluid to flow through the flow path 26 in response to the temperature detection result of the temperature sensor 24.

[0095] The battery unit of the twelfth embodiment includes a filler member disposed in the space between the core member 12 and the face plate 14a, which allows the battery unit of the twelfth embodiment to be provided with desired functions.

[0096] In the battery unit of the thirteenth aspect, the filling member includes at least one of an explosion-proof member, a heat insulating member, a sound absorbing member, a fire extinguishing agent, and a latent heat storage material, thereby allowing the battery unit of the thirteenth aspect to have the functions of the explosion-proof member, the heat insulating member, the sound absorbing member, the fire extinguishing agent, and the latent heat storage material.

[0097] In the battery unit of the fourteenth aspect, the multiple protrusions 18 have the function of fixing the battery 20. This makes it possible for the battery unit of the fourteenth aspect to prevent the battery 20 from shifting position inside.

[0098] The manufacturing method of the battery unit of the fifteenth aspect includes the steps of forming a protrusion 18 on at least one surface of the core member 12, arranging a battery 20 on the core member 12, and joining a face plate 14 to the protrusion 18. This results in a battery unit in which the battery 20 and the panel structure are integrated.

[0099] The manufacturing method of the battery unit of the sixteenth aspect includes the steps of forming a protrusion 18 on at least one surface of the core member 12, joining the face plate 14 to the protrusion 18, and inserting the battery 20 into the space between the core member 12 and the face plate 14. This results in a battery unit in which the battery 20 and the panel structure are integrated.

[0100] The manufacturing method of the battery unit of the seventeenth aspect includes the steps of forming a protrusion 18 on at least one surface of the core member 12, shaping the core member 12 and the face plate 14 fused to the protrusion 18 into a three-dimensional shape, shaping the battery 20 into a three-dimensional shape, placing the battery 20 on the core member 12, and joining the face plate 14 to the protrusion 18. This results in a battery unit in which the battery 20 and the panel structure are integrated. Furthermore, the manufacturing method of the battery unit of the seventeenth aspect results in a battery unit that can be used in a higher temperature environment.

[0101] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the contents of these embodiments. The above-mentioned components include those that a person skilled in the art can easily imagine, those that are substantially the same, and those that are within the so-called equivalent range. Furthermore, the above-mentioned components can be appropriately combined. Furthermore, various omissions, substitutions, or modifications of the components can be made without departing from the gist of the above-mentioned embodiments. [Explanation of symbols]

[0102] 10, 10A, 10B Battery Unit 12 Core material 14,14a,14b Faceplate 16 Joint 18 Convex 20 Battery 22 Recess 24 Temperature Sensor 26 Flow Path 28 Solar Cells

Claims

1. a plate-shaped core member having a plurality of protrusions on at least one surface and recesses on the other surface corresponding to the positions at which the protrusions are formed; A plate-shaped face plate disposed on the plurality of protruding portions; a battery disposed in a space between the core member and the face plate; a joint portion selectively formed between the face plate and the plurality of protrusions, the joint portion connecting the core member and the face plate; A battery unit comprising:

2. A plate-shaped core member having a plurality of protrusions on at least one surface, A plate-shaped face plate disposed on the plurality of protruding portions; a battery disposed in a space between the core member and the face plate; a joint portion selectively formed between the face plate and the plurality of protrusions, the joint portion connecting the core member and the face plate; Equipped with The protrusions are formed on both sides of the core member, A first face plate is disposed on one surface of the core member, A second face plate is disposed on the other surface of the core member, The battery is disposed in a space between the core member and the second face plate. Battery unit.

3. The battery is a secondary battery. The battery unit according to claim 1 or 2.

4. The secondary battery is a lithium ion battery or an all-solid-state battery. The battery unit according to claim 3 .

5. The core member and the face plate are made of a thermoplastic resin. The battery unit according to claim 1 .

6. an insulating sheet is provided at a contact portion between the battery and the core member and at a contact portion between the battery and the face plate; The battery unit according to claim 1 .

7. The insulating sheet is provided on the battery. The battery unit according to claim 6.

8. The face plate has a charging port for the battery on an outer surface. The battery unit according to claim 1 .

9. The face plate has a solar cell provided on an outer surface thereof. The battery unit according to any one of claims 1 to 8.

10. The protrusions are formed on both sides of the core member, A first face plate is disposed on one surface of the core member, A second face plate is disposed on the other surface of the core member, The battery is disposed in a space between the core member and the second face plate. A battery unit according to any one of claims 1 and 3 to 9.

11. a temperature adjustment system between the plurality of core members and the first face plate; The battery unit according to claim 2 or 10.

12. The temperature adjustment system comprises: A flow path through which a fluid flows; a temperature sensor that detects a temperature between the first face plate and the second face plate; The battery unit according to claim 11.

13. a filler member disposed in a space between the core member and the first face plate; The battery unit according to any one of claims 10 to 12.

14. The filling material includes at least one of an explosion-proof material, a heat insulating material, a sound absorbing material, a fire extinguishing agent, and a latent heat storage material; The battery unit according to claim 13.

15. The plurality of protrusions have a function of fixing the battery. The battery unit according to any one of claims 1 to 14.

16. A step of shaping a core member to form a convex portion on at least one surface of the core member and a concave portion on the other surface corresponding to the position where the convex portion is formed; placing a battery on the core member; bonding a face plate to the protrusion; A method for manufacturing a battery unit, comprising:

17. A step of forming a convex portion on both sides of a core member; joining a first face plate to the protrusion formed on one surface of the core member; joining a second face plate to the protrusion formed on the other surface of the core member; disposing a battery in a space between the core member and the second face plate; A method for manufacturing a battery unit, comprising:

18. forming a protrusion on at least one surface of the core member; bonding a face plate to the protrusion; inserting a battery into a space between the core member and the faceplate; A method for manufacturing a battery unit, comprising:

19. forming a protrusion on at least one surface of the core member; A step of forming the core member and a face plate fused to the protrusion into a three-dimensional shape; forming the battery into a three-dimensional shape; placing the battery on the core member; bonding the face plate to the protrusion; A method for manufacturing a battery unit, comprising:

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