CN113809453A - Manufacturing method of flexible stretchable battery pack - Google Patents
Manufacturing method of flexible stretchable battery pack Download PDFInfo
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- CN113809453A CN113809453A CN202111056752.6A CN202111056752A CN113809453A CN 113809453 A CN113809453 A CN 113809453A CN 202111056752 A CN202111056752 A CN 202111056752A CN 113809453 A CN113809453 A CN 113809453A
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
- H01M50/238—Flexibility or foldability
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
- H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
- H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
- H01M50/222—Inorganic material
- H01M50/224—Metals
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
- H01M50/24—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries from their environment, e.g. from corrosion
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
- H01M50/242—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries against vibrations, collision impact or swelling
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Battery Mounting, Suspending (AREA)
Abstract
The invention discloses a manufacturing method of a flexible stretchable battery pack, which comprises the following steps of: respectively placing the battery cores in a mold and injecting glue to the battery cores to form a battery core glue injection layer; respectively placing the PCB boards in a mould and injecting glue to the PCB boards to form PCB board glue injection layers; connecting 1 or more battery cells with battery cell gel-casting layers in series and parallel, and electrically connecting the battery cells with 1 or more PCB boards with PCB board gel-casting layers through wires to form an internal battery cell module; the manufacturing steps of the stretchable packaging shell are as follows: adopt elastic material to carry out blow molding or injection moulding or compression moulding or extrusion with inside electric core module and be tensile encapsulation shell. The manufacturing method of the application encapsulates each module of the internal battery cell module respectively, and secondary encapsulation is carried out on the stretchable encapsulation shell, so that the stretchable battery cell module has good stretchable protection performance and good safety.
Description
Technical Field
The invention relates to the technical field of batteries, in particular to a manufacturing method of a flexible stretchable battery pack.
Background
The current flexible battery uses an ultrathin flexible battery cell, can realize bending, has certain flexibility, and has the following defects: the bending times are limited, the service life of the battery is lost when the bending times are more, and the capacity is reduced to be between 1mAh and 100 mAh; moreover, the existing ultrathin flexible battery cell can only be bent and cannot be stretched or twisted. In addition, current flexible battery product is for realizing flexibility and bending, generally does not have the protective housing, lacks the outside protection to flexible battery, and the security is too low, takes place to pierce through security problems such as fracture easily.
Disclosure of Invention
The following presents a simplified summary of embodiments of the invention in order to provide a basic understanding of some aspects of the invention. It should be understood that the following summary is not an exhaustive overview of the invention. It is not intended to determine the key or critical elements of the present invention, nor is it intended to limit the scope of the present invention. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is discussed later.
The invention provides a manufacturing method of a flexible stretchable battery pack, which comprises the following steps:
inside electric core module preparation step includes:
respectively placing the battery cores in a mold and injecting glue to the battery cores to form a battery core glue injection layer; the battery cell is packaged in the battery cell glue injection layer to form an island structure, a patch panel (a circuit expansion interface) for electric connection (electric connection with a PCB (printed circuit board) or other battery cells) is reserved on one side (not covered by the battery cell glue injection layer) of the island structure, and the patch panel is electrically connected with the battery cell by taking a wire as a bridge to form an island bridge structure; the battery cell gel-casting layer does not comprise one side of the battery cell positioned on the adapter plate;
respectively placing the PCB boards in a mould and injecting glue to the PCB boards to form PCB board glue injection layers;
connecting 1 or more battery cells with battery cell gel-casting layers in series and parallel, and electrically connecting the battery cells with 1 or more PCB boards with PCB board gel-casting layers through wires to form an internal battery cell module;
the manufacturing method of the stretchable packaging shell comprises the following steps: adopt elastic material to carry out blow molding or injection moulding or compression moulding or extrusion with inside electric core module and be tensile encapsulation shell. The internal battery cell module is packaged in the stretchable packaging shell, and when the stretchable packaging shell deforms under the action of pressure or tensile force, the battery cells of the internal battery cell module and the PCB keep an electric connection relationship in the elastic expansion constraint layer of the stretchable packaging shell. Wherein the elastic material may be rubber (e.g. TPU) or silicone or latex or other soft material.
The connection relationship between the battery cells and the PCB is designed according to actual needs, for example, two or more battery cells and one PCB are provided, and each battery cell is electrically connected to the PCB; for example, a plurality of battery cells and two PCB boards are designed, the battery cells can be divided into two groups according to actual needs, one group is connected with one PCB board, the other group is connected with the other PCB board, and the two PCB boards are electrically connected with each other; for example, a plurality of battery cells and N PCBs (N > 2) are designed, the plurality of battery cells may be divided into N groups, the battery cells of the N groups are respectively connected to the N PCBs in a one-to-one correspondence, and the N PCBs are electrically connected to each other.
This application adopts above-mentioned scheme, at first carry out the modularization with inside electric core module and handle, also separate inside electric core module for electric core and PCB board promptly, encapsulate (glue injection layer) each electric core and PCB board alone again, and adopt the island bridge structure to pass through the wire electricity each other between each part and connect, then encapsulate once more to inside electric core module through the encapsulation shell of can stretching, through two-layer flexible encapsulation, make whole flexible battery group have fine stretch and collapsibility.
Further, the internal battery cell module and the stretchable packaging shell are achieved through high-frequency welding. The stretchable packaging shell is trimmed through the trimming die, a trimming line (an art designing line) is arranged on the periphery of the stretchable packaging shell, and when the internal battery cell module is combined with the stretchable packaging shell, a welding edge is cut off during welding to ensure the attractiveness of a final product.
As a preferred embodiment, the internal cell module further includes one or more electrical connectors electrically connected to each of the cells and the PCB, the electrical connectors being used to connect to and conduct electricity to an external module, and the internal cell module is used to supply electricity to the external module electrically connected to the internal cell module through the electrical connectors. For example, the flexible and foldable battery pack can be connected with an external heating module to supply power to the heating module, and can also be connected with other functional modules (such as a refrigeration functional module, a vibration functional module and the like) to supply power to the functional modules, and the flexible and foldable battery pack is particularly suitable for being used on a wearable device.
As a possible implementation, the electrical connector includes a male connector and a female connector, the male connector and the female connector are mutually matched and electrically connected, the female connector is electrically connected to each of the battery cells and the PCB, and the male connector is electrically connected to the external module, so that the external module and the internal battery cell module are electrically connected after the male connector and the female connector are matched and connected, thereby supplying power to the external module by the internal battery cell module. Public head is connected or USB connects or DC connects through Type-C with female seat, that is to say, electric connector is that the public female head of Type-C connects, or the public female head of USB connects, or the public female head of DC connects, also can be other electric connection structure.
Preferably, the public head and the female seat of electric connector mutually support and inhale the structure through ordinary magnetism or the magnetism of circular telegram auto-lock structure realization of inhaling, and inside electric core module is inhaled the structure through this magnetism and is fixed on shoes. When electric connector is circular telegram auto-lock magnetism structure, it not only undertakes the structure effect and fixes inside electric core module on wearable equipment or clothing, still is responsible for electrically conducting.
Preferably, the keysets still extends outside the electric core injecting glue layer and rather than the wire (preferably elastic wire) of electricity connection, and is corresponding, but tensile encapsulation shell corresponds wire position department is equipped with protruding working of plastics, through protruding working of plastics high frequency with tensile encapsulation shell fixed welding together to play fine water-proof effects.
For further improving the waterproof effect, one side of the electric core glue injection layer on the adapter plate is provided with a gradually reducing structure, and the gradually reducing structure wraps the connection part of the adapter plate and the wire. Above-mentioned waterproof construction can protect welding position, further strengthens the security performance of inside electric core module.
For the security performance such as the resistance vibration of realizing inside electric core module, strike, extrusion, fall, it is preferred, to electric core injecting glue specifically includes: two steel plates with gum are pasted on the front and back surfaces of the battery cell (one surface of the steel plate with the gum faces outwards); the electric core that will paste the put steel sheet is placed in the mould to this electric core injecting glue, colloid parcel electric core remove the position of placing the steel sheet and the position that electric core is located the keysets during the injecting glue, also the colloid can not wrap up electric core completely, only can wrap up the part that electric core did not paste the steel sheet and be equipped with one side of keysets, make the injecting glue module fill. Preferably, the thickness of the steel plate is preferably 0.05mm to 0.15 mm.
Preferably, the cell glue injection layer wraps a space of 3mm-4mm around the cell and has a chamfer with a radius of 1.5mm-2.5mm, and the size ensures the protection effect on the cell on the premise of not increasing the larger size of the cell module.
For the security performance such as the resistance vibration of realizing inside electric core module, strike, extrusion, fall, the PCB board body structure design of inside electric core module is as follows: the PCB glue injection layer wraps a 3-4 mm space around the PCB and is provided with a chamfer with the radius of 1.5-2.5 mm, and the size ensures the protection effect on the PCB on the premise of not increasing the larger size of the PCB module.
Furthermore, the PCB also extends out of the stretchable packaging shell and is provided with an output line electrically connected with the PCB, and the output line is used for being connected to an external power supply to charge the battery cell. Furthermore, the output wire consists of a wire and a wire glue SR, the wire glue SR is used for welding the wire and the stretchable packaging shell together when the stretchable packaging shell is welded at high frequency, the sealing performance is ensured to achieve the waterproof effect, and the wire can be a common wire or an elastic wire; the structure size of the line glue SR can be designed into a minimum size structure on the premise of ensuring air tightness.
Furthermore, a switch key is further arranged on the PCB and can be used for a power switch and/or a gear adjusting switch. Correspondingly, the position of the stretchable packaging shell corresponding to the switch key is provided with a key cap, so that a user can conveniently press and adjust the stretchable packaging shell. Preferably, the key cap is made of silica gel. When the switch key is used as a gear adjusting switch, each gear represents the magnitude of input current and duty ratio (the ratio of the power-on time and the time of different electricity), for example, the gear can be designed into three gears, the duty ratio of 90% of the first gear (the discharge time is nine percent), 70% of the second gear and 50% of the third gear, and can be adjusted at any time, so that the use of a user is facilitated.
Further, be equipped with the lamp plate on the PCB board, but stretch encapsulation shell is located lamp plate position department and still is equipped with the leaded light post, and is preferred, the leaded light post is located on the switch button and is located the key cap, and it adopts injection molding process to realize, uses materials such as atomizing translucent or full transparent PC, ABS, PP. Preferably, the light guide column can be directly clamped in the key cap or fixed inside the key cap through a double-sided adhesive tape. Be equipped with 1 or a plurality of LED lamp on the lamp plate, when a plurality of LED lamp dispersion set up, the leaded light post can gather a plurality of lamps apart from far away on the lamp plate and scatter to the button cap of whole switch again together, and the light of different colours has been solved to this structure has the problem of luminance difference on the button cap.
As a preferred embodiment, for the appearance design and the counter weight consideration of convenient encapsulation shell, and avoid whole group battery both sides atress uneven and toward one side skew, influence life, inside electric core module design is symmetrical structure, and it includes first electric core, filling module, PCB board and the second electric core that places in proper order, first electric core and second electric core connect back with the PCB board electricity is connected, the filling module is the same basically with the shape and the size of the PCB board that has the glue injection layer to make inside electric core module use the middle part to form bilateral symmetry structure as the center.
For the tensile and collapsible performance of the inside electric core module in the tensile encapsulation shell of further improvement, it is preferred, each electric core with adopt the elastic wire to connect between the PCB board, during the preparation, the elastic wire can weld on the pad of each module. The elastic wire can be realized by the elastic wire of the prior application of the applicant, and can also be realized by other elastic wires realized by the prior art.
Furthermore, the stretchable packaging shell is of a symmetrical structure and comprises a first packaging part wrapping the first battery cell, a second packaging part wrapping the filling module, a third packaging part wrapping the PCB and a fourth packaging part wrapping the second battery cell, the first packaging part and the second packaging part are connected through a first elastic connection structure, the second packaging part and the third packaging part are connected through a second elastic connection structure, the third packaging part and the fourth packaging part are connected through a third elastic connection structure, and the stretchable packaging shell forms a bilateral symmetry structure by taking the middle part of the second elastic connection assembly as the center. First elastic connection structure, second elastic connection structure and third elastic connection structure are along the length direction tensile structure of can stretching the encapsulation shell respectively, and it can stretch, buckle or twist and be used for the electric connection wire of the inside electric core module in the protection encapsulation shell of can stretching. Realize further flexibility on the basis of guaranteeing the life of flexible group battery and stretch, first elastic connection structure and third elastic connection structure are shorter connection structure, second elastic connection structure is longer connection structure, and the length of second elastic connection structure is greater than first elastic connection structure, and is less than the length of first encapsulation portion or second encapsulation portion (along the length direction's of the encapsulation shell of can stretching length). The first elastic connecting structure and the third elastic connecting structure are approximately equal (the lengths of the first elastic connecting structure and the third elastic connecting structure can be slightly different due to manufacturing process problems).
In order to realize further flexible stretching on the basis of ensuring the service life of the flexible battery pack, the first packaging part and/or the second packaging part and/or the third packaging part and/or the fourth packaging part are arc-shaped packaging shells. Preferably, preset sizes are reserved on the upper, lower, left and right sides of the arc-shaped packaging shell and an internal accommodating component (a battery cell or a PCB) respectively, for example, 0.3mm is reserved on the left and right sides respectively, and 0.15mm is reserved on the upper and lower sides respectively as a size and a production error, and of course, the left and right reserved sizes or the upper and lower reserved sizes can be different and are set according to actual production requirements; further preferably, the top thickness of the arc-shaped packaging shell is smaller than the thickness of the two sides, for example, the top thickness is 1.0mm, and the thickness of the two sides of the shell is 2 mm.
As another preferred embodiment, the internal battery cell module is a symmetric structure, and includes a first battery cell, a first PCB, a second PCB and a second battery cell, which are sequentially disposed, the first battery cell is electrically connected to the first PCB, the second PCB is electrically connected to the second battery cell, the first PCB and the second PCB are electrically connected to each other, and the first PCB having the glue injection layer and the second PCB having the glue injection layer have substantially the same shape and size (the first PCB and the second PCB in the glue injection layer may have the same size or may have different sizes, and may be appropriately adjusted by the thickness of the glue injection layer), so that the internal battery cell module forms a left-right symmetric structure with the middle portion as the center.
This application has the flexible battery group that wider angle of buckling (0 ~ 180 degrees), tensile length are longer (0 ~ 30%), have certain torsion angle (0 ~ 90 degrees), and its group battery capacity can reach more than 1500mAh moreover. It has the following advantages:
1. the flexible battery has the advantages that the outer parts of the existing flexible battery products are not provided with protective shells, so that the flexible battery is not protected, the safety problems such as puncture and rupture are easy to occur, and the like;
2. the battery core of the internal battery core module is injected with the steel plate through the glue injection process, so that the battery core module has the performances of resisting vibration, impact, extrusion, falling and the like, and the safety is improved;
3. the stretchable packaging shell with the arc-shaped design enables the battery pack to have a certain bending degree, and the elastic connection structure with the bending and stretching performance enables the whole flexible battery pack to be more attached to a human body;
4. the island bridge structure is used, the rigid battery cell modules are connected through the elastic lead, and the flexibility of the battery pack is realized by utilizing the characteristics of stretchability, bending, twisting and conductivity of the battery cell modules;
5. the application fields are wide, such as intelligent clothing, flexible electronics, medical equipment, flexible sensors, flexible displays and the like; in the wearing field, the flexible battery pack can be arranged in clothes, deforms along with the movement of a body and continuously supplies power to electric appliances (a refrigerating electric appliance, a luminous electric appliance, a heating electric appliance and the like) in the clothes, and more comfortable clothes wearing experience is provided; on arranging shoes in, the heating plate of shoes supplies power, stretches to buckle along with the motion of shoes to satisfy the travelling comfort requirement. In the aspect of household appliances, the electric heating scarf can be used for wearing headsets, heating scarves, hats and the like;
in conclusion, the structure of the application has strong adjustability and strong universality, can design corresponding structure sizes according to different use conditions to meet the use requirements of customers, and has good practicability.
Drawings
The invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like reference numerals are used throughout the figures to indicate like or similar parts. The accompanying drawings, which are incorporated in and form a part of this specification, illustrate preferred embodiments of the present invention and, together with the detailed description, serve to further explain the principles and advantages of the invention. On the attachment
In the figure:
fig. 1a is a first schematic diagram of an internal battery cell module in embodiment 1 of the present invention;
fig. 1b is a second schematic diagram of an internal battery cell module in embodiment 1 of the present invention;
FIG. 2 is a schematic view of a stretchable package casing in embodiment 1 of the present invention;
fig. 3 is a schematic view of an arc-shaped package casing in embodiment 1 of the present invention;
fig. 4 is a schematic diagram of an internal cell module in embodiment 2 of the present invention;
fig. 5 is a first schematic diagram of a third cell of the internal cell module in embodiment 2 of the present invention;
fig. 6 is a second schematic diagram of a third cell of the internal cell module in embodiment 2 of the present invention;
fig. 7 is a third schematic diagram of a third battery cell of the internal battery cell module in embodiment 2 of the present invention;
fig. 8 is a fourth schematic diagram of a third cell of the internal cell module in embodiment 2 of the present invention;
fig. 9 is a first schematic diagram of a PCB board of an internal cell module in embodiment 2 of the present invention;
fig. 10 is a second schematic diagram of a PCB board of an internal cell module in embodiment 2 of the present invention;
FIG. 11 is a first schematic view of a stretchable packaging casing according to embodiment 2 of the present invention;
FIG. 12 is a second schematic view of the stretchable packaging casing in embodiment 2 of the present invention;
FIG. 13 is a first schematic diagram of an output line in embodiment 2 of the present invention;
FIG. 14 is a second schematic diagram of an output line in embodiment 2 of the present invention;
FIG. 15 is a schematic view of a light guide bar according to embodiment 2 of the present invention;
fig. 16 is a schematic diagram of an internal cell module in embodiment 3 of the present invention.
Detailed Description
Embodiments of the present invention will be described below with reference to the accompanying drawings. Elements and features depicted in one drawing or one embodiment of the invention may be combined with elements and features shown in one or more other drawings or embodiments. It should be noted that the figures and description omit representation and description of components and processes that are not relevant to the present invention and that are known to those of ordinary skill in the art for the sake of clarity.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Example 1
The embodiment of the invention provides a manufacturing method of a flexible stretchable battery pack, which comprises the following steps:
process 1, inside electric core module preparation step includes:
respectively placing the battery cores in a mold and injecting glue to the battery cores to form a battery core glue injection layer; the battery cell is packaged in the battery cell glue injection layer to form an island structure, a patch panel (a circuit expansion interface) for electric connection (electric connection with a PCB (printed circuit board) or other battery cells) is reserved on one side (not covered by the battery cell glue injection layer) of the island structure, and the patch panel is electrically connected with the battery cell by taking a wire as a bridge to form an island bridge structure; the battery cell gel-casting layer does not comprise one side of the battery cell positioned on the adapter plate;
respectively placing the PCB boards in a mould and injecting glue to the PCB boards to form PCB board glue injection layers;
connecting 1 or more battery cells with battery cell gel-casting layers in series and parallel, and electrically connecting the battery cells with 1 or more PCB boards with PCB board gel-casting layers through wires to form an internal battery cell module;
process 2, stretchable packaging shell manufacturing steps, including: adopt elastic material to carry out blow molding or injection moulding or compression moulding or extrusion with inside electric core module and be tensile encapsulation shell. The internal battery cell module is packaged in the stretchable packaging shell, and when the stretchable packaging shell deforms under the action of pressure or tensile force, the battery cells of the internal battery cell module and the PCB keep an electric connection relationship in the elastic expansion constraint layer of the stretchable packaging shell. Wherein the elastic material may be rubber (e.g. TPU) or silicone or latex or other soft material.
Referring to fig. 1a, 1b and 2, the flexible and stretchable battery pack manufactured by the above manufacturing method includes an internal battery cell module 100 and a stretchable packaging casing 200 covering the external of the internal battery cell module 100. In this embodiment, referring to fig. 1a and fig. 1b, the internal battery cell module 100 includes a first battery cell 101, a filling module 102, a PCB 103, and a second battery cell 104, which are sequentially disposed, the first battery cell 101 and the second battery cell 104 are connected in parallel and then connected to the PCB 103, each battery cell is connected to the PCB by a wire, and the outsides of each battery cell, the PCB, and the wire are wrapped by an injection molding layer; the internal battery cell module 100 is enclosed in the stretchable packaging casing 200, and when the stretchable packaging casing 200 is deformed under the action of pressure or tensile force, each battery cell of the internal battery cell module 100 and the PCB board keep an electrical connection relationship in the elastic expansion constraint layer of the stretchable packaging casing 200. The stretchable package housing 200 is an injection molded part, a compression molded part or an extrusion molded part made of an elastic material. The resilient material may be rubber (e.g. TPU) or silicone or latex or other soft material.
The internal battery cell module 100 has a symmetrical structure, and the filling module 102 is substantially the same as the PCB 103 having an adhesive injection layer in shape and size, so that the internal battery cell module 100 forms a left-right symmetrical structure with the middle portion as the center.
Correspondingly, referring to fig. 2, the stretchable packaging casing 200 is a symmetrical structure and includes a first packaging part 201 wrapping the first cell 101, a second packaging part 202 wrapping the filling module 102, a third packaging part 203 wrapping the PCB 103, and a fourth packaging part 204 wrapping the second cell 104, the first packaging part 201 and the second packaging part 202 are connected by a first elastic connection structure 205, the second packaging part 202 and the third packaging part 203 are connected by a second elastic connection structure 206, the third packaging part 203 and the fourth packaging part 204 are connected by a third elastic connection structure 207, and the stretchable packaging casing 200 forms a left-right symmetrical structure with the middle part of the second elastic connection assembly as a center. The first elastic connection structure 205, the second elastic connection structure 206 and the third elastic connection structure 207 are respectively stretchable structures along the length direction of the stretchable package housing 200, which can stretch, bend or twist and are used for protecting the electrical connection wires of the internal battery cell module 100 inside the stretchable package housing 200. To realize further flexible stretching on the basis of ensuring the service life of the flexible battery pack, the first elastic connection structure 205 and the third elastic connection structure 207 are shorter connection structures, the second elastic connection structure 206 is a longer connection structure, and the length of the second elastic connection structure 206 is greater than that of the first elastic connection structure 205 and less than that of the first packaging part 201 or the second packaging part 202 (the length along the length direction of the stretchable packaging housing 200). The first elastic connection structure 205 and the third elastic connection structure 207 are substantially equal (the lengths may be slightly different due to manufacturing process issues).
In order to realize further flexibility and stretching on the basis of ensuring the service life of the flexible battery pack, in this embodiment, referring to fig. 3, the first encapsulating portion 201 wrapping the first electric core 101 is an arc-shaped encapsulating shell, the second encapsulating portion wrapping the filling module is also an arc-shaped encapsulating shell, the third encapsulating portion has the same structure as the second encapsulating portion, and the fourth encapsulating portion has the same structure as the first encapsulating portion. The arc-shaped packaging shell and the internal accommodating component (the battery cell or the PCB 103) are respectively reserved with preset sizes at the upper, lower, left and right sides, for example, 0.3mm is reserved at the left and right sides, and 0.15mm is reserved at the upper and lower sides as the size and the production error, of course, the left and right reserved sizes or the upper and lower reserved sizes can be different and are set according to the actual production requirement; further preferably, the top thickness of the arc-shaped packaging shell is smaller than the thickness of the two sides, for example, the top thickness is 1.0mm, and the thickness of the two sides of the shell is 2 mm.
In order to further improve the stretchable and foldable performance of the internal battery cell module 100 in the stretchable packaging shell 200, each battery cell is connected with the PCB by an elastic wire. The elastic wire can be realized by the elastic wire of the prior application of the applicant, and can also be realized by other elastic wires realized by the prior art.
This application adopts above-mentioned scheme, at first carry out the modularization with inside electric core module 100 and handle, also separate inside electric core module 100 for electric core and PCB board, encapsulate (glue injection layer) each electric core and PCB board alone again, and adopt the island bridge structure to pass through elasticity wire electricity each other between each part and connect, then encapsulate once more to inside electric core module 100 through can stretching encapsulation shell 200, through two-layer flexible encapsulation, make whole flexible battery group have fine stretching and collapsible performance.
Example 2
Referring to fig. 4, in this embodiment, the internal cell module 100 has a symmetric structure, and includes a third cell 111, a first PCB 112, a second PCB 113, and a fourth cell 114, which are sequentially disposed, where the third cell 111 is electrically connected to the first PCB 112, the second PCB 113 is electrically connected to the fourth cell 114, the first PCB 112 is electrically connected to the second PCB 113, and the first PCB 112 having an adhesive injection layer and the second PCB 113 having an adhesive injection layer have substantially the same shape and size (the first PCB 112 and the second PCB 113 in the adhesive injection layer may have the same size or different sizes, and may be appropriately adjusted by the thickness of the adhesive injection layer), so that the internal cell module 100 forms a left-right symmetric structure with the middle portion as the center.
In order to realize safety performance of the internal battery cell module 100, such as vibration resistance, impact resistance, extrusion resistance, and falling resistance, referring to fig. 5 to 8, a third battery cell (the third battery cell may also be used in the first battery cell and the second battery cell mentioned in embodiment 1, or may be a fourth battery cell in this embodiment) of the internal battery cell module 100 is specifically designed as follows: the third cell 111 is encapsulated in the cell gel layer 115 to form an island structure, and an adapter plate 116 (circuit expansion interface) for electrical connection (electrical connection with a PCB board or other cells) is reserved on one side of the island structure, and the adapter plate 116 is electrically connected with the third cell 111 as a bridge through a wire to form an island-bridge structure. The island bridge structure is used, the rigid battery cell modules are connected through the elastic lead, and the flexibility of the battery pack is realized by utilizing the characteristics of stretching, bending, twisting and electric conduction of the battery cell modules. The adapter plate 116 further extends out of the battery cell adhesive injection layer 115 and is electrically connected with a wire 117 (preferably an elastic wire), steel plates 118 are respectively attached to the front and the back of the battery cell, the thickness of each steel plate is preferably 0.1mm, the battery cell adhesive injection layer 115 wraps the battery cell, and the adapter plate 116 is exposed; cell gel casting layer 115 is located one side of keysets 116 and is equipped with convergent structure 119, and convergent structure 119 has wrapped up the connecting portion of keysets 116 and wire 117, and welding position can be protected to this convergent structure, further strengthens inside cell module 100's security performance.
In this embodiment, the cell gel layer 115 wraps up the space of 3.5mm around the cell and has a chamfer with a radius of 2mm, and this dimension ensures the protection effect on the cell on the premise of not increasing the larger size of the cell module.
For the security performance such as the resistance vibration, impact, extrusion, fall of realizing inside electric core module 100, refer to 9 and fig. 10, the PCB board body structure design of inside electric core module 100 is as follows: the first PCB 112 and the second PCB 113 have the same structure, and the first PCB 112 is described as follows: the first PCB 112 is wrapped with a PCB glue injection layer 122. In this embodiment, the PCB injection layer 122 wraps the 3.5mm space around the first PCB 112 and has a chamfer with a radius of 2mm, which guarantees the protection effect on the PCB without increasing the larger size of the PCB 103 module.
Referring to fig. 11 and 12, the first PCB further extends out of the stretchable packaging casing 200 and is electrically connected to an output line 123 of the first PCB 112, and the output line 123 is used for connecting to an external power source to charge the battery cells. Referring to fig. 13 and 14, the output line 123 is composed of a wire 1231 and a wire glue 1232(SR), the wire glue 1232(SR) is used for welding the wire with the stretchable packaging case 200 during high frequency welding, so as to ensure the sealing property and achieve the waterproof effect, and the wire may be a common wire or an elastic wire; the structure size of the line glue 1232(SR) can be designed as a minimum size structure on the premise of ensuring air tightness.
Referring to fig. 11 and 12, the second PCB is provided with a switch button 124, which may be used for a power switch or a gear adjustment switch. When the gear adjusting switch is used, each gear represents the magnitude and the duty ratio of input current (the ratio of the time of electrifying and the time of different electricity), and for example, the gear can be designed into three gears, the duty ratio of 90% of the first gear (the discharge time is nine percent), 70% of the second gear and 50% of the third gear, and can be adjusted at any time, so that the use of a user is facilitated.
Referring to fig. 12, the flexible stretchable battery pack is formed by connecting two cells connected in parallel, a PCB, and a symmetrical filling module (which may be replaced by a circuit board module or a cell module) by a wire, wherein the two cells, the PCB, and the symmetrical filling module are respectively packaged into an arc structure to form a stretchable arc-structured battery pack.
In addition, be equipped with the lamp plate on the PCB board 103, the position department that the encapsulation shell 200 of can stretching is located the lamp plate still is equipped with the leaded light post, and the schematic diagram of leaded light post is seen in figure 15, and it adopts injection molding process to realize, uses material such as atomizing translucent or full transparent PC, ABS, PP. Be equipped with 1 or a plurality of LED lamp on the lamp plate, when a plurality of LED lamp dispersion set up, the leaded light post can gather a plurality of lamps far away apart on the lamp plate and scatter to whole switch face again together, and the light of different colours has been solved to this structure has the problem of luminance difference on pressing the key cap.
Example 3
In this embodiment, different from embodiments 1 and 2, the internal cell module further includes two electrical connectors (the number of which can be set according to actual needs) electrically connected to each cell and the PCB. Referring to fig. 16, the internal cell module 100 includes a fifth cell 131, a third PCB 132, a fourth PCB 133, a sixth cell 134, a first electrical connector 135 and a second electrical connector 136, which are sequentially disposed, the fifth cell 131 is electrically connected to the third PCB 132, the fourth PCB 133 is electrically connected to the sixth cell 134, the third PCB 132 is electrically connected to the fourth PCB 133, the first electrical connector 135 is electrically connected to the third PCB 132, and the second electrical connector 136 is electrically connected to the fourth PCB 133. The third PCB 132 with the glue injection layer and the fourth PCB 133 with the glue injection layer have substantially the same shape and size (the third PCB 132 and the fourth PCB 133 in the glue injection layer may have the same size or may have different sizes, and may be appropriately adjusted by the thickness of the glue injection layer), so that the internal battery cell module 100 forms a left-right symmetrical structure with the middle portion as the center.
The first electrical connector 135 and the second electrical connector 136 are of the same structure, are used for connecting an external module and conducting electricity, and enable the internal cell module to supply electricity to the external module electrically connected with the internal cell module through the electrical connectors. It may also be a structural fastener at the same time.
As a feasible solution, the first electrical connector 135 includes a male connector and a female connector that are mutually matched and electrically connected, the female connector is electrically connected to each electrical core and the PCB, and the male connector is electrically connected to the external module, so that the external module and the internal electrical core module are electrically connected after the male connector and the female connector are matched and connected, thereby realizing that the internal electrical core module supplies power to the external module. Wherein, public head and female seat can be through Type-C connection or USB connection or DC connection, also can be other electric connection structure.
Flexible battery on the present market is through very thin electric core in order to realize its flexible effect, but their flexibility only can buckle unable tensile, and the angle of buckling is very little, the bending number of times can lose the battery life many, meanwhile capacity is lower (1mAh ~ 100mAh), the group battery angle of buckling that this application realized through above-mentioned scheme is very wide (0 ~ 180 degree), tensile length is very long (0 ~ 30%), certain torsion angle (0 ~ 90 degree) has, and the group battery capacity can reach more than 1500mAh, this group battery voltage 7.4V in addition, capacity 2750mAh, itself has certain degree of buckling, in addition have the tensile property of buckling, it is human more to laminate.
In the foregoing description of specific embodiments of the invention, features described and/or illustrated with respect to one embodiment may be used in the same or similar way in one or more other embodiments, in combination with or instead of the features of the other embodiments.
It should be emphasized that the term "comprises/comprising" when used herein, is taken to specify the presence of stated features, elements, steps or components, but does not preclude the presence or addition of one or more other features, elements, steps or components.
While the present invention has been disclosed above by the description of specific embodiments thereof, it should be understood that all of the embodiments and examples described above are illustrative and not restrictive. Various modifications, improvements and equivalents of the invention may be devised by those skilled in the art within the spirit and scope of the appended claims. Such modifications, improvements and equivalents are also intended to be included within the scope of the present invention.
Claims (10)
1. A method of making a flexible and stretchable battery pack, comprising:
manufacturing an internal battery cell module:
respectively placing the battery cores in a mold and injecting glue to the battery cores to form a battery core glue injection layer; the battery cell is packaged in the battery cell glue injection layer to form an island structure, a switching plate for electric connection is reserved on one side of the island structure, and the switching plate is electrically connected with the battery cell through a wire serving as a bridge to form an island bridge structure; the battery cell gel-casting layer does not comprise one side of the battery cell positioned on the adapter plate;
respectively placing the PCB boards in a mould and injecting glue to the PCB boards to form PCB board glue injection layers;
connecting 1 or more battery cells with battery cell gel-casting layers in series and parallel, and electrically connecting the battery cells with 1 or more PCB boards with PCB board gel-casting layers through wires to form an internal battery cell module;
the manufacturing steps of the stretchable packaging shell are as follows:
carrying out blow molding or injection molding or compression molding or extrusion molding on the internal battery cell module by adopting an elastic material to form a stretchable packaging shell; the internal battery cell module is packaged in the stretchable packaging shell, and when the stretchable packaging shell deforms under the action of pressure or tensile force, the battery cells of the internal battery cell module and the PCB keep an electric connection relationship in the elastic expansion constraint layer of the stretchable packaging shell.
2. The method of making a flexible stretchable battery pack according to claim 1, characterized in that: injecting glue into the battery cell specifically comprises: two steel plates with gum are attached to the front surface and the back surface of the battery cell; the battery core with the steel plate placed on the battery core is placed in the mold, glue is injected to the battery core, and the glue wraps the battery core when injecting glue, so that the part where the steel plate is placed and the part where the battery core is located on the adapter plate are removed.
3. The method of making a flexible stretchable battery pack according to claim 1, characterized in that: the cell glue injection layer wraps a space of 3mm-4mm around the cell and is provided with a chamfer with the radius of 1.5mm-2.5 mm.
4. The method of making a flexible stretchable battery pack according to claim 1, characterized in that: the PCB glue injection layer wraps a 3mm-4mm space around the PCB and is provided with a chamfer with the radius of 1.5mm-2.5 mm.
5. A method of manufacturing a flexible stretchable battery pack according to any one of claims 1 to 4, characterized in that: the internal battery cell module further comprises one or more electric connecting pieces electrically connected with the battery cells and the PCB, the electric connecting pieces are used for connecting external modules and conducting electricity, and the internal battery cell module supplies power for the external modules electrically connected with the internal battery cell module through the electric connecting pieces.
6. A method of manufacturing a flexible stretchable battery pack according to any one of claims 1 to 4, characterized in that: the internal battery cell module and the stretchable packaging shell are welded through high frequency.
7. A method of manufacturing a flexible stretchable battery pack according to any one of claims 1 to 4, characterized in that: the adapter plate also extends out of the battery core glue injection layer and is electrically connected with a wire of the battery core glue injection layer, correspondingly, a protruding plastic part is arranged at the position of the stretchable packaging shell corresponding to the wire, and the stretchable packaging shell is fixedly welded together through the high frequency of the protruding plastic part.
8. A method of manufacturing a flexible stretchable battery pack according to any one of claims 1 to 4, characterized in that: the battery cell glue injection layer is provided with a gradually reducing structure at one side of the adapter plate, and the gradually reducing structure wraps the connection part of the adapter plate and the wire.
9. A method of manufacturing a flexible stretchable battery pack according to any one of claims 1 to 4, characterized in that: the inside electric core module is symmetrical structure, and it is including the first electric core, fill module, PCB board and the second electric core that place in proper order, first electric core and second electric core connect back with the PCB board electricity is connected, the shape and the size of fill module and the PCB board that has the injecting glue layer are the same basically to make inside electric core module use the middle part to form bilateral symmetry structure as the center.
10. The method of making a flexible stretchable battery pack according to claim 9, characterized in that: the stretchable packaging shell is of a symmetrical structure and comprises a first packaging part wrapping a first battery cell, a second packaging part wrapping a filling module, a third packaging part wrapping a PCB and a fourth packaging part wrapping a second battery cell, the first packaging part and the second packaging part are connected through a first elastic connection structure, the second packaging part and the third packaging part are connected through a second elastic connection structure, the third packaging part and the fourth packaging part are connected through a third elastic connection structure, and the stretchable packaging shell forms a bilateral symmetry structure by taking the middle part of the second elastic connection assembly as the center.
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| CN111916582A (en) * | 2020-08-26 | 2020-11-10 | 深圳市神通天下科技有限公司 | Bluetooth headset battery protective layer |
| CN213850653U (en) * | 2020-11-12 | 2021-08-03 | 浙江荷清柔性电子技术有限公司 | Flexible sleep monitoring device and pillow of sleeping |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113794010A (en) * | 2021-09-09 | 2021-12-14 | 嘉兴极展科技有限公司 | Flexible battery pack of stretching |
| CN113794010B (en) * | 2021-09-09 | 2023-09-19 | 嘉兴极展科技有限公司 | Flexible stretchable battery pack |
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