CN1053997C - 电池组件及其成形方法 - Google Patents

电池组件及其成形方法 Download PDF

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CN1053997C
CN1053997C CN94190700A CN94190700A CN1053997C CN 1053997 C CN1053997 C CN 1053997C CN 94190700 A CN94190700 A CN 94190700A CN 94190700 A CN94190700 A CN 94190700A CN 1053997 C CN1053997 C CN 1053997C
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weld
shell
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inner casing
battery component
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布兰·J·哈塞摩
斯科特·戴维·布尤特勒
阿德南·阿科绍
马克·斯蒂芬·布里森
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Motorola Solutions Inc
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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Abstract

包含电池的电池组件包括适用于容纳电池(404)的电池的一个外壳(402)；沿该外壳(402)放置的一个焊接表面(410)；一个内壳(408))，适用于密封单元电池(404)的电池和具有焊接到该外壳(402)的焊接表面的一个表面；和在该焊接表面提供一个焊接，将内壳(408)焊接到外壳(402)。另外，一种成形电池组件的方法包括步骤：在该电池组件外壳的焊接表面内定位电池的电池；以一个内壳密封电池的电池，该内壳具有相应于该外壳焊接表面的一个表面；和焊接该内壳相应表面到该外壳的焊接表面。该电池组件及其成形的方法减少了重量和制造的复杂性。

Description

电池组件及其成形方法
本申请是本发明的共同发明人Adnan Aksoy和Mark S.Bresin于1992年9月14日提交的、本受让人的未授权的美国申请序号07/944,610、名称为电池组件的部分继续。申请人根据35USC部分120要求发明的优先权。
本发明涉及蓄电池单元电池组件，具体涉及电池组件的结构。
便携式设备如双向无线电设备的电池组件典型地包括多个单元电池，这些电池具有都在一个外壳内焊接在一起的接点。各单元电池使用金属薄片互连，这些金属薄片点焊在电池端部。通常，互连的单元电池再点焊到柔性线路，随后插入一个电池外壳中。这个制造方法是以低效的组装过程和不必要的部件及劳动制造的，导致过大的制造费用和可靠性的下降。
用于消费者电子设备如摄影机、无线电设备、CD播放机等的消费者装入的电池典型地在其一端具有弹簧装入接点，和接到电池相对端的金属接点。消费者装入的电池组件不要求一般可在电池组件中找到的额外电路。便携式无线电设备的电池组件通常包括电阻、热敏电阻、二极管和其它能使该电池组件再充电和/或保持安全的部件。因此，消费者装入的电池室仅可能在外壳上压制了金属，蓄电池单元电池和电路之间的电气衰耗在这些应用中不太重要。
其它电池组件可以是消费者装入的或者是由制造商装入和密封的，典型地包括多个单元电池，它们是热装在一起或者包装在一个塑料壳中。而且，这些单元电池中的许多典型地通过焊接薄片电气连接一起到各个电池的不同的端子(正或负)。随后，焊接的电池热装在一起并且插入一个外壳。而且，这个组装过程是低效的，导致过大的劳动和制造成本。
减少电子消费产品的重量的努力与增加电池组件装配的容易程度或可制造性的努力一样影响着电池组件装配。为此，以较少部件和零件特性的能力在减少组装步骤的数量中是关键性的。据此，需要一种电池组件，该电池组件提供了消费者装入电池组件的方便，减轻了重量，有更高的效率和能够在组装及制造中减少成本。
图1是一电池组件的透视图。
图2是根据本发明的第一实施例的电池组件的透视图。
图3是根据表发明的第二实施例的电池组件的透视图。
图4是根据本发明的第三实施例的电池组件的透视图。
图5是在图1中线A-A处的壁310的部件分解图。
图6是根据本发明的固定机构第一实施例的分解图。
图7是根据本发明的固定机构第二实施例的分解图。
图8是根据本发明的固定机构第三实施例的分解图。
图9是根据本发明的第四实施例的电池组件的透视图。
图10是根据本发明的定位机构的分解图。
图11是图9在线B-B处的电池组件截面图。
图12是图11截面图的另一个实施例。
一个电池组件包括具有一整体的闩锁机构的一个第一外壳部件，可拆卸地装在第一外壳部件的一个框架，插入该框架和第一外壳部件的多个电池，在该框架上的电路，用于连接多个电池并提供充电和电源接点，和一个第二外壳部件，它基本上是层状的并且固定地装在所述第一外壳部件上。
参见图1，它示出一个电池组件的透视图，它在由Mark S.Bresin于1992年3月9日提交的、已转让给本受让人莫托罗拉公司的、申请号为07/848465、名称为无焊接电池组件的美国专利申请中讨论了，因此引用供参考。电池组件10包括具有一个顶部2和一个底部4的一个外壳。外壳这两部分最好做成咬合在一起。可替代地、外壳这两部分也可用超声波焊接在一起。外壳顶部2还包括一个闩锁机构3，它与在底部4中的凹口区5啮合，允许可拆卸的连接电池组件10到无线电设备(未示出)。在外壳部分2和4内，放置有一个框架11(用于保持单元电池12)，它可拆卸地安装在至少一个外壳部分。
参见图2，示出了根据本发明的电池组件100的透视图。电池组件100最好包括一个第一外壳部件104，它具有装入或集成入第一外壳部件104中的一个闩锁机构103。接着，框架111装入第一外壳部件104。该框架最好经过该框架中的沟槽150和外壳部件104中的啮合轨道152咬合入第一外壳部件。可替代地，框架111也可以组合为第一外壳部件104的一部分。另一个选择是用超声波焊接框架111到第一外壳部件104。然后分别具有正端和负端114和113的电池112被定向并插入框架111。最好包括电阻(未示出)、多极开关(30)和热敏电阻(40)的电路装置安装在框架111上提供充电和电源接点，和本领域公知的用于安全充电可再充电电池组件的合适的电路。可替代地，电路装置可包括具有一些部件如电阻、多极开关和热敏电阻的柔性电路，该电路进一步互连该电池。最后，第二外壳部件102最好固定接到第一外壳部件。为了最大地减少重量，第二外壳部件102最好是塑料层压片，如在其内表面上具有粘合剂的聚碳酸脂，以便粘附在第一外壳部件104上。可替代地，第二外壳部件102可用超声波焊接到第一外壳部件104。另外，第二外壳部件102可用作电池组件100的标牌。
参见图3，该图示出根据本发明的另一种电池组件200。电池组件200包括：一个第一外壳202，最好具有整体地形成在第一外壳中的咬合机构204。电池组206最好是预先包装好的多个单元电池，放入并保持在咬合机204内。电池组206最好也包含一个柔性电路212，可在单元电池之间、接点之间和其它所需的部件如电阻和热敏电阻(未示出)之间提供进一步互连。最后，第二外壳部件220放在电池组206的顶部并且咬合到第一外壳部件202。第二外壳部件最好具有开口214，用于由该咬合机构204固定。另外，开口216成形在第二外壳部件中，在柔性电路212上所示接点插入开口216时开口接触这些接点。同样，第一外壳部件202具有开口205，允许柔性电路212上所示接触点插入。任选地，通过使用在第一外壳的内侧部分与电池组206的底部之间的双面粘合材料208(如双面胶带)和使用第二外壳220的内侧部分与单元电池封装210的顶部之间的双面粘合材料207，可进一步使电池组件220具有整体特性。
参看图4，该图示出根据本发明的电池组件的第三实施例。该电池组件通常包括：一个基底部分或外壳302，它适用于保持具有多个单元电池的蓄电池304。可以理解，蓄电池304包括在前面实施例中所叙述的任何柔性金属片或电路。为了在外壳302中保持蓄电池304，可使用一层或几层粘合材料306。例如，粘合材料306可以是胶水或某种形式的双面胶带。粘合材料306可用于将蓄电池304固定在外壳302中。而且，在该电池顶部可采用另一粘合材料306固定内壳308，以便在外壳302内保持蓄电池304。
内壳308通常适于套在壁310上，壁310通常围绕外壳302的周边延伸。壁310、支撑面311和任何粘合材料306可用于防止蓄电池304在外壳302内移位。内壳308由模压的热成形塑料材料或某种其它合适的材料构成。内壳308最好包括在热成形塑料中整体形成的一个标牌。壁310最好包括一个能量导向体312(在图4的线A-A得到的图5横截面详细表示)。能量导向体312在超声波焊接技术中采用。具体地说，内壳308的一个肩形部分314可用超声波焊接到能量导向体312。超声波焊接可沿整个壁310或在选择的部分根据需要提供。本领域公知的任何超声波焊接设备都可使用。
再有，一个固定机构包括：多个接片部分316，放置在壁310基底的周围，将内壳308固定到外壳302，沿着底脚320的相应容纳部分318包括在内壳308内。闩锁316/容纳部分318的各种实施例参照图6-8详细地叙述。最后，粘合材料可放置在底脚320周围。将内壳308固定到外壳302，可以使用粘合材料粘接、超声波焊接和闩锁的任一种或任何组合。
参见图6，图中示出固定机构第一实施例的分解图。该固定机构包括：一个接头322，通常插入凹座324中。例如可使用图6的固定机构在超声波焊接时相对于外壳302保持内壳308的位置。
参见图7，图中示出了固定机构第二实施例的分解图。该固定机构包括：一个接头部分326，适于卡住内壳308的凹槽328。图6的固定机构也可用于在超声波焊接时相对于外壳302保持内壳308的位置。
最后，参见图8，图中示出固定机构第三实施例的分解图。该固定机构包括：一个闩锁330，适于确实地啮合位于内壳308的底脚318内的孔332。具体地说，闩锁330包括两部分，它们可被压紧以啮合孔332。可以理解，本领域公知的其它类型的闩锁机构都可用于确实地啮合上部壳体。
现在翻到图9，图中示出根据电池组件第四实施例的电池组件的透视图。该电池组件通常包括：一个外壳402，适用于保持具有多个单元电池的蓄电池404，为了将蓄电池404保持在外壳402中，可在该蓄电池的任一侧上使用粘合材料406，例如，粘合材料406可以是胶水或某种形式的双面胶带；还可以包括一个内壳408，以便将蓄电池404保持在外壳402内。
图9的实施例与图4的实施例不同，并不包括壁310来卡住电池而使其不在外壳内位移及提供能量导向器使能超声波焊接到外壳的肩形部分。相反地，沿着外壳402的表面提供一个能量导向体以便提供超声波焊接到外壳408的底脚412.超声波焊接可沿整个能量导向体410或在选择的部分提供。
外壳402可任选地包括一个定位片414，以便在超声波焊接期间能适当地相对于外壳402定位内壳408的位置。定位机构详细地示于图10中。底脚412包括适用于容纳定位片414的一个凹槽415。最后，定位导柱416也可选择地被定位以帮助电池的制作。图11和12以在图9的线B-B剖开的横截面详细地示出了定位机构416。
现在翻至图11，图9的线B-B的剖面图表示了内壳408与外壳402的定位和在能量导向410的超声波焊接。具体地说，定位导柱416提供内壳408的基准点。另外，可包括一个坝体418，在超声波焊接期间防止内壳408的底脚412移动。即，因为能量导向体是沿着外壳402的倾斜部分放置的，在超声波焊接期间通常是水平的底脚412被迫处于倾斜位置。因此，坝体418防止底脚412离开定位导柱416的移动。虽然示出的底脚412放置在沿外壳402的一个特定位置，但可以理解，能量导向体410可放置在沿壁的任何位置。
翻到图12，一个可替代的实施例装入了包括能量导向体410的一个校平表面420。校平表面420防止底脚412在超声波焊接期间被迫处于倾斜位置。
总之，本发明减少了制造的复杂性和整个电池的重量。特别是，超声波焊接与粘合连接的组合减少设备的重量和复杂性。一个壁可卡住该蓄电池。放置在该壁顶部、含有多个单元电池的蓄电池的能量导向体可提供超声波焊接区域。内壳可放置在该壁上以密封该蓄电池。内壳的肩形部分可用超声波焊接到在该壁顶部的能量导向体上。另一方案，该壁可用放置在外壳的一个能量导向体代替，其中内壳的底脚以超声波焊接到该能量的定向体。因此，本发明与现有技术的设备相比减少了复杂性和成本。

Claims (10)

1.一种电池组件，至少包含一个单元电池，其特征在于，包括：
一个外壳，用于容纳所述的至少一个单元电池，所述的外壳具有一个内表面；
一个焊接表面，位于所述外壳的所述内表面上；
一个内壳，用于封装所述外壳内的所述至少一个单元电池，并且具有一个表面，焊接到所述外壳的所述焊接表面；和
一个焊接区，在所述的焊接表面上，将所述的内壳固定到所述外壳，且在所述外壳之内。
2.根据权利要求1所述的电池组件，其特征在于，所述的内壳是模压热成形的塑料，具有一个肩形部分和一个底脚部分，所述的焊接是在所述的底脚部分进行的。
3.根据权利要求1所述的电池组件，其特征在于，所述的焊接表面包括：一个能量导向体，用于超声波焊接到所述的内壳上。
4.根据权利要求1所述的电池组件，其特征在于，所述的焊接表面包括：一个壁，用于卡住所述的电池。
5.根据权利要求1所述电池组件，其特征在于，
所述的外壳具有一个内表面和一个壁，所述的壁从所述内表面凸出，用于容织所述的至少一个单元电池；及
所述的内壳，用于覆盖住所述的壁和至少一个单元电池，其中所述的内壳被焊接到所述外壳的所述焊接表面。
6.根据权利要求5所述的电池组件，其特征在于，所述的焊接表面包含：一个能量导向体，用于超声波焊接到所述的内壳。
7.根据权利要求1所述的电池组件，其特征在于：
所述的焊接表面包含：一个能量导向体，它沿着所述外壳的内表面设置；和
所述的内壳具有：一个底脚部分，放置在所述的能量向体上，所述的底脚部分超声波焊接到所述能量导向体上。
8.根据权利要求7所述的电池组件，其特征在于：
所述的外壳，具有一个壁，从其内表面凸出，用于容纳所述至少一个单元电池；及
所述的内壳由热成形塑料成形，与所述壁的形状相符。
9.一种成形电池组件的方法，其特征在于，包括以下步骤：
沿一个外壳的内表面成形一个焊接表面；
在所述的电池组件的所述外壳的所述焊接表面内放置至少一个单元电池；
由一个内壳密封所述的至少一个单元电池在所述的外壳内，所述的内壳具有一个焊接表面，所述的焊接表面与所述的外壳的焊接表面相对应；及
将所述的内壳的相应的焊接表面焊接到所述外壳的焊接表面。
10.根据权利要求9所述的成形电池组件的方法，其特征在于，所述的“将所述内壳的相应焊接表面焊接到所述外壳的焊接表面”的步骤包括：在所述的内壳的底脚处提供超声波焊接到位于所述外壳上的一个能量导向体。
CN94190700A 1993-09-20 1994-07-25 电池组件及其成形方法 Expired - Fee Related CN1053997C (zh)

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