CN114072961A - Composite molded body, method for producing same, battery pack, electric tool, and electric vehicle - Google Patents
Composite molded body, method for producing same, battery pack, electric tool, and electric vehicle Download PDFInfo
- Publication number
- CN114072961A CN114072961A CN202080048479.XA CN202080048479A CN114072961A CN 114072961 A CN114072961 A CN 114072961A CN 202080048479 A CN202080048479 A CN 202080048479A CN 114072961 A CN114072961 A CN 114072961A
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- China
- Prior art keywords
- molded body
- resin
- resin molded
- composite
- bubbles
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Images
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
- H01M50/242—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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/04—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C44/06—Making multilayered articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1615—The materials being injected at different moulding stations
-
- 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
- H01M50/227—Organic material
-
- 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
- H01M50/231—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 having a layered structure
-
- 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
-
- 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
- H01M50/247—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
-
- 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
- H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
-
- 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
- H01M50/258—Modular batteries; Casings provided with means for assembling
-
- 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)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Aviation & Aerospace Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Biophysics (AREA)
- Computer Hardware Design (AREA)
- Battery Mounting, Suspending (AREA)
Abstract
The composite molded body includes a first resin molded body and a second resin molded body in contact with the first resin molded body. The first resin molded body includes a plurality of bubbles in a portion in contact with the second resin molded body, and a part of the resin constituting the second resin molded body enters the plurality of bubbles.
Description
Technical Field
The invention relates to a composite molded body, a method for producing the same, a battery pack, an electric tool, and an electric vehicle.
Background
A composite molded body in which two or more resin molded bodies are integrated is used in various technical fields including battery packs. As a method for molding a composite molded article, a two-color molding method or a multi-color molding method is known.
Patent document 1 describes that a composite molded article having strong interface adhesion, which cannot be obtained by the conventional double molding method, can be produced simply, economically and efficiently without providing a mechanical anchor shape or using an adhesive by roughening the surface of the primary molded article in contact with the secondary molded portion in advance so that the surface area thereof is 1.5 times or more as large as that of a smooth surface.
Patent document 1: japanese patent laid-open No. 2000-108205
Disclosure of Invention
As described above, in the composite molded body, it is desired to improve the adhesion between the first resin molded body and the second resin molded body. For example, in a battery pack for an electric power tool or an electric vehicle, since an impact is often applied, a technique for improving adhesion between a first resin molded body and a second resin molded body is particularly desired in a composite molded body used for the battery pack.
The invention aims to provide a composite molded body capable of improving the adhesion, a manufacturing method thereof, a battery pack, an electric tool and an electric vehicle.
In order to solve the above problem, a first aspect of the present invention is a composite molded body including a first resin molded body and a second resin molded body in contact with the first resin molded body, wherein the first resin molded body includes a plurality of cells in a portion in contact with the second resin molded body, and a part of a resin constituting the second resin molded body enters the plurality of cells.
A second aspect of the present invention is a method for producing a composite molded body, including the steps of: a molten resin is supplied onto the surface of the first resin molded body, whereby the resin is caused to enter a plurality of cells contained in the surface, and a second resin molded body is molded.
In the first invention, the contact of the first resin molded body with the second resin molded body includes not only the case where both resin molded bodies are in direct contact but also the case where both resin molded bodies are in indirect contact with a functional layer (e.g., a surface-modified layer) or the like interposed therebetween.
In the first and second aspects of the present invention, the composite molded body may be a two-color molded body including two resin molded bodies, or may be a multi-color molded body including three or more resin molded bodies.
According to the present invention, the adhesion of the composite molded article can be improved.
Drawings
Fig. 1 is a perspective view showing an example of an external appearance of a battery pack according to an embodiment of the present invention.
Fig. 2 is a sectional view taken along line II-II of fig. 1.
Fig. 3 is an exploded perspective view showing an example of the structure of the battery pack according to the embodiment of the present invention.
Fig. 4 is a cross-sectional view showing an example of the configuration of the housing.
Fig. 5 is an enlarged cross-sectional view showing a part of an interface of the housing shown in fig. 4.
Fig. 6 is a schematic diagram showing an example of a configuration of an electric power tool as an application example.
Fig. 7 is a schematic diagram showing an example of a configuration of a hybrid vehicle as an application example.
FIG. 8A is a plan view of the two-color molded article of example 1.
FIG. 8B is a side view of the two-color molded article of example 1.
Fig. 9 is a view showing an SEM image of the upper bottom surface of the first resin plate.
Detailed Description
[ constitution of Battery pack ]
An example of the structure of the battery pack 100 according to an embodiment of the present invention will be described below with reference to fig. 1 to 5. As shown in fig. 1, the battery pack 100 has a hexagonal prism shape. The shape of the battery pack 100 is not limited to this, and may have a prismatic shape other than a hexagonal prism shape, a cylindrical shape, an elliptical cylindrical shape, a polyhedral shape, a spherical shape, an elliptical spherical shape, a free curved surface shape, or the like.
As shown in fig. 1 to 3, the battery pack 100 includes a battery cell 20, a case 10, foam resin members 30A and 30B, and a Protection Circuit Module (PCM) 40. The foamed resin members 30A and 30B and the protection circuit module 40 may be provided or not provided as needed.
The battery pack 100 is used for, for example, an electric vehicle, an electric device, and the like, and more specifically, is used for an electric motorcycle, an electric bicycle, an electric power-assisted bicycle, a hybrid car, a power tool (electric power tool, and the like), and the like.
(Battery unit)
The battery unit 20 has a first end face portion 20S opposing to each other1And a second end face portion 20S2And a first end face part 20S1And a second end face portion 20S2Peripheral surface portion 20S therebetween3. As shown in fig. 2 and 3, the battery unit 20 includes a plurality of batteries 21, a holder 22, and tabs 23A and 23B. The retainer 22 may be provided or not provided as needed.
(Battery)
The battery 21 is a cylindrical battery having a first end and a second end. The first end portion is, for example, a positive terminal portion, and the second end portion is, for example, a negative terminal portion. The plurality of batteries 21 are arranged such that the central axes of the batteries 21 are parallel to each other. The plurality of batteries 21 are arranged in a plurality of rows, for example. The plurality of cells 21 may also be in a stacked configuration as follows: the rows of the adjacent two cells 21 are shifted from each other in the row direction by a length substantially equal to the radius of the outer diameter circumference of the cell 21.
First ends of the plurality of batteries 21 are disposed on the first end surface portion 20S of the battery unit 201Second end portions of the plurality of cells 21 are arranged at the second end face portion 20S of the battery cell 202And (3) side. The battery 21 is, for example, a reusable secondary battery. Examples of the secondary battery include, but are not limited to, a lithium ion secondary battery, a lithium ion polymer secondary battery, and the like.
(holder)
The holder 22 holds a plurality of batteries 21. The holder 22 is made of, for example, a resin material. The holder 22 has a first end face portion 20S1And a second end face portion 20S2A plurality of hole portions 22C therebetween. The hole 22C is a cylindrical space having substantially the same size as the battery 21, and accommodates the battery 21. The plurality of holes 22C are formed with the center axis of each hole 22C and the first end surface portion 20S1And a second end face portion 20S2Are arranged in an orthogonal manner. Both ends of the hole 22C are open, and the first and second ends of the battery 21 accommodated in the hole 22C are exposed from the holder 22. The retainer 22 is configured to be provided on the first end surface portion 20S1And a second end face portion 20S2Can be divided into a first holder 22A and a second holder 22B.
(Tab)
The tab 23A electrically connects the first end of the plurality of batteries 21 held by the holder 22 and the protection circuit module 40. The tab 23B electrically connects the second end portions of the plurality of batteries 21 held by the holder 22 and the protection circuit module 40. The tabs 23A, 23B electrically connect the plurality of cells 21 in parallel. The connection form of the plurality of batteries 21 is not limited to the parallel connection, and the plurality of batteries 21 may be connected in series or in series-parallel.
The tabs 23A, 23B are thin plate-shaped and made of a conductive material such as metal. One main surface of the tab 23A is provided on the first end surface portion 20S of the battery cell 201The above. One main surface of the tab 23B is provided on the second end face portion 20S of the holder 222The above. The tab 23A has a terminal portion 23A extending from the peripheral edge portion1、23A2. The tab 23B has a terminal portion 23B extending from the peripheral edge portion1、23B2. Terminal portion 23A1、23A2And terminal portion 23B1、23B2From the peripheral surface part 20S of the battery cell 203Project in the same direction. Terminal portion 23A1、23A2The tab 23A is electrically connected to the terminal portion 23B of the protection circuit module 401、23B2The tab 23B is electrically connected to the protection circuit module 40. Terminal portion 23A1、23A2And terminal portion 23B1、23B2And also supports the protection circuit module 40 on the peripheral surface part 20S of the battery unit 203The function of (1).
(protective circuit Module)
The protection circuit module 40 monitors the state of the battery 21 and performs various protection operations for protecting the plurality of batteries 21. For example, when the state of the battery 21 is overcharged, the charging of the battery 21 is stopped. Or when the battery 21 is overdischarged, the discharge of the battery 21 is stopped. The protection circuit module 40 electrically connects an external device (not shown) such as an electric vehicle or an electric device to the battery unit 20. The protection circuit module 40 is provided on the peripheral surface portion 20S of the battery cell 203The terminal 23A of the tab 23A1、23A2And terminal portions 23B of the tabs 23B1、23B2And (4) supporting.
As shown in fig. 2 and 3, the protection circuit module 40 includes a substrate 41, a control unit 42, and a connector 43. The control section 42 is provided on the substrate 41. The control unit 42 is connected to the terminal 23A of the tab 23A via a wire (not shown)1、23A2And terminal portions 23B of the tabs 23B1、23B2And (6) electrically connecting. The controller 42 is electrically connected to the connector 43 via a wire (not shown). The control unit 42 controls the battery unit 20. Specifically, for example, the control unit 42 controls charging and discharging of the plurality of batteries 21. The control unit 42 performs the various protection operations described above.
The connector 43 is an example of an external connection terminal for connecting the battery pack 100 to an external device (not shown) such as an electric vehicle or an electric device. The connector 43 is opposite to the first end face part 20S of the battery unit 201The protruding mode is set.
(case)
As shown in fig. 2 and 3, the case 10 houses the battery cell 20, the foamed resin members 30A and 30B, and the protection circuit module 40. The case 10 protects the battery cell 20 from impact caused by dropping or the like, external environment, and the like. The case 10 contains synthetic resin.
As shown in fig. 1 to 3, the case 10 includes a cylindrical wall portion 11C, a first end surface portion 11A that closes a first open end of the wall portion 11C, and a second end surface portion 11B that closes a second open end of the wall portion 11C. Wall 11C covers peripheral surface 20S of battery cell 203。
First end surface portion 11A and first end surface portion 20S of battery unit 201Oppositely arranged, covering the first end face part 20S of the battery unit 201. Second end surface 11B and second end surface 20S of battery cell 202Oppositely arranged, covering the second end face 20S of the battery cell 202。
As shown in fig. 3, the housing 10 is configured to be separable into a housing portion 10A having the first end surface portion 11A and a cover portion 10B having the second end surface portion 11B at a position closer to the second end surface portion 11B than an intermediate position between the first end surface portion 11A and the second end surface portion 11B. The case 10 has an opening 11D on the second end surface 11B side. The connector 43 is exposed from the opening 11D.
The case 10 is a so-called two-color molded body, and includes a case main body 11 and an impact absorbing material 12. The case 10 corresponds to a specific example of the "composite molded body" or the "two-color molded body" of the present invention. The case body 11 corresponds to a specific example of the "first resin molded body" of the present invention. The impact absorbing material 12 corresponds to a specific example of the "second resin molded body" of the present invention.
(case body)
As shown in fig. 4, the housing main body 11 is a foam molded body including a plurality of bubbles (foam cells) 11E. A part of the plurality of air bubbles 11E exists on the surface of the housing main body 11, and at least one of the plurality of air bubbles 11E existing on the surface has an opening 11F as shown in fig. 4 and 5. As shown in fig. 5, the air bubbles 11E preferably have a shape in which the peripheral edge of the opening 11F of the air bubbles 11E protrudes toward the center of the opening 11F (hereinafter referred to as an "undercut shape"). Since the air cells 11E have such an undercut shape, it is difficult to pull out the second synthetic resin (synthetic resin constituting the impact absorbing material 12) that has entered the air cells 11E, and therefore, the adhesion between the case main body 11 and the impact absorbing material 12 can be further improved. Details of the second synthetic resin will be described later. The housing body 11 is harder than the impact absorbing material 12. In the present specification, "hardness" refers to indentation hardness. The case main body 11 contains a first synthetic resin (one-shot molded resin). The housing main body 11 may contain one or two or more additives as necessary.
The first synthetic resin comprises plastic. The plastic may be either crystalline or non-crystalline. The plastic includes, for example, at least one selected from the group consisting of general purpose plastics, quasi-general purpose plastics, engineering plastics, quasi-super engineering plastics, and the like.
Examples of the general-purpose plastic include vinyl chloride, general-purpose polystyrene (GPPS), low-density polyethylene, high-impact polystyrene (HIPS), polypropylene, and the like. Examples of the quasi-general-purpose plastic include acrylic resins, AS resins (copolymerized synthetic resins of acrylonitrile and styrene), ABS resins (copolymerized synthetic resins of acrylonitrile, butadiene, and styrene), and the like. Examples of the engineering plastics include Polycarbonate (PC), modified polyphenylene ether (m-PPE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyamide, polyacetal, and the like. Examples of the quasi-super engineering plastics include polyarylate, polysulfone, polyetherimide, and polyphenylene sulfide. Examples of the super engineering plastic include polyether ether ketone (PEEK), polyamide imide, wholly aromatic ester, and polyimide.
Examples of the additive include at least one selected from the group consisting of fine particles (inorganic fine particles, organic fine particles, and the like), antistatic agents, heat stabilizers, antioxidants, dispersants, flame retardants, surface control agents (leveling agents, and the like), plasticizers, and the like.
(impact-absorbing Material)
The impact absorbing material 12 absorbs an impact applied to a corner of the battery pack 100 at the time of dropping or the like. The impact absorbing material 12 is in contact with the housing main body 11. The impact absorbing material 12 is provided at a corner of the outer side surface of the case main body 11. Specifically, the housing body 11 is provided at an intersection between a first end surface and a side surface, an intersection between a second end surface and a side surface, and an intersection (side ridge) between adjacent side surfaces.
The impact absorbing material 12 contains a second synthetic resin (overmolding resin). The impact absorbing material 12 may further contain additives as needed. The second synthetic resin comprises an elastomer. The elastomer includes at least one of a synthetic rubber and a thermoplastic elastomer. The synthetic rubber includes at least one selected from the group consisting of diene rubber, olefin rubber, polysulfide rubber, silicone rubber, fluorine rubber, polyurethane rubber, ether rubber, and the like. More specifically, for example, the synthetic rubber includes at least one selected from the group consisting of styrene-butadiene rubber (SBR), Butadiene Rubber (BR), Isoprene Rubber (IR), ethylene-propylene-diene rubber (EPDM), Chloroprene Rubber (CR), acrylonitrile-butadiene rubber (NBR), acrylic rubber (ACM), fluorine rubber (FKM), silicone rubber, and the like. The elastomer includes, for example, at least one selected from the group consisting of silicone elastomers, ester elastomers, acrylic elastomers, polyurethane elastomers, styrene elastomers, and the like. As the additive, for example, the same additive as the case body 11 can be exemplified.
The impact absorbing material 12 has a linear shape and extends so as to cover the intersecting portions. As shown in fig. 4 and 5, a part of the second synthetic resin constituting the impact absorbing material 12 enters the plurality of cells 11E. Thereby, since the anchor effect can be obtained, the adhesion between the case body 11 and the impact absorbing material 12 can be provided. The shock absorbing material 12 has a linear shape and is provided so as to cover the intersecting portions in consideration of the weight of the battery pack 100. Although a configuration in which the impact absorbing material 12 is disposed over the entire surface is also conceivable, the weight of the battery pack 100 increases in the configuration covering the entire surface, and impact resistance may be impaired. Further, when used in an electric power tool, the disadvantage of poor workability occurs. By locally disposing the impact absorbing material 12 only at the intersection where an impact is applied, the impact resistance can be improved while suppressing the weight.
The average diameter D of the openings 11F of the plurality of air bubbles 11E included in the portion in contact with the impact absorbing material 12 (i.e., the interface portion between the housing main body 11 and the impact absorbing material 12)O(hereinafter referred to as "average opening diameter DO". ) Preferably 100 to 1500 μm, more preferably 100 to 1000 μm, and still more preferably 500 to 1000 μm. If the average opening diameter D of the air bubbles 11EOIf the thickness is 100 μm or more, the molten second synthetic resin tends to enter the cells 11E having undercut shapes in the secondary molding step. Therefore, since the adhesion between the case body 11 and the impact absorbing material 12 can be improved, the impact resistance of the battery pack 100 can be improved. The details of the secondary molding step will be described later. On the other hand, if the average opening diameter D of the air bubbles 11EOIf the thickness exceeds 1500 μm, the appearance of the housing body 11 may be impaired, and the mechanical strength of the housing body (first resin molded body) 11 may be reduced.
The average opening diameter D of the air bubbles 11EOThe results were obtained as follows. First, a small piece including the interface of the case body 11 and the impact absorbing material 12 is cut out from the case 10. Next, the small piece is cut at the interface between the case body 11 and the impact absorbing material 12 by, for example, FIB (Focused Ion Beam), so that a portion of the surface of the case body 11 that is in contact with the impact absorbing material 12 (i.e., a portion of the surface of the case body 11 where the interface with the impact absorbing material 12 is formed) is exposed. Next, an SEM (Scanning Electron Microscope) image of the exposed portion (exposed surface) was taken, 50 air bubbles 11E were randomly selected from the SEM image, and the opening diameter d of the air bubbles 11E was measuredO. Here, when the opening 11F of the bubble 11E is not circular, the maximum distance (so-called maximum feret diameter) among the distances between two parallel lines drawn from all angles is set as the opening diameter d of the bubble 11E so as to be in contact with the contour of the opening 11FO. Then, the process of the present invention is carried out,opening diameters d of 50 air bubbles 11E to be measuredOSimply averaging (arithmetic mean) to obtain the average opening diameter D of the air bubbles 11EO。
The average depth A of the bubbles 11E relative to the average maximum diameter D of the bubbles 11EmaxRatio of (A)/(D)max) X 100) is preferably 40% or more and 90% or less, more preferably 50% or more and 90% or less, and further more preferably 60% or more and 80% or less. Here, the average maximum diameter D of the bubbles 11EmaxAnd the average depth A of the air bubbles 11E represents the average maximum diameter D of the air bubbles 11E contained in the portion in contact with the impact absorbing material 12 (i.e., the interface between the case main body 11 and the impact absorbing material 12) and having the openings 11FmaxAnd an average depth a. If the ratio R is 40% or more, a large number of air bubbles 11E having a sufficient depth can be present in the surface of the case main body 11 at the portion in contact with the impact absorbing material 12. Therefore, since the adhesion between the case body 11 and the impact absorbing material 12 can be improved, the impact resistance of the battery pack 100 can be improved. If the ratio R is 60% or more, as shown in fig. 5, the bubbles 11E having an undercut shape can be present in a large amount in the portion of the surface of the case main body 11 that is in contact with the impact absorbing material 12. Therefore, the adhesion between the case body 11 and the impact absorbing material 12 can be further improved. If the ratio R is 90% or less, the opening diameter d can be made sufficiently largeOThe air bubbles 11E of (a) are present in a large amount in a portion of the surface of the housing main body 11 which is in contact with the impact absorbing material 12. Therefore, in the secondary molding step, the melted second synthetic resin can be made to easily enter the plurality of bubbles 11E existing in the portion of the surface of the housing main body 11 that is in contact with the impact absorbing material 12 through the opening 11F. Therefore, the adhesion between the case body 11 and the impact absorbing material 12 can be further improved.
The above ratio R is obtained as follows. First, a small piece including the interface of the case body 11 and the impact absorbing material 12 is cut out from the case 10. Next, the chip is cut in a direction perpendicular to the interface by, for example, FIB, to form a cross section. Then, after taking the SEM images of the cross sections, 50 SEM images of the cross sections were randomly selected to be included in the connection with the impact absorbing material 12Air bubbles 11E at the contact portion (i.e., the interface between the case body 11 and the impact absorbing material 12) and having openings 11F, and the maximum diameter d of the air bubbles 11E was measuredmaxAnd a depth a. Here, the maximum diameter d of the bubble 11EmaxThe maximum distance (so-called maximum feret diameter) is the distance between two parallel lines drawn from all angles so as to contact the outline of the bubble 11E. Next, the maximum diameter d of 50 air bubbles 11E to be measuredmaxSimply averaging (arithmetic mean) to obtain the average maximum diameter D of the bubbles 11Emax. The measured depths a of the 50 air cells 11E are simply averaged (arithmetic mean), and the average depth a of the air cells 11E is obtained. Next, the average maximum diameter D obtained as described above is usedmaxAnd an average depth A, and a ratio R (═ A/D) is determinedmax)×100)。
(foaming resin component)
The foamed resin members 30A and 30B function as a buffer member for buffering external force transmitted from the case 10 to the battery 21. Further, the battery pack also has a function as a holding member for holding the battery cell 20 at a predetermined position in the case 10.
The foamed resin members 30A, 30B are provided in the space between the case 10 and the battery cell 20. More specifically, the foamed resin member 30A is provided on the first end surface portion 11A of the case 10 and the first end surface portion 20S of the battery cell 201In the meantime. The foamed resin member 30B is provided on the second end surface 11B of the case 10 and the second end surface 20S of the battery cell 202In the meantime.
The foamed resin members 30A and 30B are, for example, an aggregate of expanded beads that are expanded by steam heating. The foamed resin members 30A, 30B contain at least one selected from the group consisting of polyphenylene ether (PPE) based resins, Polystyrene (PS) based resins, olefin based resins (for example, polypropylene, polyethylene, etc.) and the like as a main component. The foaming resin members 30A and 30B may contain known additives as needed.
The foamed resin member 30A is a plate-like member having a first end surface portion 20S in contact with the battery cell 201A first main surface part facing the first main surface part, and a second main surface part facing the first end surface part 11A of the housing 10Two main faces. The foamed resin member 30B is a plate-like member having a second end face 20S in contact with the battery cell 202A first main surface portion facing the first end surface portion 11a of the housing 10, and a second main surface portion facing the second end surface portion 11B of the housing 10.
The side surface of the foamed resin member 30A has a recess 31 recessed away from the inner surface of the case 10. The recess 31 supports the connector 43. In the present embodiment, since the connector 43 is provided on the foamed resin member 30B side, the recess 31 of the foamed resin member 30A may not be provided. In the present embodiment, the foamed resin members 30A and 30B have the same configuration in consideration of productivity, and therefore, both the foamed resin members 30A and 30B have the recessed portions 31.
[ method for manufacturing case ]
An example of a method for manufacturing the housing 10 having the above-described configuration will be described below. A two-color molding method is used in the method for manufacturing the housing 10.
(one-shot Forming Process)
The case body 11 is molded by, for example, injection molding. Specifically, first, the first synthetic resin and the blowing agent are mixed in a molten state, and the blowing agent is dissolved/diffused in the first synthetic resin. As blowing agent, N is preferably used2Gas, CO2Supercritical Fluid (SCF) such as gas. Next, the first synthetic resin in which the foaming agent is dissolved/diffused is supplied to the primary-side molding region of the mold and is cured, thereby molding the case body 11 including the plurality of bubbles 11E. After molding, the mold is opened and the housing body 11 is conveyed to the secondary-side molding area of the mold.
(Secondary Molding Process)
The impact absorbing material 12 is molded on the corner in the outer side surface of the case main body 11 by, for example, injection molding. Specifically, first, the mold is closed again, and the molten second synthetic resin is supplied to the secondary-side molding region of the mold. Thereby, the molten second molten resin is supplied so as to contact the corner portion of the outer side surface of the case main body 11, and the molten second synthetic resin enters the plurality of bubbles 11E present on the outer side surface of the case main body 11. Here, the corner portion to which the molten second molten resin is supplied is an intersection portion between the first end face and the side face, an intersection portion between the second end face and the side face, and an intersection portion between adjacent side faces (side edge portion) of the case main body 11. After the second synthetic resin is supplied, the impact absorbing material 12 is molded by curing the second synthetic resin. Thereby, the case 10 as a two-color molded body was obtained. Then, the mold is opened again, and the case 10 is taken out.
[ Effect ]
In the battery pack 100 according to the embodiment, the case 10 that houses the battery cells 20 includes a case main body (first resin molded body) 11 and an impact absorbing material (second resin molded body) 12 provided on the case main body 11. The case main body 11 includes a plurality of air bubbles 11E in a portion in contact with the impact absorbing material 12. By the part of the second synthetic resin contained in the impact absorbing material 12 entering the plurality of cells 11E, the anchoring effect can be obtained. Therefore, the adhesion between the case body 11 and the impact absorbing material 12 can be improved. Therefore, the impact resistance of the battery pack 100 (e.g., the drop strength of the battery pack 100) can be improved.
Since a part of the second synthetic resin contained in the impact absorbing material 12 enters the plurality of cells 11E, an anchor effect can be obtained, and therefore, a combination of the first synthetic resin and the second synthetic resin, which has been difficult to use in the past, can be used because of poor adhesion.
Since the case main body 11 is a foam molded body including a plurality of cells 11E, the case main body 11 can be reduced in weight. Therefore, the battery pack 100 can be reduced in weight.
A method for manufacturing a case 10 according to an embodiment includes: a step of molding a case main body (first resin molded body) 11 including a plurality of cells 11E using a molten first synthetic resin mixed with a foaming agent such as a supercritical fluid; and a step of molding an impact absorbing material (second resin molded body) 12 by supplying a second synthetic resin in a molten state so as to be in contact with the outer surface of the case main body 11, and allowing the second synthetic resin to enter the plurality of air bubbles 11E included in the outer surface. Accordingly, the adhesion between the case body 11 and the impact absorbing material 12 can be improved without roughening the surface of the case body 11 by mechanical or physical secondary processing or without providing an adhesive between the case body 11 and the impact absorbing material 12. Therefore, it is possible to improve the impact resistance of the battery pack 100 (for example, the drop strength of the battery pack 100) while suppressing an increase in the production cost of the case 10 (i.e., the battery pack 100) and a decrease in the production efficiency.
< modification example >
While one embodiment of the present invention has been specifically described above, the present invention is not limited to the above-described one embodiment, and various modifications can be made based on the technical idea of the present invention.
For example, the configurations, methods, steps, shapes, materials, numerical values, and the like recited in the above embodiments are merely examples, and configurations, methods, steps, shapes, materials, numerical values, and the like different from those described above may be used as necessary. The configurations, methods, steps, shapes, materials, numerical values, and the like of the above embodiments can be combined with each other without departing from the gist of the present invention.
In the numerical ranges recited in the above-described embodiment, the upper limit or the lower limit of the numerical range in a certain stage may be replaced with the upper limit or the lower limit of the numerical range in another stage. The materials exemplified in the above embodiment may be used singly or in combination of two or more unless otherwise specified.
In the above-described embodiment, the case where the impact absorbing material 12 is provided at the corner of the case main body 11 has been described, but the impact absorbing material 12 may be provided at a portion other than the corner of the case 10, or the impact absorbing material 12 may be provided at a portion other than the corner of the case 10 together with the corner of the case 10. In order to improve the impact resistance of the battery pack 100 when it is dropped or the like, it is preferable that the impact absorbing material 12 be provided at the corner of the case body 11 as in the above-described embodiment.
In the above-described embodiment, the case where a part (corner) of the outer side surface of the case body 11 is covered with the impact absorbing material 12 has been described, but the entire or substantially the entire outer side surface of the case body 11 may be covered with the impact absorbing material 12. In this case, the case main body 11 is formed of the foam molded body, and the deterioration of the design can be prevented.
In the above-described embodiment, the case where the present invention is applied to the case 10 for the battery pack 100 has been described, but the present invention is not limited thereto, and the present invention can also be applied to a composite molded body (for example, a housing, a laminate (a laminate plate, a laminate sheet, or the like), an exterior material, or the like used in an electronic device, an electrical device, a building component, a vehicle (for example, a vehicle (an automobile, a motorcycle, or the like), an airplane, a amusement instrument, or the like), furniture (for example, a table, a desk, or the like), a manufacturing apparatus, an analysis device, or the like. When the case 10 is cracked by an impact, the battery 21 is accommodated in the battery pack 100, and therefore, a user may touch the inside to get an electric shock. In the present embodiment, since the shock absorbing material 12 is firmly held by the case main body 11, the case 10 can be prevented from being cracked by the shock. Therefore, a safer battery pack 100 can be configured.
In the above-described embodiment, the case where the composite molded article is a two-color molded article has been described, but the present invention is not limited thereto, and the present invention may be applied to a multi-color molded article of three or more colors. In this case, the present invention may be applied to a part of adjacent resin molded bodies, or may be applied to all adjacent resin molded bodies.
In the above-described embodiment, the case where the case main body 11 is the foam molded body including the plurality of cells 11E has been described, but the impact absorbing material 12 may be a foam molded body including the plurality of cells 11E instead of the case main body 11. In this case, the impact absorbing material 12 corresponds to a specific example of the "first resin molded body" of the present invention, and the case main body 11 corresponds to a specific example of the "second resin molded body" of the present invention. Alternatively, both the case main body 11 and the impact absorbing material 12 may be a foam molded body including a plurality of cells 11E. In this case, either one of the case main body 11 and the impact absorbing material 12 corresponds to a specific example of the "first resin molded body" of the present invention. The other corresponds to a specific example of the "second resin molded article" of the present invention.
In the above-described embodiment, the case where the case body 11 and the impact absorbing material 12 are molded by the same mold has been described, but the case body 11 and the impact absorbing material 12 may be molded by different molds.
< application example >
[ electric Power tool as an application example ]
Hereinafter, an electric power tool 500 including any one of the battery packs 100 according to the above-described embodiment and the modification thereof will be described with reference to fig. 6.
The electric power tool 500 is, for example, an electric drill, and includes a control unit 502 and a power source 503 inside a tool body 501 made of a plastic material or the like. A drill 504 as a movable portion is mounted to the tool body 501 so as to be movable (rotatable), for example.
The control unit 502 controls the operation of the entire electric power tool (including the use state of the power source 503), and includes, for example, a CPU. The power source 503 includes one or more of the battery packs 100 according to the above-described embodiment and the modifications thereof. The control unit 502 supplies electric power from the power source 503 to the drill 504 in response to an operation of an operation switch, not shown.
[ hybrid vehicle as an application example ]
The following describes a power storage system for a vehicle including any one of the battery packs 100 according to the above-described embodiment and its modified examples.
Fig. 7 schematically shows a configuration of a hybrid vehicle in which a series hybrid system is employed as a vehicle power storage system. The series hybrid system is a system that runs by an electric power drive force conversion device using electric power generated by a generator driven by an engine or electric power temporarily stored in a battery.
This hybrid vehicle 600 is equipped with an engine 601, a generator 602, an electric power/driving force conversion device 603, drive wheels 604a, drive wheels 604b, wheels 605a, wheels 605b, a power storage device 608, a vehicle control device 609, various sensors 610, and a charging port 611. The power storage device 608 includes one or two or more of the battery packs 100 according to the above-described embodiment and the modifications thereof.
The hybrid vehicle 600 runs with the electric-power drive force conversion device 603 as a power source. An example of the electric power driving force conversion device 603 is a motor. The electric power-driving force conversion device 603 is operated by the electric power of the power storage device 608, and the rotational force of the electric power-driving force conversion device 603 is transmitted to the driving wheels 604a, 604 b. Note that, by using direct current-alternating current (DC-AC) conversion or reverse conversion (AC-DC conversion) at a necessary portion, either an alternating current motor or a direct current motor can be used as the electric power driving force conversion device 603. The various sensors 610 control the engine speed via a vehicle control device 609, or control the opening degree of a throttle valve (throttle opening degree), not shown. The various sensors 610 include a speed sensor, an acceleration sensor, an engine speed sensor, and the like.
The rotational force of the engine 601 is transmitted to the generator 602, and the electric power generated by the generator 602 can be stored in the power storage device 608 by the rotational force.
When the hybrid vehicle is decelerated by a brake mechanism, not shown, resistance at the time of deceleration is applied to the electric-power driving-force conversion device 603 as rotational force, and regenerative electric power generated by the electric-power driving-force conversion device 603 by the rotational force is stored in the power storage device 608.
Although not shown, an information processing device that performs information processing regarding vehicle control based on information regarding the secondary battery may be provided. As such an information processing device, for example, there is an information processing device that displays the remaining battery level based on information on the remaining battery level.
In the above application example, a series hybrid vehicle that runs by a motor using electric power generated by a generator driven by an engine or electric power temporarily stored in a battery has been described as an example, but a vehicle that can use a battery according to the present invention is not limited to this. For example, a parallel hybrid vehicle may be used by appropriately switching between three modes, i.e., engine-only running, motor-only running, and engine-and-motor running, using an engine and a motor as drive sources, or may be an electric vehicle that runs by driving only a drive motor without using an engine.
Examples
The present invention will be specifically described below with reference to examples, but the present invention is not limited to these examples.
In the following examples and comparative examples, the average opening diameter D of the bubblesOAnd the average depth A of the bubbles relative to the average maximum diameter D of the bubblesmaxRatio of (A)/(D)max) X 100) was obtained by the measurement method described in the above-described embodiment.
[ examples 1 to 6]
(one-shot Forming Process)
First, molten polycarbonate (first synthetic resin) and N were mixed2Gas (supercritical fluid) to make N2The gas dissolves/diffuses into the polycarbonate. Then, using a solvent/diffusion of N2The isosceles trapezoid-shaped first resin plate (first resin molded body) shown in fig. 8A and 8B was molded from a gaseous polycarbonate by an injection molding method.
In the one-shot forming process, the N dissolved/diffused in the polycarbonate is adjusted2The size (diameter) of the gas is such that the average opening diameter D of a plurality of bubbles contained in one main surface of the first resin sheetOAs shown in Table 1, the thickness of the film was in the range of 50 μm to 2000 μm. At this time, the ratio R (average depth A of the bubbles relative to the average maximum diameter D of the bubbles)maxRatio of (A)/(D)max) X 100) was adjusted to a constant value of 60% independent of the sample. N is a radical of2Size (diameter) of gas passing through N2The injection amount of the gas, the injection pressure, and the temperature of the molding resin (polycarbonate) were adjusted in combination.
An SEM image of the upper bottom surface of the first resin plate is shown in fig. 9. As can be seen from fig. 9, a plurality of open bubbles exist on the upper bottom surface of the first resin plate.
(Secondary Molding Process)
Next, an isosceles trapezoid-shaped second resin plate (second resin molded body) shown in fig. 8A and 8B is molded adjacent to the upper bottom portion of the first resin plate by an injection molding method using a molten thermoplastic polyetherester elastomer (second synthetic resin). Thus, a two-color molded article (composite molded article) was obtained.
Comparative example 1
In the one-shot forming process, N is used2A two-color molded article was obtained in the same manner as in example 1, except that the first synthetic resin in which the gas was dissolved/diffused was used to mold the first resin plate.
(evaluation of bonding Strength)
The two-color molded article obtained as described above was subjected to a tensile test to evaluate the bonding strength of the two-color molded article. The following shows the details of the conditions of the tensile test.
Measurement equipment: instron tensile testing machine
Stretching speed: 10mm/min
Distance between chucks: 50mm
By applying the configuration of the two-color molded body having the bonding strength of 40MPa to the battery pack, the impact resistance of the battery pack (for example, the drop strength of the battery pack) can be improved. This is because the mass of the battery pack of the two-color molded article having a mass of 3kg was about 300mm when it was dropped from 1m2The surface of (2) was subjected to a stress value of 40 MPa.
(evaluation of mechanical Strength of first resin molded body)
The same procedure as the above-mentioned one-shot molding is used with N dissolved/diffused2A standard cubic casing (first resin molded body) having a mass of 3kg and a wall thickness of 4mm was molded from a gaseous polycarbonate by injection molding. The cubic standard shell was dropped from a height of 1m, the weakest part of the cubic standard shell, namely, the corner part was hit against the concrete surface, and then the shell was visually observed for breakageStatus. The results are shown in Table 1. The symbols "o" and "x" shown in table 1 indicate the following evaluation results.
O: the shell is not damaged
X: the housing has a breakdown
Table 1 shows the structures and evaluation results of two-color molded articles of examples 1 to 6 and comparative example 1.
[ Table 1]
The following is known from the above evaluation results.
From the viewpoint of improving the bonding strength of the two-color molded article, the average opening diameter D of the cells contained in the one main surface of the first resin plateOPreferably 50 μm or more, more preferably 100 μm or more and 1500 μm or less, still more preferably 100 μm or more and 1000 μm or less, and particularly preferably 500 μm or more and 1000 μm or less.
From the viewpoint of improving the impact resistance of the battery pack, the average opening diameter D of the cells contained in the one main surface of the first resin plateOPreferably 100 to 1500 μm, more preferably 100 to 1000 μm, and still more preferably 500 to 1000 μm.
If the average opening diameter D of the bubblesOWhen the thickness exceeds 1500 μm, the amount of bubbles per unit volume in the first resin plate increases, and the mechanical strength of the first resin plate becomes weak, so that the bonding strength is sufficient, but this is not preferable. Therefore, in order to suppress a decrease in mechanical strength of the first resin sheet, the average opening diameter D of the bubbles contained in the one main surface of the first resin sheetOThe upper limit of (2) is preferably 1500 μm or less.
[ examples 7 to 12]
Adjusting the N of the dissolution/diffusion in the carbonate2The size (diameter) of the gas is such that the ratio R of a plurality of bubbles contained in one main surface of the first resin sheet (average depth A of the bubbles relative to average maximum diameter D of the bubbles)maxIn a ratio R) ofThe ranges shown in table 2. At this time, the average maximum diameter D of the bubblesmaxThe adjustment was about 500 μm, independent of the sample. N is a radical of2Size (diameter) of gas passing through N2The injection amount of the gas, the injection pressure, and the temperature of the molding resin (polycarbonate) were adjusted in combination. Except for this, a two-color molded article was obtained in the same manner as in example 1.
(evaluation of bonding Strength)
The joint strength of the two-color molded article obtained as described above was evaluated in the same manner as in example 1.
Table 2 shows the structures and evaluation results of two-color molded articles of examples 7 to 12 and comparative example 1.
[ Table 2]
Dmax: an average maximum diameter of air bubbles contained in one main surface of the first resin plate
A: an average depth of the bubbles contained in the one main surface of the first resin plate
The following is known from the above evaluation results.
From the viewpoint of improving the bonding strength of the two-color molded article, the average depth a of the bubbles is relative to the average maximum diameter D of the bubblesmaxThe ratio R of (b) is preferably 20% or more, more preferably 40% or more and 90% or less, further more preferably 50% or more and 90% or less, and particularly preferably 60% or more and 80% or less.
From the viewpoint of improving the impact resistance of the battery pack, it is preferably 40% or more and 90% or less, more preferably 50% or more and 90% or less, and still more preferably 60% or more and 80% or less.
Description of the reference numerals
10a shell; a 10A accommodating part; 10B a cover part; 11a housing body; 11A first end face portion; 11B a second end surface portion; 11C wall portion; an 11D opening part; 11E air bubbles; 11F opening; 12 an impact absorbing material; 20 battery cells; 20S1A first end face portion; 20S2A second end surface portion; 20S3A peripheral face portion; 21 a battery; 22a holder; 22A first holder; 22B a second holder; a 22C hole portion; 23A, 23B tabs; 23A1、23A2、23B1、23B2A connection terminal; 30A, 30B foamed resin members; 31 a recess; 40 a protection circuit module; 41 a substrate; 42 a control unit; 43 a connector; 100 battery packs; 500 electric tool; 600 hybrid vehicle.
Claims (17)
1. A composite molded body is provided with:
a first resin molded body; and
a second resin molded body in contact with the first resin molded body,
the first resin molded body contains a plurality of bubbles in a portion in contact with the second resin molded body,
a part of the resin constituting the second resin molded body enters the plurality of bubbles.
2. The composite molded body according to claim 1,
at least one of the plurality of bubbles has an opening,
the periphery of the opening protrudes toward the center of the opening.
3. The composite molded body according to claim 1,
the second resin molded body contains an elastomer,
the first resin molded body contains plastic.
4. The composite molded body according to claim 3,
the plastic comprises at least one selected from the group consisting of general purpose plastics, quasi-general purpose plastics, engineering plastics, quasi-super engineering plastics, and super engineering plastics.
5. Composite shaped body according to any one of claims 1 to 4, wherein,
the first resin molded body is a foam molded body.
6. Composite shaped body according to any one of claims 1 to 5, wherein,
the first resin molded body is harder than the second resin molded body.
7. Composite shaped body according to any one of claims 1 to 6, wherein,
a plurality of the bubbles have an opening,
the average diameter of the openings is 100 to 1000 [ mu ] m.
8. Composite shaped body according to any one of claims 1 to 7, wherein,
the ratio of the average depth of the bubbles to the average maximum diameter of the bubbles is 60% to 80%.
9. Composite shaped body according to any one of claims 1 to 8, wherein,
the first resin molded body is a main body of the housing,
the second resin molded body is provided on an outer side surface of the case main body.
10. The composite molded body according to claim 9,
the second resin molded body is provided at least one intersection portion of the case main body.
11. Composite shaped body according to any one of claims 1 to 10, wherein,
the first resin molded body and the second resin molded body constitute a two-color molded body.
12. A battery pack is provided with:
a battery; and
the composite molded body according to any one of claims 1 to 11,
the composite molded body is a case for housing the battery.
13. A kind of electric tool is provided, which comprises a power tool,
the battery pack according to claim 12 is provided.
14. An electric vehicle is provided with a power source,
the battery pack according to claim 10 is provided.
15. A method for producing a composite molded body, comprising the steps of:
a second resin molded body is molded by supplying a molten resin in contact with the surface of a first resin molded body, and causing the molten resin to enter a plurality of bubbles contained in the surface.
16. The method of manufacturing a composite molded body according to claim 15, further comprising the steps of:
the first resin molded body is molded using a molten resin mixed with a foaming agent.
17. The method for producing a composite molded body according to claim 16,
the foaming agent is a supercritical fluid.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
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| JP2019-123868 | 2019-07-02 | ||
| JP2019123868 | 2019-07-02 | ||
| PCT/JP2020/025974 WO2021002417A1 (en) | 2019-07-02 | 2020-07-02 | Composite molded body and method for producing same, battery pack, electric tool, and electric vehicle |
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| CN114072961A true CN114072961A (en) | 2022-02-18 |
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| EP4250450A1 (en) * | 2022-03-23 | 2023-09-27 | Andreas Stihl AG & Co. KG | Battery pack, system comprising the battery pack and an electrically driven processing apparatus and method for manufacturing the battery pack |
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| US20050058890A1 (en) * | 2003-09-15 | 2005-03-17 | Kenneth Brazell | Removable battery pack for a portable electric power tool |
| CN101253036A (en) * | 2005-09-01 | 2008-08-27 | 国立大学法人大阪大学 | Method for joining metal and resin and metal-resin composite, method for joining glass and resin and glass-resin composite, and method for joining ceramic and resin and ceramic-resin composite |
| JP2008221519A (en) * | 2007-03-09 | 2008-09-25 | Seiko Epson Corp | Synthetic resin molding and electronic equipment |
| JP2012144673A (en) * | 2011-01-14 | 2012-08-02 | Kanto Auto Works Ltd | Method for joining foamed resin |
| KR20160076940A (en) * | 2014-12-23 | 2016-07-01 | 주식회사 성우하이텍 | Welding method for aluminium sheet and carbon fiber reinforced plastics sheet |
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| JP2952709B2 (en) * | 1990-11-27 | 1999-09-27 | 株式会社イノアックコーポレーション | Method of manufacturing cushion body of different hardness |
| JP3044248B2 (en) * | 1997-05-08 | 2000-05-22 | 安比古 久保田 | Method for manufacturing synthetic resin member and method for manufacturing snowboard |
| JP2000108205A (en) * | 1998-10-06 | 2000-04-18 | Polyplastics Co | Plastic composite molding and its manufacture |
| JP4802733B2 (en) * | 2005-07-01 | 2011-10-26 | パナソニック電工株式会社 | Molded product and manufacturing method thereof |
| JP5458529B2 (en) * | 2008-08-22 | 2014-04-02 | 東レ株式会社 | Joining method and integral molded product |
| JP5393365B2 (en) * | 2009-09-11 | 2014-01-22 | 日産自動車株式会社 | Battery module |
| JP2012046168A (en) * | 2010-07-27 | 2012-03-08 | Jtekt Corp | Electric power steering device |
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- 2020-07-02 WO PCT/JP2020/025974 patent/WO2021002417A1/en active Application Filing
- 2020-07-02 CN CN202080048479.XA patent/CN114072961A/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20050058890A1 (en) * | 2003-09-15 | 2005-03-17 | Kenneth Brazell | Removable battery pack for a portable electric power tool |
| CN101253036A (en) * | 2005-09-01 | 2008-08-27 | 国立大学法人大阪大学 | Method for joining metal and resin and metal-resin composite, method for joining glass and resin and glass-resin composite, and method for joining ceramic and resin and ceramic-resin composite |
| JP2008221519A (en) * | 2007-03-09 | 2008-09-25 | Seiko Epson Corp | Synthetic resin molding and electronic equipment |
| JP2012144673A (en) * | 2011-01-14 | 2012-08-02 | Kanto Auto Works Ltd | Method for joining foamed resin |
| KR20160076940A (en) * | 2014-12-23 | 2016-07-01 | 주식회사 성우하이텍 | Welding method for aluminium sheet and carbon fiber reinforced plastics sheet |
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| WO2021002417A1 (en) | 2021-01-07 |
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Application publication date: 20220218 |