Battery tray and packaging structure

Abstract

The present invention provides a battery tray that houses a plurality of columnar batteries, the battery tray being capable of suppressing erroneous detections, during image inspection, regarding the presence or absence of a battery, etc. This battery tray accommodating a plurality of columnar batteries is provided with a plurality of recesses (22) into which respective one ends of the batteries are fitted, and which are such that the plurality of batteries are held such that the batteries that are adjacent are separated from each other. The shape of the recesses (22) conforms to the outer diameter shape of the batteries, and protrusions (26) having a shape different from the outer diameter shape of the batteries are formed on the bottom surface of the recesses (22).

Description

Battery Tray and Packaging Structure

[0001] The present disclosure relates to a battery tray and a packaging structure including the battery tray, and more particularly to a battery tray and a packaging structure for storing a plurality of columnar batteries.

[0002] Batteries are widely used as power sources for various electronic devices and the like. Examples of batteries include primary batteries typified by dry batteries and secondary batteries that can repeatedly perform charging and discharging. These batteries have various shapes such as columnar shapes (e.g., cylindrical and prismatic) and sheet-like shapes, but columnar batteries are the most common.

[0003] Conventionally, when packaging a plurality of columnar batteries, for example, trays having a plurality of concave shapes corresponding to the outer diameter shape of the batteries are fixed by fitting them vertically.

[0004] For example, Patent Document 1 discloses a packaging structure for packaging a plurality of columnar batteries, which includes a storage case having a bottom plate and side plates disposed on the outer edge of the bottom plate, a first tray disposed directly above the bottom plate and fixed to the storage case, and a second tray disposed above the first tray. The first tray includes a plurality of first recesses into which one end of the battery fits, and is fixed to the storage case such that the bottom side of the first recess faces the bottom plate. The second tray includes a plurality of second recesses into which the other end of the battery fits. The plurality of batteries are held such that one end is fitted into the first recess of the first tray and the other end is fitted into the second recess of the second tray, and adjacent batteries are separated from each other. The bottom side of the first recess has a portion protruding outward relative to the corner so as to be separated from the corner of one end of the fitted battery.

[0005] In the battery receiving process or the like, there are cases where the upper tray (corresponding to the second tray in Patent Document 1) is removed and the battery is taken out or reinserted from the lower tray (corresponding to the first tray in Patent Document 1). In this case, the presence or absence of the battery in each recess of the lower tray (corresponding to the first recess in Patent Document 1) is determined by image inspection to detect the location of battery removal or insertion.

[0006] International Patent Application Publication No. WO 2013 / 031194 Pamphlet

[0007] In the case of a tray like the first tray described in Patent Document 1, the shape of the recess in the tray follows the shape of the outer diameter of the battery, which leads to a problem where the device may falsely detect that there is a battery in the recess even when there is no battery there, due to the effects of light reflection, etc.

[0008] The purpose of this disclosure is to provide a battery tray that can suppress false detections in image inspection, such as the presence or absence of batteries, in a battery tray that accommodates a plurality of columnar batteries, and a packaging structure equipped with the battery tray.

[0009] This disclosure relates to a battery tray for housing a plurality of columnar batteries, comprising a plurality of recesses into which one end of each battery fits and which holds the plurality of batteries apart from adjacent batteries, wherein the shape of the recesses is in line with the outer diameter of the battery, and the bottom surface of each recess is provided with a protrusion having a shape different from the outer diameter of the battery.

[0010] This disclosure relates to a packaging structure for packaging a plurality of columnar batteries, comprising: a housing case having a bottom plate and side plates positioned on the outer edge of the bottom plate; a first tray positioned on the bottom plate and housed in the housing case; and a second tray positioned above the first tray, wherein the first tray is a battery tray and is housed in the housing case with the bottom side of the recesses facing the bottom plate; the second tray has a plurality of second recesses into which the other end of the battery fits; the plurality of batteries are held in a state in which one end is fitted into the recess of the first tray and the other end is fitted into the second recess of the second tray, with adjacent batteries spaced apart from each other.

[0011] This disclosure provides a battery tray that can suppress false detections in image inspection, such as the presence or absence of batteries, in a battery tray that accommodates multiple columnar batteries, and a packaging structure equipped with the battery tray.

[0012] This is a perspective view of an example of a housing case in a packaging structure according to an embodiment of this disclosure. This is a perspective view of an example of a battery tray (first tray) according to an embodiment of this disclosure. This is a perspective view of an example of a second tray in a packaging structure according to an embodiment of this disclosure. This is a schematic diagram showing an example of the interior of a packaging structure according to an embodiment of this disclosure. This is a schematic diagram showing an example of the bottom surface of a battery tray (first tray) according to an embodiment of this disclosure.

[0013] Embodiments of this disclosure will be described below. These embodiments are examples of implementing this disclosure, and this disclosure is not limited to these embodiments.

[0014] The packaging structure according to this embodiment is for packaging multiple columnar batteries, for example, multiple cylindrical lithium-ion secondary batteries. These batteries are cylindrical in shape, with one end being the negative electrode and the other end being the positive electrode, and the positive electrode has a convex shape that protrudes from the central part of the circular end face, for example.

[0015] Figure 1 shows an example of a storage case used in the packaging structure according to this embodiment. The storage case 10 shown in Figure 1 is made of, for example, paper material such as corrugated cardboard, resin, etc., and four side plates 12 are arranged approximately perpendicular to the rectangular bottom plate 14 on its outer edge. In other words, the storage case 10 is a box-shaped case without a lid. The height of the side plates 12 from the bottom plate 14 is, for example, approximately the same height as the battery.

[0016] Figure 2 shows an example of a first tray, which is a battery tray used in the packaging structure according to this embodiment. The first tray 20 shown in Figure 2 is made of a rectangular resin plate, such as polypropylene, with a plurality of recesses (sometimes called "first recesses") 22 formed therein. The first tray 20 is placed on the bottom plate 14 of the storage case 10. The first tray 20 is housed in the storage case 10 such that the bottom side of the first recesses 22 of the first tray 20 faces the bottom plate 14 of the storage case 10. For example, one or more claws protruding from the side of the first tray 20 may fit into grooves formed in the storage case 10, thereby fixing the first tray 20 to the storage case 10.

[0017] The shape of the recess 22 (first recess 22) is slightly larger than the diameter of the battery to be housed and conforms to the outer diameter shape of the battery. In the example shown in Figure 2, the shape of the first recess 22 is circular, conforming to the circular outer diameter shape of the cylindrical battery to be housed. If the battery to be housed is prismatic, the shape of the first recess 22 should be rectangular, conforming to the rectangular outer diameter shape of the prismatic battery.

[0018] An example of a second tray used in the packaging structure according to this embodiment is shown in Figure 3. The second tray 30 shown in Figure 3 is made of a rectangular resin plate, such as polypropylene, with multiple recesses, or second recesses 32, formed therein. The shape of the second recesses 32 is slightly larger than the diameter of the battery to be housed and follows the shape of the battery's outer diameter. In the example shown in Figure 3, the shape of the second recesses 32 is circular, following the circular outer diameter of the cylindrical battery to be housed. As will be described later, the second tray 30 is used, for example, by placing it above the first tray 20 after one end of multiple batteries has been fitted into the first recesses 22 of the first tray 20, and then fitting the other end of the batteries into the second recesses.

[0019] Figure 4 shows the packaging structure according to this embodiment, with one side panel 12 of the storage case 10 removed to reveal the interior. One end of each of the multiple batteries 40 (the negative electrode side in the example of Figure 4) is fitted into the first recess 22 of the first tray 20, which is placed on the bottom plate 14 of the storage case 10. As a result, each of the multiple batteries 40 is held apart from the adjacent batteries 40 (with a certain distance between the sides of the batteries 40), and they stand side by side.

[0020] The other end of the battery 40, which is on the upper side (the positive electrode side in the example of Figure 4), is fitted into the second recess 32 of the second tray 30. In this way, both ends of the battery 40 are fitted into the first recess 22 and the second recess 32, and each battery 40 is fixed and held in place by the first recess 22 of the first tray 20 and the second recess 32 of the second tray 30. In this manner, each of the multiple batteries 40 is fixed and held in a state where it is spaced apart from the adjacent batteries 40.

[0021] A retaining member 50 made of cardboard or other paper material may be placed on top of the second tray 30 to hold it down. The second tray 30 may also be fixed to the storage case 10 by fixing this retaining member 50 to the storage case 10.

[0022] Figure 5 shows an example of the bottom surface of the battery tray (first tray) according to this embodiment.

[0023] In the battery tray (first tray 20) according to this embodiment, the shape of the recess (first recess 22) is in line with the outer diameter of the battery 40, and a protrusion 26 having a shape different from the outer diameter of the battery 40 is formed on the bottom surface of the recess (first recess 22). This makes it possible to suppress false detections in image inspection, such as the presence or absence of a battery. For example, by constructing an image inspection logic that detects the shape of the protrusion 26, it is possible to detect the presence or absence of a battery in each first recess 22.

[0024] The protrusion 26 has a shape different from the outer diameter shape of the battery 40, and is not particularly limited as long as it has a shape that can be recognized and identified by image inspection. The protrusion 26 functions as a detectable part in image inspection, etc. The protrusion 26 may be, for example, a convex shape that protrudes above the bottom surface of the first recess 22, or a concave shape that protrudes below the bottom surface of the first recess 22. The protrusion 26 may be formed on the bottom surface of the first recess 22, for example, when forming a tray by vacuum forming.

[0025] The protrusion 26 can be, for example, a polygonal shape such as a triangle, square, pentagon, or hexagon, or a cross shape or a cross groove shape, if the battery 40 has a circular outer diameter. The protrusion 26 can be, for example, a polygonal shape such as a triangle, pentagon, or hexagon, or a cross shape or a cross groove shape, if the battery 40 has a square outer diameter. Of these, the cross shape and cross groove shape are mainly used because they are easy to recognize and identify by the image reading unit in image inspection.

[0026] For example, in Figure 5(a), the shape of the first recess 22 is circular in relation to the circular outer diameter shape of the battery 40, and a cross-shaped protrusion 26 is formed on the bottom surface of the first recess 22, which is different from the circular outer diameter shape of the battery 40.

[0027] For example, in Figure 5(b), the shape of the first recess 22 is circular in relation to the circular outer diameter of the battery 40. On the bottom surface of the first recess 22, a cross-shaped groove is formed, for example, in the center of a circular protrusion 26 that is smaller than the circular outer diameter of the battery 40. As a result, four fan-shaped protrusions 26 that differ from the circular outer diameter of the battery 40 are formed (in this specification, this shape of protrusion is referred to as the "cross-groove shape").

[0028] For example, in Figure 5(c), the shape of the first recess 22 is circular in relation to the circular outer diameter shape of the battery 40, and a square (rectangular) protrusion 26, which is different from the circular outer diameter shape of the battery 40, is formed on the bottom surface of the first recess 22.

[0029] For example, in Figure 5(d), the shape of the first recess 22 is circular in relation to the circular outer diameter shape of the battery 40, and a triangular protrusion 26, which is different from the circular outer diameter shape of the battery 40, is formed on the bottom surface of the first recess 22.

[0030] The depth or height of the protrusion 26 is preferably 1 mm or more. If the depth or height of the protrusion 26 is less than 1 mm, it may be difficult for the image reading unit to recognize and identify it during image inspection.

[0031] The size of the area forming the protrusion 26 is preferably 40% or more of the bottom surface of the recess (first recess 22). If the size of the area forming the protrusion 26 is less than 40% of the bottom surface of the first recess 22, the battery may not be able to be held approximately vertically, or shavings may be generated from the tray due to friction with the bottom surface of the battery.

[0032] In the packaging method according to this embodiment, for example, packaging begins with preparing a storage case 10. The first tray 20 is placed inside the storage case 10 and fixed in place. The first tray 20 is housed inside the storage case 10 such that the bottom side of the first recess 22 faces the bottom plate 14 of the storage case 10.

[0033] Next, one end of each of the batteries 40 to be packaged (the negative electrode side in the example of Figure 4) is fitted into each of the first recesses 22 of the first tray 20. The batteries 40 are fitted into the first recesses 22 and held in an almost vertical position.

[0034] Once all the batteries 40 to be packaged are fitted into the first recess 22, the second tray 30 is placed on the other end of the batteries 40 (the positive terminal side in the example of Figure 4), and the other end of the batteries 40 is fitted into each of the second recesses 32 of the second tray 30. In this way, each of the multiple batteries 40 is fixed and held in place, separated from the neighboring batteries 40.

[0035] If necessary, the retaining member 50 may be placed on the second tray 30 and the retaining member 50 and the storage case 10 may be fixed together.

[0036] Here, the depth of the first recess 22 of the first tray 20 may be in the range of 5% to 50% of the height of the battery 40, or it may be in the range of 10% to 30%.

[0037] If the depth of the first recess 22 of the first tray 20 is less than 5% of the height of the battery 40, it may not be possible to keep the battery 40 approximately vertical after it has been placed in the first recess 22, and when the second tray 30 is placed on the battery 40, the other end of the battery 40 may not fit into the second recess 32. If the depth of the first recess 22 is 5% or more of the height of the battery 40, it becomes easier to reliably keep the battery 40 approximately vertical after it has been placed in the first recess 22.

[0038] If the depth of the first recess 22 in the first tray 20 exceeds 50% of the height of the battery 40, it may take too long to insert the battery 40 into the first recess 22, or conversely, it may take extra effort to remove the battery 40 from the first recess 22. Also, if information such as a lot number is printed on the side of the battery 40, if the depth of the first recess 22 is large, the printed area may rub against the first recess 22 during packaging or transportation, making the printed information unreadable. If the depth of the first recess 22 is 50% or less of the height of the battery 40, it becomes easier to insert and remove the battery 40.

[0039] The distance between the first tray 20 and the second tray 30 should be, for example, in the range of 30% to 90% of the height of the batteries 40. If the distance between the first tray 20 and the second tray 30 is less than 30% of the height of the batteries 40, it may take time to remove the packaged batteries 40. If the distance between the first tray 20 and the second tray 30 exceeds 90% of the height of the batteries 40, it may become difficult to hold the batteries 40 in place if they are subjected to vibration or shock during packaging, and adjacent batteries 40 may come into contact with each other.

[0040] The shortest distance between adjacent batteries 40 within the storage case 10 should be, for example, in the range of 5% to 50% of the diameter of the battery 40. If the shortest distance between batteries 40 is less than 5% of the diameter of the battery 40, adjacent batteries 40 may come into contact with each other due to vibration or shock, and if it exceeds 50%, the battery packaging density will decrease, which may increase packaging costs and transportation costs.

[0041] The diameter of the bottom (circular) portion of the first recess 22 should be slightly larger than the diameter of the battery 40. Alternatively, the first recess 22 may have a tapered shape, where the diameter increases from the bottom towards the opening, or conversely, the diameter narrows from the opening towards the bottom. Having such a tapered shape in the first recess 22 makes it easier to insert the battery 40 into the first recess 22 and to remove the battery 40 from the first recess 22.

[0042] The taper angle in this taper shape may be, for example, in the range of 1 degree or more and 20 degrees or less. If this taper angle is less than 1 degree, it will be difficult to fit the battery 40 into the first recess 22 and also difficult to remove it, which may increase the working time. If this taper angle exceeds 20 degrees, the battery 40 may not be securely held, and the battery 40 may rattle in the packed state, or when an impact or the like is applied, the adjacent batteries 40 may come into contact with each other.

[0043] The second recess 32 may also have the same taper shape as the first recess 22. The taper angle of the second recess 32 may also be in the range of 1 degree or more and 20 degrees or less, similar to the first recess 22. By having such a taper shape, it becomes easier to fit the battery 40 into the second recess 32, and it becomes easier to remove the second tray 30 fitted with the battery 40 upward.

[0044] As shown in FIG. 4, the outer peripheral portion of the bottom surface of the first recess 22 may be provided with a depression 24 that protrudes outward (downward) or is further recessed one step from the recess. Thereby, when the battery 40 is fitted into the first recess 22, the outer peripheral portion of the bottom surface of the first recess 22 is separated from the corner portion of one end of the battery 40 and is in a non-contact state. If there is no such depression 24, when the battery 40 is transported or the like in the packed state, the corner portion of one end of the battery 40 and the outer peripheral portion of the bottom surface of the first recess 22 may rub against each other due to vibrations during transportation or the like, and the first tray 20 may be scraped off. Then, the generated scrap powder or the like may adhere to the electrode of the battery 40 (for example, the negative electrode on the bottom surface side), which may cause a contact failure when using this battery 40. If there is a depression 24 in the first recess 22, the contact between the outer peripheral portion of the bottom surface of the first recess 22 and the corner portion of one end of the battery 40 is suppressed, the generation of scrap powder during transportation or the like is suppressed, and almost no contact failure of the battery 40 occurs. That is, the terminal portion of the battery 40 is kept clean while being held by the packaging structure according to the present embodiment.

[0045] As shown in Figure 3, a terminal recess 34 corresponding to the positive terminal protruding from the positive electrode end of the battery 40 may be formed in the center of the bottom surface of the second recess 32. The side and bottom surfaces of the terminal recess 34 should be formed in such a way that they remain in a non-contact state with the positive terminal. That is, the depth of the terminal recess 34 should be greater than the height of the positive terminal, and the diameter of the terminal recess 34 should be greater than the diameter of the positive terminal. This makes it less likely for the positive terminal to come into contact with the second tray 30 when the peripheral edge of the bottom surface of the second recess 32 comes into contact with the upper peripheral edge of the positive electrode side of the battery 40, and even if vibrations are applied during transportation, it is possible to suppress the generation of shavings from the second tray 30 and their adhesion to the positive terminal. For this reason, when the battery 40 is used as a power source for electronic devices, poor contact and poor conductivity caused by shavings from the second tray 30 can be suppressed.

[0046] In the packaging structure according to this embodiment, multiple columnar batteries 40 are sandwiched and fixed between the first tray 20 and the second tray 30, eliminating the need to insert materials to suppress contact between adjacent batteries 40, thereby reducing costs. Furthermore, the electrode portions of the batteries can be kept clean during transportation. In addition, the process of fitting the batteries 40 into the first recess 22 of the first tray 20 can be easily performed, and the automation and mechanization of packaging can be easily carried out. Moreover, even with a small amount and variety of packaging materials, multiple batteries 40 can be securely held without contacting each other, enabling safe transportation at a low packaging cost. Unpacking can also be easily performed. Furthermore, if the first tray 20 and the second tray 30 are formed from synthetic resin mixed with, for example, a rust inhibitor, it is possible to suppress the rusting of the batteries 40 during storage and transportation.

[0047] (Other Embodiments) The embodiments described above are illustrative examples of the Disclosure, and the Disclosure is not limited to these examples. These examples may be combined with or partially replaced with well-known, conventional, or prior art. Modifications that would be easily conceived by those skilled in the art are also included in the Disclosure. For example, the type and number of batteries to be packaged in a single packaging structure are not particularly limited, nor are the materials and shapes of the housing case particularly limited.

[0048] The battery 40 to be packed is, for example, a lithium-ion secondary battery, and it is not limited to a lithium-ion secondary battery and may be any type of battery. As long as the shape is columnar, such as cylindrical or prismatic. The battery may have an insulating outer tube attached to its side surface, or may not have an outer tube. Even without an outer tube, contact with adjacent batteries is suppressed, so safe storage, transportation, etc. can be carried out.

[0049] The side plates of the housing case 10 do not have to be present on all four sides. At least a pair of parallel side plates is sufficient. If the side surface portion without the side plates of the housing case 10 is covered by a cushioning material, an outer case, etc., the battery can be protected.

[0050] The first tray 20 and the second tray 30 may be made of, for example, a resin such as polypropylene, or may be made of a resin other than polypropylene, or may be made of other materials such as paper or metal. When paper is used, paper dust may be generated, and it takes time to ensure insulation for metal, so it is better to be made of resin rather than paper or metal. Also, a composite material such as a material obtained by laminating a resin film on the surface of a metal sheet may be used.

[0051] The batteries 40 to be packed may be arranged such that the negative electrodes face the bottom plate side of the housing case 10 as shown in FIG. 4, or the positive electrodes may face the bottom plate side of the housing case 10, or not only one pole of all the batteries faces the bottom plate side of the housing case 10. Some of the batteries may be arranged such that the positive electrodes face the bottom plate side, and the other batteries may be arranged such that the negative electrodes face the bottom plate side.

[0052] A marking may be applied to a part of the first tray 20, and the position of each individual battery may be identified using the marking as a reference point. This makes it possible to identify each individual battery 40 being packaged. For example, if the battery characteristics of each battery 40 are recorded before packaging, when a battery with specific battery characteristics is needed, it will be immediately clear which battery in the package is needed and that battery can be retrieved. The battery characteristics of each battery 40 packaged may also be written on the outside of the packaging. The marking may be printed, or any means may be used, such as cutting out a part of the tray or changing the shape of a part of the tray (for example, creating a protrusion). Alternatively, the marking may be applied to the second tray 30.

[0053] The first tray 20 and the second tray 30 may be provided with protrusions that extend from the upper or lower surface of the tray. This allows for gaps to be created between the upper and lower trays when multiple trays are stacked, making it easy to remove the trays one by one.

[0054] The first tray 20 and the second tray 30 may have the same shape. For example, the tray may have a recess that includes both a recess 24 on the outer circumference of the bottom and a recess 34 for the positive terminal, that is, a recess that combines the first recess 22 and the second recess 32. This makes it possible to use the same tray for both the first tray 20 and the second tray 30, thereby reducing packaging costs.

[0055] The arrangement of the batteries 40 may be in a hexagonal grid or a rectangular grid, in addition to the square grid as in the embodiment.

[0056] The storage case 10 may be further packaged with an outer case or the like. In that case, the retaining member 50 may be part of the outer case.

[0057] If the first tray 20 is provided with claws and the corresponding side panels of the storage case 10 are provided with grooves, the number of claws and grooves can be adjusted as follows: for example, if multiple claws are provided on two opposing sides of the first tray 20 and multiple grooves are provided on the corresponding side panels of the storage case 10, the first tray 20 will be more easily secured to the storage case 10. Alternatively, claws may be provided on all four sides of the first tray 20 and grooves may be provided on all four side panels of the storage case.

[0058] 10 Storage case, 12 Side panel, 14 Bottom plate, 20 First tray, 22 Recess (first recess), 24 Indentation, 26 Protrusion, 30 Second tray, 32 Second recess, 34 Terminal recess, 40 Battery, 50 Retaining member.

Claims

1. A battery tray for storing multiple columnar batteries, comprising a plurality of recesses into which one end of each battery fits and which holds the plurality of batteries apart from adjacent batteries, wherein the shape of the recesses conforms to the outer diameter of each battery, and the bottom surface of each recess is provided with a protrusion having a shape different from the outer diameter of each battery.

2. A packaging structure for packaging a plurality of columnar batteries, comprising: a housing case having a bottom plate and side plates positioned on the outer edge of the bottom plate; a first tray positioned on the bottom plate and housed in the housing case; and a second tray positioned above the first tray, wherein the first tray is the battery tray described in claim 1, and is housed in the housing case such that the bottom side of the recesses faces the bottom plate; the second tray has a plurality of second recesses into which the other end of the battery fits; and the plurality of batteries are held in a state in which adjacent batteries are spaced apart, with one end of each battery fitted into the recess of the first tray and the other end of each battery fitted into the second recess of the second tray.

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