CN100382356C - 二次电池的整体盖组件及其制造方法 - Google Patents

二次电池的整体盖组件及其制造方法 Download PDF

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CN100382356C
CN100382356C CNB2004100836749A CN200410083674A CN100382356C CN 100382356 C CN100382356 C CN 100382356C CN B2004100836749 A CNB2004100836749 A CN B2004100836749A CN 200410083674 A CN200410083674 A CN 200410083674A CN 100382356 C CN100382356 C CN 100382356C
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金营泽
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Abstract

一种二次电池的整体盖组件，包括：形成二次电池顶部并在二次电池充电或放电时用作接线端子的盖叠层；通过模具注入成型与该盖叠层彼此结合为一个整体的垫圈，该盖叠层的外围部分嵌入到垫圈中，垫圈使盖叠层同二次电池的壳绝缘并密封盖叠层和壳之间的间隙；该盖叠层具有形成于盖叠层最低元件处的凹槽或孔，且一部分垫圈嵌入到凹槽或孔中；该垫圈沿该盖叠层最低元件的底平面从边缘向中心延伸且将该凹槽或孔覆盖形成密封固定结构，另外，本发明还公开了一种二次电池的整体盖组件的制造方法。

Description

二次电池的整体盖组件及其制造方法
技术领域
本发明涉及二次电池(secondary battery)及其制造方法，更特别地涉及形成二次电池顶部的盖组件结构及其制造方法。
背景技术
在本领域内，众所周知二次电池是可再充电的，并且可以在尺寸较小的情况下生产出较大容量的二次电池。根据二次电池的材料，二次电池可分为镍-氢(Ni-MH)电池、锂(Li)电池、锂离子(Li离子)电池和聚合物锂(PLI)电池，或根据它们的外观分成圆柱状电池和正方形电池。
根据制造二次电池的典型方法，将包括阳极板、阴极板和隔板的电极组件固定到通常由铝或铝合金制成的壳内，将电解质注入到壳内，然后密封壳装置。每个壳具有一电极接线柱，其形成于壳上部，与壳绝缘；并具有正极性或负极性，其极性决定了壳的极性。另外，每个壳包括一正温度系数(PTC)元件、一热熔丝和一保护电路模块(PCM)。
二次电池使用果冻卷构造形式的电极结构，果冻卷构造通过一起卷绕阳极板、阴极板和插入在阳极板与阴极板之间的隔板而形成。电池的形状决定电池使用的果冻卷的形状。也就是说，圆柱状电池使用卷绕成圆柱状的果冻卷，正方形电池使用卷绕成具有拐角和直边的多边形的果冻卷。
图1为具有典型构造的常规二次电池的截面图。如图1所示，圆柱状二次电池包括用于产生电势差的电极组件110，用于容纳电极组件110的圆柱状壳120，装配在圆柱状壳120顶部的盖组件130，以防止电极组件110从圆柱状壳120上分离，和注入到圆柱状壳120内的电解质140，以便使离子在电极组件110的电极间移动。盖组件130具有装在盖组件130上的各种安全装置。
圆柱状壳120具有向内弯曲的夹紧部分121以将盖组件130向里推和向内压下的凸圆部分122以将盖组件130向上推。
盖组件130包括导电的安全孔装置131、印刷电路板132、PTC元件133和阳极盖134。导电的安全孔装置131具有焊接到阳极引线111的底并具有在电池过度充电或异常受热时能反转的凸起部分。印刷电路板132置于导电的安全孔装置131上面并与其电连接和机械连接。印刷电路板132具有在导电的安全孔装置131的凸起部分被反转时能被切断的电路。PTC元件133置于印刷电路板132上面并与其电连接和机械连接。当被加热至超过规定温度时，PTC元件133就被断电。阳极盖134置于PTC元件133上面并与其电连接和机械连接。阳极盖134允许电流流至外部。绝缘垫圈135环绕在彼此堆叠的导电的安全孔装置131、印刷电路板132、PTC元件133和阳极盖134的圆周部分，并使它们同圆柱状壳120绝缘。
但是，在常规圆柱状二次电池的盖组件130中，导电的安全孔装置131、印刷电路板132、PTC元件133和阳极盖134只是简单地彼此堆叠，并且绝缘垫圈135的中心部分135a、下部夹紧部分135b和上部夹紧部分135c简单地与包括彼此堆叠的导电的安全孔装置131、印刷电路板132、PTC元件133和阳极盖134的圆周部分接触。因此，绝缘垫圈135不能充分地密封壳内和壳外之间的间隙，并当内部压力过度增加时，可使壳内部气体通过盖组件130和绝缘垫圈135之间的夹缝渗漏。
发明内容
因此，为解决现有技术中出现的上述问题作出本发明，本发明的一个目的是提供二次电池的整体盖组件及其制造方法，该盖组件包括盖叠层和更紧密地环绕并夹紧盖叠层的绝缘垫圈，盖叠层包括导电的安全孔装置、印刷电路板、PTC元件和阳极盖。本发明的另一个目的是提供二次电池的整体盖组件及其制造方法，其能简化制造二次电池的过程，从而提高了生产率并降低了制造成本。
为实现上述目的，本发明提供一种二次电池的整体盖组件，该整体盖组件包括：形成于二次电池顶部、并在二次电池充电或放电时用作接线端子的盖叠层；和通过模具注入成型与该盖叠层彼此结合为一个整体的垫圈，该盖叠层的外围部分嵌入到垫圈中，垫圈使盖叠层同二次电池的壳绝缘并密封盖叠层和壳之间的间隙；该盖叠层具有形成于盖叠层最低元件处的凹槽或孔，且一部分垫圈嵌入到凹槽或孔中；该垫圈沿该盖叠层最低元件的底平面从边缘向中心延伸且将该凹槽或孔覆盖形成密封固定结构。
而且，为实现上述目的，本发明提供一种二次电池的整体盖组件的制造方法，该方法包括：(1)通过排列和堆叠盖叠层的元件形成盖叠层；(2)将盖叠层嵌入到模具中用于垫圈成型，同时保持盖叠层的排列和堆叠状态；和(3)向模具内注入成型材料，从而形成整体盖组件，其中垫圈与盖叠层整体成型在一起，以使盖叠层的外围部分嵌入到垫圈中；(4)形成盖叠层包括在盖叠层最低元件底面的外围部分形成凹槽或孔，使一部分垫圈嵌入到该凹槽或孔中，且使该垫圈沿该盖叠层最低元件的底平面从边缘向中心延伸且将该凹槽或孔覆盖形成密封固定结构。
其中，该整体盖组件至少包括安全孔装置、印刷电路板(具有电流中断装置，如断路器)、一正温度系数元件和阳极盖中的一个。
本发明提供的二次电池的整体盖组件，它包括通过在盖叠层的外围部分嵌入到垫圈内的状态下注入成型而彼此结合成体的盖叠层和垫圈，其中盖叠层包括导电的安全孔装置、印刷电路板、PTC元件和阳极盖。另外，优选在盖叠层最低元件的外围部分形成孔或凹口，因此绝缘垫圈被嵌入到孔或凹口内，从而提高了盖叠层和绝缘垫圈之间的装配力。
附图说明
从以下结合附图的详细描述中将能更明显地看到本发明的上述和其它目的、特征和优点。
图1为常规圆柱状二次电池的载面图；
图2为根据本发明的盖组件的截面图；及
图3为根据本发明的盖组件的整体成型工艺的流程图。
具体实施方式
下文中，将结合附图详细描述本发明的优选实施方式。
图2为根据本发明的二次电池盖组件的截面图。如图2所示，根据本发明的盖组件包括盖叠层和绝缘垫圈235。
盖叠层包括导电的安全孔装置231、印刷电路板232、PTC元件233和阳极盖234。
导电的安全孔装置231密封二次电池的壳并能通过二次电池内产生的压力向外(在图中为向上)弯曲。导电的安全孔装置231具有在正常状态下向内(在图中为向下)变形或凸起的中心部分。导电的安全孔装置231的向下凸起或变形部分与从放在二次电池壳内的电极组件的阳极板中延伸出的阳极接头电连接。
印刷电路板232放在导电的安全孔装置231上面，并传递来自于阳极接头的电流到阳极盖234。印刷电路板232具有电流中断装置，当电池的内部压力由于反常操作如过度充电等而超过规定值时，能通过导电的安全孔装置231的变形而使电流中断装置断掉并中断电流。印刷电路板232通常由环氧基树脂制成。印刷电路板232包括在导电的安全孔装置231的变形部分上方延伸并越过其的横梁(traverse)和连接到横梁相对端的环形元件。横梁具有可折断部分，当导电的安全孔装置231的变形部分反转时，可通过导电的安全孔装置231的变形部分施加的力撕开可折断部分。可折断部分为通过横梁中心和端部形成缝的弱化部分。可折断部分可具有单一种类的至少两个缝，或具有缝和槽的组合。
PTC元件233为电流调节器，当电池温度升高超过安全极限时，它能立即提高电阻以调节或中断电流。在根据本发明的二次电池盖组件中，PTC元件233为可省略的。
阳极盖234具有大量孔。阳极盖234为可与外端子接触的元件。
包括如上所述元件的盖叠层与绝缘垫圈235一起装配。为了装配盖叠层与绝缘垫圈235，当绝缘垫圈235成型时，将盖叠层嵌入并与绝缘垫圈235形成整体。然后，将盖叠层的一部分边嵌入到绝缘垫圈235内。整体成型在绝缘垫圈235中的盖叠层每个元件(即导电的安全孔装置231、印刷电路板232、PTC元件233和阳极盖234中的每一个)的边都单独地与绝缘垫圈235结合。因此，盖叠层和绝缘垫圈235完全地彼此结合而在它们中间没有任何间隙。这里，当在盖叠层中省略某些元件如PTC元件233时，只将盖叠层的其它元件彼此堆叠然后在成型绝缘垫圈235的同时嵌入到绝缘垫圈235中。
另外，在盖叠层的最低元件印刷电路板232的外围部分形成孔或凹口H。因此，当绝缘垫圈235成型时，绝缘垫圈235就被嵌入到孔或凹口H中，从而增强了盖叠层和绝缘垫圈235之间的装配力。优选孔或凹口H具有上部比下部宽的楔形形状。这里，孔或凹口H不仅可具有截头圆锥体形状，而且可具有包括多角棱柱形状的各种形状，如三角棱柱、直角棱柱、五角棱柱等。另外，尽管图2只示出了形成于盖叠层最低元件处的孔或凹口H，但可在盖叠层较低的两个元件或全部元件处形成孔或凹口H。
图3为根据本发明优选实施方式的盖组件的整体成型工艺的流程图。如图3所示，根据本发明的盖组件的注入成型法包括：排列并彼此堆叠盖叠层的元件(S31)；提起并转移盖叠层(S32)；将盖叠层嵌入并支撑在模具内(S33)；注入成型材料，从而注入成型垫圈与盖叠层在一起(S34)；和从模具中取出盖组件(S35)。
在元件排列和堆叠步骤(S31)中，构成盖叠层的导电的安全孔装置231、印刷电路板232、PTC元件233和阳极盖234进行排列，并一个接一个地堆叠。然后，将排列并堆叠的盖叠层采用如气动式加压销支撑并夹持。这里，加压销可具有夹子的形状，并优选用与垫圈相同的材料制成。
在盖叠层提起和转移步骤(S32)中，将已用加压销等支撑并夹持的盖叠层用嵌入架的双销、镊子等提起并夹持，然后通过自动控制操作移动到模具。
在盖叠层嵌入和支撑步骤(S33)中，将移动到模具的盖叠层嵌入到模具内，然后用夹持销等夹持以便进行垫圈的注入成型。这里，优选夹持销用与垫圈相同的材料制成。
在注入成型步骤(S34)中，以这样一种方式注入成型垫圈，即嵌入并夹持在模具内的盖叠层的边被部分地嵌入到垫圈中。这里，在盖叠层的下部元件处形成孔或凹口，熔融的垫圈在注入成型过程中被嵌入到孔或凹口中，从而增强了盖叠层和垫圈之间的装配力。垫圈由为绝缘材料的聚合物树脂如聚丙烯等制成。
在盖组件取出步骤(S35)中，从模具中取出已被整体注入成型的包括盖叠层和垫圈的盖组件，然后落到输出运送带上。
如上所述，本发明提供了二次电池的整体盖组件，从而大大增加了盖组件的盖叠层与环绕并夹紧盖叠层的绝缘垫圈之间的紧密性，其中盖叠包括层导电的安全孔装置231、印刷电路板232、PTC元件233和阳极盖234。另外，根据本发明的二次电池盖组件的形成方法能使只利用一个设备装配二次电池，从而大大降低了制造二次电池的所需设备数量、制造时间、制造成本等，并因此提高了生产率。
尽管为了说明目的已描述了本发明的优选实施方式，但本领域的技术人员能认识到在不脱离权利要求公开的发明范围和精神的情况下，各种改变、增加或代替都是可能的。

Claims (8)

1.一种二次电池的整体盖组件，其特征在于，该整体盖组件包括：
形成于二次电池顶部、并在二次电池充电或放电时用作接线端子的盖叠层；和
通过模具注入成型与该盖叠层彼此结合为一个整体的垫圈，该盖叠层的外围部分嵌入到垫圈中，垫圈使盖叠层同二次电池的壳绝缘并密封盖叠层和壳之间的间隙；
该盖叠层具有形成于盖叠层最低元件处的凹槽或孔，且一部分垫圈嵌入到凹槽或孔中；
该垫圈沿该盖叠层最低元件的底平面从边缘向中心延伸且将该凹槽或孔覆盖形成密封固定结构。
2.如权利要求1所述的整体盖组件，其特征在于，该盖叠层包括安全孔装置、断路器、一正温度系数元件和阳极盖。
3.如权利要求1所述的整体盖组件，其特征在于，该凹槽或孔具有上部和下部，且上部具有大于下部的宽度。
4.如权利要求1所述的整体盖组件，其特征在于，嵌入该凹槽或孔的部分垫圈呈三角棱柱、直角棱柱或五角棱柱。
5.如权利要求1、2、3或4所述的整体盖组件，其特征在于，该盖叠层具有形成于该盖叠层全部元件的凹槽或孔。
6.一种二次电池的整体盖组件的制造方法，该方法包括：
(1)通过排列和堆叠盖叠层的元件形成盖叠层；
(2)将盖叠层嵌入到模具中用于垫圈成型，同时保持盖叠层的排列和堆叠状态；和
(3)向模具内注入成型材料，从而形成整体盖组件，其中垫圈与盖叠层整体成型在一起，以使盖叠层的外围部分嵌入到垫圈中；
(4)形成盖叠层包括在盖叠层最低元件底面的外围部分形成凹槽或孔，使一部分垫圈嵌入到该凹槽或孔中，且使该垫圈沿该盖叠层最低元件的底平面从边缘向中心延伸且将该凹槽或孔覆盖形成密封固定结构。
7.如权利要求6所述的二次电池的整体盖组件的制造方法，其特征在于，凹槽或孔具有上部和下部，且上部具有大于下部的宽度。
8.如权利要求6至7中任意一项所述的二次电池的整体盖组件的制造方法，其特征在于，用由与垫圈相同的材料制成的夹具保持盖叠层的排列和堆叠状态。
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