JP2003132861A - Manufacturing method of battery pack - Google Patents

Abstract

PROBLEM TO BE SOLVED: To surely block to encroach melted resin into a resin encroaching blocking portion in molding a resin molding portion. SOLUTION: A manufacturing method of a pack battery is to mold a resin molding portion 1 in a molding chamber 11 of a die 10, temporary fixing a battery 2 to the molding chamber 11 of the die 10. It molds to insert a part or all of the battery 2 in molding this resin molding portion 1. Further, the manufacturing of the pack battery provides a resin encroaching blocking portion 9 for blocking encroachment of molten plastic to mold the resin molding portion 1, in molding the resin molding portion 1 in the molding chamber 11. Air is pressed into the molding portion for molding this resin encroaching blocking portion 9. This pressured air blocks to encroach the melted plastic into the molding portion of the resin encroaching blocking portion 9.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a battery pack, and more particularly, to manufacturing a battery pack in which a battery is temporarily fixed in a molding chamber of a mold and connected to the battery to mold a plastic resin molding portion. Regarding the method.

[0002]

2. Description of the Related Art A battery pack has been developed in which a battery is temporarily fixed in a molding chamber of a mold to mold a resin molding portion. This battery pack can be manufactured by insert molding a core pack of a battery connecting necessary parts such as a circuit board and an output terminal into a resin molding part. Insert molding involves temporarily fixing the core pack of the battery to the molding chamber of the mold that molds the plastic, and sticking the plastic injected into the molding chamber to the battery and circuit board of the core pack that is temporarily fixed. Mold. In this manufacturing method, the battery and the circuit board can be integrally fixed to the molded resin molded portion. This method has a feature that a battery, a circuit board, or the like can be firmly fixed in place when the resin molding portion is molded. Further, the assembly process of storing the battery or the like in a fixed position in a separately molded plastic case can be omitted. That is, since molding and fixing can be performed at the same time, there is a feature that mass production can be performed inexpensively and efficiently. A method of manufacturing a battery pack by this method is described in JP 20
No. 00-315483. This manufacturing method is shown in FIG.
As shown in FIG. 3, when molding the resin molding part to be the outer case, the circuit board 5 and the battery 2 are temporarily fixed in the molding chamber 11 of the mold 10 and the molten plastic is injected into the molding chamber 11. To be done. In this battery pack, a part of the circuit board 5 and the battery 2 is insert-molded and fixed to the resin molding portion.

[0003]

In the above-described method for manufacturing a battery pack, since some or all of the core pack is embedded in the resin molding part, various adverse effects may occur. For example, if the opening of the safety valve is buried and closed in the resin molding portion, the gas discharged from the opened safety valve cannot be smoothly discharged to the outside. This makes it impossible to effectively prevent the internal pressure of the outer can from rising due to the safety valve. Further, if a protective element such as a breaker, a PTC, or a temperature sensor is embedded in the resin molding portion, it may not operate normally. This is because the molten resin that molds the resin molding part enters the inside of the breaker or PTC. The resin that enters the inside of the breaker impedes the operation of the movable contact of the breaker. The resin that enters the PTC trips the PTC and hinders normal operation. Furthermore, if the PTC is embedded in the resin molding portion, the resin that penetrates between the PTC and the battery impedes heat conduction, and the temperature of the battery cannot be detected quickly.

These adverse effects can be eliminated by providing a resin intrusion prevention portion for preventing the intrusion of plastic when molding the resin molding portion. For example, a resin intrusion prevention unit can be provided in the opening of the safety valve so that the gas discharged from the opened safety valve can be discharged from the resin molding unit to the outside. Further, a breaker or PTC can be arranged in the resin intrusion prevention portion to prevent the resin molding the resin molding portion from invading into these. further,
A battery pack is manufactured by making a core pack by connecting all of the circuit board and protective elements, and insert-molding this core pack into the resin molding part. The removed core pack may be insert-molded in the resin molding portion, and then the protective element may be attached to the battery pack for manufacture. In the latter battery pack, it is necessary to provide a void for arranging the protective element in the resin molding portion.

In any of the manufacturing methods, it is extremely difficult to accurately provide the resin intrusion prevention portion when molding the resin molding portion. This is because the molten resin that has been heated and pressed enters the portion where the resin intrusion prevention portion is provided. The resin that has been heated and melted penetrates through the extremely fine gap and enters the resin invasion blocking portion. For example, as shown in FIG. 2, a convex portion 35 protruding inside the molding chamber 11 of the mold 10.
When the resin injection is blocked by and the resin intrusion prevention portion 9 is provided on the surface of the sealing plate 2C of the battery 2, if a gap is formed at the tip of the convex portion 35, the resin passes through this. The resin that has passed through the gap of the convex portion 35 is brought into close contact with the surface of the sealing plate 2C of the battery 2 to close the opening of the safety valve provided on the sealing plate 2C. This problem can be eliminated by closely contacting the convex portion 35 for molding the resin intrusion prevention portion 9 with the surface of the sealing plate 2C of the battery 2. However, since the surface of the sealing plate of the battery has irregularities, the convex portions of the mold cannot be closely attached without a gap. Therefore, it is necessary to form the resin intrusion prevention portion by blocking the resin flow at the convex portion so that the resin does not flow into the surface of the sealing plate. When the resin leaks from the gap, the convex portion that blocks the flow of the resin causes the resin to enter the portion serving as the resin intrusion preventing portion.

The present invention was developed for the purpose of solving such drawbacks. An important object of the present invention is to provide a method of manufacturing a battery pack, which can reliably prevent heated and pressurized molten resin from entering the resin invasion preventing part when the resin molding part is molded. is there. Another important object of the present invention is to provide a method of manufacturing a battery pack that can reliably prevent molten resin from entering the resin intrusion prevention portion even if there is some dimensional error in the mold or core pack. To do.

[0007]

According to the method for manufacturing a battery pack of the present invention, the battery 2 is temporarily fixed in the molding chamber 11 of the mold 10, and the resin molding portion 1 is molded in the molding chamber 11 of the mold 10.
When molding the resin molding part 1, a part or the whole of the battery 2 is inserted and molded. Further, in the manufacturing method of the present invention, when the resin molding portion 1 is molded in the molding chamber 11, the resin intrusion prevention portion 9 is provided to prevent the molten plastic for molding the resin molding portion 1 from invading. Pressurized gas is supplied to a molding portion for molding the resin intrusion prevention portion 9. This pressurized gas prevents the molten plastic from entering the molded portion of the resin invasion blocking portion 9.

According to the manufacturing method of the present invention, the resin invasion preventing portion 9 can be molded by the hollow molding portion 25 of the mold 10 projecting into the molding chamber 11 of the mold 10. This method has a feature that the resin intrusion prevention portion 9 can be accurately molded. This is because the hollow molding part 25 of the mold 10 molds. Furthermore, according to this method, pressurized gas can be supplied to the hollow molding portion 25 to prevent the molten plastic from entering the resin invasion preventing portion 9.

The resin intrusion prevention portion 9 can be provided in contact with the safety valve 21 provided in the battery 2. In this battery pack, the gas discharged from the opened safety valve 21 can be discharged to the outside from the resin invasion prevention unit 9. Further, the resin intrusion prevention part 9 can be provided so as to contact the protection element 6 connected to the battery 2. In this method, the protection element 6
Since the whole of the above is not embedded in the resin molding portion 1, it is possible to prevent the molten resin from entering the case of the protective element 6 and causing a failure. In this battery pack, a core pack 15 in which a protection element 6 is connected to a battery 2 is temporarily fixed to a mold 10 and a resin intrusion prevention portion 9 is provided in contact with the protection element 6 provided in the core pack 15. Produced. In addition, the resin intrusion prevention section 9
Can be provided between the protection element 6 and the battery 2.
In this battery pack, the resin between the protective element 6 and the battery 2 does not interrupt the heat conduction, and the protective element 6 can quickly detect the battery temperature.

Further, according to the manufacturing method of the present invention, the core pack 15 connecting the protection element 6 and the holder 4 to the battery 2 is temporarily fixed to the mold 10, and the resin invasion preventing portion is attached to the holder 4 of the core pack 15. 9 is provided, and the resin invasion prevention part 9 and the mold 10 form a closed chamber, and pressurized gas is supplied to the closed resin invasion prevention part 9 to mold the resin molding part 1. In this method, it is not necessary to provide the mold 10 with a portion for molding the resin intrusion prevention portion 9, and the resin intrusion prevention portion 9 can be molded with a simple structure. Further, the resin intrusion prevention portion 9 may be provided inside the holder 4 which cannot be molded by the mold 10.

In the battery pack having the holder 4, the resin intrusion-preventing portion 9 is provided in the holder 4 and the protective element 6 is disposed therein, so that the resin molding portion 1 can be molded.
In addition, the resin intrusion prevention portion 9 provided on the holder 4 is attached to the safety valve 2
The resin molding part 1 can also be molded so as to communicate with 1.

The protective element 6 of the battery 2 is a breaker that interrupts the current when an overcurrent flows, a PTC or a fuse that interrupts the current when the battery temperature becomes higher than a set temperature, a thermistor or a temperature sensor that detects the battery temperature. is there.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. However, the examples described below exemplify a manufacturing method of a battery pack for embodying the technical idea of the present invention, and the present invention does not specify the manufacturing method of the battery pack as follows.

Further, in this specification, in order to facilitate understanding of the claims, the numbers corresponding to the members shown in the embodiments are referred to as "claims column" and "to solve the problem." It is added to the members shown in "Means column".
However, the members shown in the claims are not limited to the members of the embodiment.

The battery pack of FIG. 3 has a convex electrode 2 of the battery 2.
The resin molding portion 1 is fixed to the electrode end surface where B is provided. The battery pack includes the circuit board 5, the protection element 6, etc.
It is manufactured by temporarily fixing the core pack 15 of the battery 2 connected to the mold to the molding chamber of the mold, injecting the molten resin into the molding chamber, and inserting the core pack 15 into the resin molding portion 1. The core pack 15 temporarily fixed to the molding chamber is shown in FIGS. The core pack 15 of FIG. 4 and FIG.
And the protection element 6 is connected to the battery 2. The circuit board 5
It is connected to the battery 2 via the lead plate 8 and the protection element 6.
In the core pack 15 of FIGS. 6 and 7, the holder 4 is arranged between the circuit board 5 and the battery 2. The holder 4 arranges the circuit board 5 and the protection element 6 in fixed positions. The circuit board 5 is connected to the battery 2 via the lead plate 8 and the protection element 6, and the holder 4 is arranged between the battery 2 and the circuit board 5 via the circuit board 5. The holder 4 is molded of plastic separately from the resin molding part 1.

The battery 2 is a rechargeable secondary battery such as a lithium ion battery, a nickel-hydrogen battery, a nickel-cadmium battery or the like. The battery 2 in FIGS. 3 to 5 is a thin prismatic battery, and the four corners of the outer can 2A are chamfered. The battery 2 of FIGS. 6 and 7 has a shape in which the corners of the four corners are chamfered with the curved surfaces on both sides of the thin prismatic battery. If you use a lithium-ion battery for a thin prismatic battery,
It has the feature that the charge capacity can be increased relative to the total capacity of the battery pack. In the battery 2 shown in the figure, the safety valve 21 is provided on the sealing plate 2C located on the electrode end surface on which the convex electrode 2B is provided. In the battery 2 shown in the figure, the convex electrode 2B is provided in the central portion of the sealing plate 2C, and the safety valve 21 is provided at a position apart from the convex electrode 2B. The battery may have a safety valve built in the convex electrode. The safety valve 21 opens when the internal pressure of the battery 2 becomes higher than the set pressure. Safety valve 2 opened
1 discharges internal gas and the like to suppress an increase in internal pressure of the outer can 2A. The safety valve 21 is a rupture film 22 that is airtightly adhered to the opening of the sealing plate 2C. Fracture film 22
Is destroyed when the internal pressure of the battery 2 reaches the set pressure, and the safety valve 21 is opened. The breaking film 22 is a metal foil, a laminated film of a metal foil and a plastic film, a plastic film, or the like so as to be broken at a set pressure. Instead of a rupture film, the safety valve may have a structure in which a part of the outer can is thinly processed to make it easier to break. Further, as shown in FIG. 8, the safety valve built in the convex electrode may have a structure in which the valve body 28 is pressed against the valve seat 29 by the elastic body 27. The safety valve 21 opens when the valve body 28 is pushed by the internal pressure and discharges gas or the like from the discharge hole 30.

The circuit board 5 is mounted with electronic parts (not shown) for realizing a protection circuit for the battery 2. In the battery pack shown in this figure, the protection circuit is mounted on the circuit board 5, but the protection circuit may be provided in the resin molding portion 1 as a small IC. In this battery pack, the circuit board 5 can be omitted.
Further, in the core pack 15 shown in FIGS. 4 and 6, the output terminal 3 is fixed to the circuit board 5.

In the battery pack, the resin molding part 1 is molded by temporarily fixing the core pack 15 in the molding chamber. In the step of molding the resin molding portion 1, a part or the whole of the components forming the core pack 15 is embedded in the resin molding portion 1 or insert-molded in a state of being in contact therewith. The resin molding portion 1 is provided with a resin intrusion prevention portion 9 in the molding process. The resin intrusion prevention portion 9 is a portion that prevents invasion of the molten resin and forms a void. The resin intrusion prevention portion 9 can also be provided between the holder 4 and the battery 2.

The battery pack shown in FIG. 3 is provided with a resin intrusion prevention section 9 as a discharge path for connecting the safety valve 21 to the outside of the resin molding section 1. The resin molding part 1 discharges gas and electrolyte discharged from the opened safety valve 21 and fragments of contents such as electrode plates and separators to the outside. In the battery pack of FIG. 3, as shown in the enlarged cross-sectional view of the main part of FIG. 9, the resin molding part 1 is provided with a resin intrusion prevention part 9. The resin intrusion prevention portion 9 is provided in the opening of the safety valve 21 of the battery 2 between the battery 2 and the protection element 6. In the core pack 15 of FIGS. 6 and 7, the holder 4 is provided with the resin intrusion prevention portion 9. The resin invasion preventing portion 9 is also communicated with the opening of the safety valve 21 so that the opening of the safety valve 21 is communicated with the outside.

Further, the battery packs of FIGS. 10 and 11 are
A resin intrusion prevention portion 9 is provided on both the resin molding portion 1 and the holder 4. The resin intrusion prevention portion 9 provided in the resin molding portion 1 communicates the opening of the safety valve 21 with the outside. The resin intrusion prevention portion 9 provided on the holder 4 is provided around the protection element 6.

The resin intrusion prevention portion 9 can house the protective element 6 therein or expose the surface of the protective element 6 insert-molded in the resin molded portion 1. In the battery packs of FIGS. 6 and 7, and FIGS. 10 and 11, the resin intrusion prevention portion 9 houses the protection element 6. The battery pack shown in FIG.
The protective element 6 is insert-molded in the resin molding part 1 and
As shown in FIG. 5, the surface of the protection element 6 is exposed at the resin intrusion prevention portion 9. These protection elements 6 are elements such as a PTC, a temperature fuse, or the like, which are connected in series with the battery 2 and cut off a current when the battery 2 becomes higher than a set temperature, or a thermistor or a temperature sensor. The temperature sensor is connected to a control circuit (not shown) to cut off the current of the battery 2. Further, as the protection element 6, a breaker that shuts off the current when an overcurrent flows through the battery 2 can be used. Breaker
It detects the battery current and shuts off the current, but converts the current to temperature and shuts off the current. Therefore, if the battery pack is built so that it is heated by the flowing current and further heated by the battery temperature, the overcurrent can be cut off more quickly. Therefore, the breaker is also preferably arranged at a position where it is effectively heated by the heat of the battery 2. That is, except that a resin is not interposed between the breaker and the battery 2 and the breaker is brought into direct contact with the battery 2, or a resin intrusion prevention portion 9 is provided between the breaker and the battery 2 to block heat. The structure is good.

The protective element 6 provided in the resin intrusion prevention portion 9 of the holder 4 of FIGS. 6 and 7 is connected by soldering one lead 6B to the convex electrode 2B. Furthermore, the protection element 6
The other lead 6A of the
It is pulled out from the opening at the right end of the resin intrusion prevention portion 9. Lead 6A pulled out of the resin intrusion prevention portion 9
Is spot-welded and connected to the lead 5A connected to one end of the circuit board 5. Further, the circuit board 5 has the opposite end connected to the battery 2 via the lead plate 8. The circuit board 5 has a lead plate 8 on the lead 5B connected to the other end.
Are spot welded. Therefore, this circuit board 5
Is connected at both ends to the battery 2 by the lead plate 8 and the protective element 6. Since the holder 4 is arranged between the circuit board 5 and the battery 2, the holder 4 is also arranged at a fixed position of the battery 2. The holder 4 is sandwiched between the circuit board 5 and the battery 2,
The circuit board 5 is arranged at a fixed position of the battery 2.

Further, the holder 4 shown in FIG.
The holding convex portion 23 is provided at the opening edge facing the. The circuit board 5 is provided with a fitting portion 24 by cutting out a position facing the holding convex portion 23. The circuit board 5 and the holder 4 are connected at a predetermined position by fitting the holding convex portion 23 into the fitting portion 24. Further, the circuit board 5 shown in FIGS. 6 and 7 has a resin injection port 19 through which a molten resin penetrates in order to embed and fix the holder 4 and the circuit board 5 in the resin molding portion 1. The resin injection port 19 in the drawing penetrates the circuit board 5, and the molten resin is also injected into the back surface of the circuit board 5.

The holder 4 of the battery pack shown in FIG.
As shown in FIGS. 2 and 13, the opening of the peripheral wall 4A is closed by the resin injection blocking wall 4B to form the resin intrusion blocking portion 9. The resin intrusion prevention portion 9 has an opening on the surface facing the battery 2, but the opening is closed by the battery 2. In order to close the opening with the battery 2, the peripheral wall 4A is formed into a shape that closely adheres to the side surface of the battery 2 without any gap, in other words, a shape that extends along the side surface of the battery 2. Also in this resin intrusion prevention section 9, since the protection element 6 disposed here can be brought close to the surface of the battery 2, the protection element 6 can promptly detect an abnormal temperature rise of the battery 2 and interrupt the current.

Further, as shown in FIG. 11, this holder 4 is provided with a convex portion 16 on the inner surface of the resin molding portion 1 for accommodating the protective element 6. The protective element 6 locally contacts the convex portion 16 and is arranged in the resin intrusion prevention portion 9. With this structure, the protection element 6 provided in the resin intrusion prevention portion 9 can interrupt the current very quickly when the battery temperature rises. The protective element 6 is disposed close to the battery 2, and the protective element 6 locally contacts the convex portion 16 to prevent the resin injection blocking wall 4.
This is because the heat conduction to B can be reduced. Further, the convex portion 16 also functions as a reinforcing rib that prevents the peripheral wall 4A from being deformed by the pressure of the supplied molten resin.

Further, in the holder 4 of FIG. 13, a connection window 17 for connecting the lead 6A of the protection element 6 is opened in a part of the resin injection blocking wall 4B. This connection window 17
Closes and closes the circuit board 5. The circuit board 5 that closes the connection window 17 is exposed inside the resin intrusion prevention portion 9. The exposed portion of the circuit board 5 is soldered to one lead 6A of the protection element 6 to be connected thereto. Furthermore, the protection element 6
In order to connect the other lead 6B of the
A through hole 18 is also opened in A. This through hole 18 is
It has a slit shape that allows the lead 6B of the metal plate to be inserted without a gap, and the lead 6B is inserted therein to be closed. Through hole 1
The lead 6 </ b> B that has passed through 8 and is drawn out of the resin intrusion prevention portion 9 is spot-welded and connected to the convex electrode 2 </ b> B of the battery 2 via the lead plate 7.

Further, the holder 4 shown in FIGS. 12 and 13 is
A support wall 4C that supports the circuit board 5 is integrally formed at the same height as the peripheral wall 4A that constitutes the resin intrusion prevention portion 9. The support wall 4C is provided at a position that supports both sides of the circuit board 5. This support wall 4C has a resin injection port 19 in the middle for embedding and fixing the circuit board 5 in the resin molding portion 1.
Is open. The resin injection port 19 is opened on both sides of the circuit board 5, and the molten resin is also injected into the back surface of the circuit board 5. Further, the holder 4 in the figure is provided with a lead guide 20 for holding the lead plate 8 at the left end portion in FIG. The lead guide 20 holds the lead plate 8 connected to the circuit board 5 and the battery 2, and holds the circuit board 5 in a fixed position of the holder 4 via the lead plate 8. The circuit board 5 in the figure has the opposite end connected to the battery 2 via the protection element 6. Both ends of the circuit board 5 are connected to the battery 2 by a lead plate 8 and a protection element 6. Since the holder 4 is arranged between the circuit board 5 and the battery 2, the holder 4 is also arranged at a fixed position of the battery 2. The holder 4 is a circuit board 5
It is sandwiched between the battery 2 and the battery 2, and the circuit board 5 is arranged at a fixed position of the battery 2.

The resin molding portion 1 insert-molds the core pack 15 including the holder 4 and the battery 2 in the step of molding the synthetic resin. Since the protection element 6 and the circuit board 5 are connected to the holder 4, the resin molding part 1 integrally connects the holder 4, the protection element 6, the circuit board 5 and the battery 2 to a fixed position. In the battery pack described above, the entire battery 2 is embedded in the resin molding portion 1 and is not inserted. The battery pack of FIG. 2 has a resin molding portion 1 molded on the end surface of the battery 2. This battery pack has a feature that the outer shape can be reduced. However,
In the battery pack, the resin molding portion 1 can be molded on three sides of the battery 2 as shown in FIG. Furthermore, the battery pack may be inserted so that a part or almost all of the battery is embedded in the resin molding portion to form a battery pack having a solid and tough structure.

Polyamide or polyurethane is used as the synthetic resin for molding the resin molding portion 1. Since these synthetic resins have a low softening temperature and a low viscosity at the time of melting, they can be molded at a lower temperature and a lower pressure than general synthetic resins. Thus, the resin molding part 1 molded at low temperature and low pressure
Has the advantages that the time required for molding can be shortened and that adverse effects on the electronic parts and the like due to heat and injection pressure during resin molding can be reduced. Particularly, in the battery pack in which the protection element 6 is provided in the resin intrusion prevention portion 9, the influence of heat on the protection element 6 due to the molten resin can be further reduced.

The above battery pack is manufactured as follows. (1) The circuit board 5 is connected to the battery 2 with the protective element 6 and the lead plate 8, and the protective element 6, the circuit board 5 and the holder 4 are arranged at fixed positions of the battery 2 to manufacture the core pack 15. In the core pack 15, the holder 4 is disposed between the circuit board 5 and the battery 2, and the holder 4 connects the circuit board 5 and the battery 2 at an accurate relative position.

(2) The core pack 15 is shown in FIGS.
The mold 10 is set in the molding chamber 11 shown in FIG. 14 shows a mold 10 for manufacturing the battery pack shown in FIG. 3, and FIG. 15 shows a mold 10 for manufacturing the battery pack shown in FIG. After setting the core pack 15 in the molding chamber 11, the mold 10 is clamped. A mold chamber 11 for molding the resin molding part 1 is formed in the mold 10 that has been clamped. This molding chamber 11
The heated molten resin is injected into the resin molding part 1 to mold it. The molten resin is injected into the mold 10 through a liquid injection hole 12
Injected from. The liquid injection hole 12 is provided so as to communicate with the molding chamber 11.

14 and 15 show a state in which the mold 10 for manufacturing the battery pack is opened. In these molds 10, a hollow molding portion 25 for molding the resin intrusion prevention portion 9 in the resin molding portion 1 is provided so as to protrude from the inner surface of the molding chamber 11. The hollow molding part 25 blocks the invasion of the molten resin injected into the molding chamber 11 to mold the resin intrusion prevention part 9. The mold 10 shown in the figure has a hollow molding part 25 on the opposite surfaces of the pair of molds 10.
Is provided so as to project. The hollow molding portions 25 provided in the pair of molds 10 bring their tip surfaces into contact with each other in a state where the molds 10 are clamped.

In the mold 10, the pressurized gas is pressed into the hollow molding portion 25 in the mold clamped state. Pressurized gas is the hollow molding part 2
The molten resin is prevented from entering the 5. The pressure in the hollow molding portion 25 to which the pressurized gas is supplied is preferably the molding chamber 1
The pressure is set to be approximately equal to or slightly higher than the pressure of the molten resin to be injected into 1. When the pressure of the molten resin and the pressure of the pressurized gas are balanced, the molten resin becomes
This is because the gas does not enter the resin molding part 5 and the pressurized gas is not discharged to the resin molding part 1. However, the pressure inside the hollow molding portion 25 may be lower than that of the molten resin. This is because even if the pressure of the pressurized gas is lower than the pressure of the molten resin, the action of limiting the penetration of the molten resin is achieved. Further, the pressure of the hollow molding portion 25 can be made higher than the pressure of the molten resin. This is because it is possible to reliably prevent the molten resin from entering the hollow molding portion 25. Air is used as the pressurized gas, but any gas that does not adversely affect the molten resin, such as nitrogen gas or carbon dioxide gas, can be used.

The mold 10 has a through hole 26 connected to the hollow molding portion 25. The through hole 26 supplies the pressurized gas to the hollow molding portion 25. The through hole 26 is provided so as to be connected to one of the hollow molding portions 25 as shown in FIG. 16, or as shown in FIG. 17, both of the pair of hollow molding portions 25 facing each other. be able to. As shown in FIG. 16, the mold 10 that is connected to one of the hollow molding portions 25 and has a through hole supplies the pressurized gas to the closed hollow molding portion 25, so that the consumption amount of the pressurized gas is increased. Can be reduced. In this structure, the through hole 26 is connected to a pressurized air source 31 or the like that supplies pressurized gas via an opening / closing valve 32. The pressure of the hollow molding portion 25 is adjusted by the pressure of the pressurized air source 31, or by connecting a pressure adjusting valve to the opening / closing valve 32. Figure 1
As shown in FIG. 7, in the structure in which the through hole 26 is provided in both of the pair of hollow molding portions 25, the pressurized gas is supplied from one through hole 26 and the pressurized gas is discharged from the other through hole 26.
In this structure, one through hole 26 is connected to the pressurized air source 31 or the like via the opening / closing valve 32, and the other through hole 26 is opened to the outside by the flow rate adjusting valve 33. With this structure, the pressure of the pressurized gas to be supplied and the flow rate of the pressurized gas to be exhausted can be controlled to adjust the pressure of the hollow molding portion 25 to the set pressure. This method
Since the pressurized gas is passed through the hollow molding portion 25, the through hole 2
6 has a feature that it can be prevented from being clogged, and dust and the like will not collect in the hollow molding portion 25.

The mold 10 provided with the resin intrusion prevention portion 9 on the holder 4 does not require the hollow molding portion 25. However, in order to prevent the molten resin from entering the resin invasion preventing portion 9, it is necessary to supply the pressurized gas. The battery pack of FIG. 10 is provided with a resin intrusion prevention portion 9 inside the holder 4. In order to supply the pressurized gas to the resin invasion preventing portion 9 inside the holder 4, a pressurized gas supply hole 34 is opened in the holder 4. Further, a mold 1 for molding this battery pack.
No. 0, as shown in the sectional view of FIG. 18, the through hole 26 connected to the supply hole 34 of the holder 4 is provided in the mold 10. The pressurized gas is supplied from the through hole 26 of the mold 10 to the supply hole 34.
And is supplied to the resin invasion preventing portion 9 in the holder 4. The mold 10 also connects the through hole 26 to the pressurized air source 31 via the opening / closing valve 32. The on-off valve 32 is a mold 10
The valve is opened in a state where the mold is clamped and the pressurized gas is supplied to the resin intrusion prevention portion 9. Even when the pressurized gas is supplied to the resin invasion preventing portion 9 in the holder 4, as shown in FIG.
It is possible to open the through hole 26 and the supply hole 34 on the opposing surface of the holder 0 and the holder 4 so that the pressurized gas can pass through the resin intrusion prevention portion 9.

18 and 19, since the holder 4 is located between the resin intrusion prevention portion 9 and the molding surface of the die 10, the supply hole 34 is opened in the holder 4 to apply the resin intrusion prevention portion 9. Supply pressurized gas. That is, this resin intrusion prevention portion 9
Is an area surrounded by the holder 4 and the battery 2.
However, as shown in FIG. 20, in the structure in which the resin intrusion prevention portion 9 is provided by the holder 4, the mold 10 and the battery 2,
The pressurized gas can be directly supplied from the through hole 26 of the mold 10 to the resin intrusion prevention portion 9 without opening the supply hole in the holder 4. The mold 10 is provided with a through hole 26 connected to a portion for molding the resin intrusion prevention portion 9. Through hole 26
18 can be connected to the on-off valve 32 and the pressurized air source 31 to supply the pressurized gas, like the mold 10 shown in FIGS. 18 and 19.

Further, as shown in FIGS. 14 and 15, the mold 10 has a positioning convex portion 13 for temporarily fixing the core pack 15 in a fixed position. The positioning convex portion 13 abuts on the surface of the holder 4 or the circuit board 5 and temporarily fixes the core pack 15 at an accurate position. In FIGS. 14 and 15, the positioning protrusions 13 located above and below press the surface of the circuit board 5 to temporarily fix it in place. These positioning convex portions 13
Presses the surface of the output terminal 3 of the circuit board 5 with the positioning convex portion 13 and brings the bottom of the battery 2 into contact with the inner surface of the molding chamber 11 of the mold 10 to position the core pack 15 in the vertical direction. Prevent the gap. Further, the positioning convex portion 13 that presses the surface of the output terminal 3 is provided from the molded resin molding portion 1 to the output terminal 3
To be exposed to the outside.

Further, the mold 10 shown in FIG. 15 has, in addition to the hollow molding portion 25 and the positioning convex portion 13, a central convex portion 14 for temporarily fixing the core pack 15 in place. The central convex portion 14 abuts on the front side surface and the back side surface of the battery 2,
Is clamped to prevent vertical displacement. Further, in the holder 4 of FIG. 13, the four corners 4D are brought into contact with the inner surfaces of the corners of the molding chamber 11 of the mold 10 to prevent the holder 4 and the circuit board 5 from being displaced in the vertical and horizontal directions. . As described above, in the mold 10, the central convex portion 14 is brought into contact with the battery 2, the positioning convex portion 13 is brought into contact with the surface of the circuit board 5, and further, the corners 4D of the holder 4 are attached to the mold 10. The core pack 15 is temporarily held in place by abutting against the inner surface.

(3) The synthetic resin melted by heating is pressed into the molding chamber 11. The molten synthetic resin is shown in FIGS.
As shown in 0, it does not enter the resin invasion blocking portion 9 while entering the molding chamber 11. The resin molding part 1 molded in the molding chamber 11 connects and fixes the circuit board 5, the holder 4, and the battery 2 in an integrated structure. The resin intrusion prevention part 9 is communicated with the outside of the resin molding part 1 without being injected with synthetic resin.

(4) Through the above steps, the core pack 15 is
The circuit board 5, the holder 4, and the battery 2 are inserted into the resin molding portion 1 and fixed in place. After that, the resin molding part 1
The surface of the molded core pack 15 is covered with a tube to complete the battery pack. Use heat-shrink tubing. After the core pack 15 in which the resin molding part 1 is molded is put into the heat shrinkable tube, the heat shrinkable tube is heated and shrunk to be closely attached to the surface.

[0041]

The method of manufacturing a battery pack according to the present invention has a feature that it is possible to reliably prevent the molten resin which is heated and pressed from entering the resin intrusion preventing portion when the resin molding portion is molded. . According to the method for manufacturing a battery pack of the present invention, when a resin molding part is molded in a molding chamber of a mold, a pressurized gas is pressed into a molding part which is provided with a resin penetration blocking part for blocking penetration of molten plastic. Because they are doing it. The pressurized air that is press-fitted into the portion where the resin intrusion prevention portion is provided surely prevents the molten plastic from entering this portion. Therefore, according to this manufacturing method, it is possible to prevent the molten plastic from entering the portion where the resin intrusion preventing portion is molded, and effectively prevent various adverse effects caused by the invading plastic. Further, this manufacturing method has a feature that even if there is some dimensional error in the mold or the core pack, it is possible to reliably prevent the molten resin from entering the resin intrusion preventing portion.

[Brief description of drawings]

FIG. 1 is a perspective view showing a conventional method for manufacturing a battery pack.

FIG. 2 is a perspective view showing a step of providing a resin intrusion prevention portion on a resin molding portion of a battery pack.

FIG. 3 is a perspective view of a battery pack manufactured by a manufacturing method according to an embodiment of the present invention.

FIG. 4 is a perspective view showing an example of a core pack of the battery pack shown in FIG.

5 is an exploded perspective view of the core pack shown in FIG.

FIG. 6 is an exploded perspective view showing another example of the core pack.

7 is an enlarged cross-sectional view of the core pack shown in FIG.

FIG. 8 is a sectional view showing another example of the safety valve.

9 is an enlarged cross-sectional view of an essential part showing a resin intrusion prevention part of the battery pack shown in FIG.

FIG. 10 is a perspective view of a battery pack manufactured by a manufacturing method according to another embodiment of the present invention.

11 is a sectional view of the battery pack shown in FIG.

12 is a perspective view of a core pack of the battery pack shown in FIG.

13 is an exploded perspective view of the core pack shown in FIG.

FIG. 14 is an exploded perspective view of a mold for molding a resin molding part of the battery pack shown in FIG.

15 is an exploded perspective view of a mold for molding a resin molding portion of the battery pack shown in FIG.

FIG. 16 is a cross-sectional view showing a state where pressurized air is supplied to the hollow molding portion to mold the resin intrusion prevention portion.

FIG. 17 is a cross-sectional view showing another example of supplying pressurized air to the hollow molding portion.

FIG. 18 is a cross-sectional view showing a state in which pressurized air is supplied to the resin intrusion prevention portion of the holder.

FIG. 19 is a cross-sectional view showing another example of supplying pressurized air to the resin intrusion prevention portion of the holder.

FIG. 20 is a cross-sectional view showing a state in which pressurized air is supplied to a resin intrusion prevention part formed by a holder, a mold and a battery.

[Explanation of symbols]

1 ... Resin molding part 2 ... Battery 2A ... Exterior can 2
B: convex electrode 2C: sealing plate 3 ... output terminal 4 ... holder 4A ... peripheral wall 4
B ... Resin injection blocking wall 4C ... Supporting wall 4D ... Corner 5 ... Circuit board 5A ... Lead 5
B ... Lead 6 ... Protective element 6A ... Lead 6
B ... Lead 7 ... Lead plate 8 ... Lead plate 9 ... Resin invasion blocking portion 10 ... Mold 11 ... Molding chamber 12 ... Liquid injection hole 13 ... Positioning convex portion 14 ... Central convex portion 15 ... Core pack 16 ... Convex portion 17 ... Connection window 18 ... Through hole 19 ... Resin injection port 20 ... Lead guide 21 ... Safety valve 22 ... Breaking film 23 ... Holding convex portion 24 ... Fitting portion 25 ... Hollow molding portion 26 ... Through hole 27 ... Elastic body 28 ... Valve body 29 ... Valve seat 30 ... Exhaust hole 31 ... Pressurized air source 32 ... Open / close valve 33 ... Flow rate adjusting valve 34 ... Supply hole 35 ... Convex portion

Continued front page    F term (reference) 4F202 AD01 AD21 AH33 CA11 CB01                       CB12 CK11 CK43 CK81 CK87                       CK90 CQ01                 4F206 AD01 AD21 AH33 JA07 JB12                       JL02 JM04 JN11 JN27 JQ81                 5H040 AA27 AA33 AA40 AY04 AY08                       JJ03

Claims (9)

[Claims] 1. A battery (2) is temporarily fixed to a molding chamber (11) of a mold (10), and a part or whole of the battery (2) is held in the molding chamber (11) of the mold (10). A method of manufacturing a battery pack for molding a resin molding part (1) to be inserted, wherein when molding the resin molding part (1) in a molding chamber (11), the resin molding part (1) is molded in a molten state. A resin intrusion prevention part (9) for preventing intrusion of plastic is provided, and pressurized gas is supplied to a molding part for molding this resin intrusion prevention part (9),
A method for manufacturing a battery pack, which comprises preventing molten plastic from entering a molded portion by pressurized gas. 2. A molding chamber for the die (10), wherein the resin invasion preventing portion (9) is formed.
Molded in the hollow molding part (25) of the die (10) protruding in (11), and supplying pressurized gas to the hollow molding part (25) to melt the plastic in the resin intrusion prevention part (9). The method of manufacturing a battery pack according to claim 1, wherein the battery pack is prevented from entering. 3. The method of manufacturing a battery pack according to claim 1, wherein the resin intrusion prevention portion (9) is provided in contact with the safety valve (21) provided in the battery (2). 4. A core pack (15) connecting a protection element (6) to a battery (2) is temporarily fixed to a mold (10),
Resin intrusion prevention part in contact with the protective element (6) provided on (15)
The method for manufacturing a battery pack according to claim 1, wherein (9) is provided. 5. A core pack (15) connecting a protective element (6) to a battery (2) is temporarily fixed to a mold (10), and the core pack is obtained.
The method for producing a battery pack according to claim 1, wherein a resin intrusion prevention part (9) is provided between the protection element (6) provided in (15) and the battery (2). 6. A core pack (15) connecting a protective element (6) and a holder (4) to a battery (2) is temporarily fixed to a mold (10),
The holder (4) of this core pack (15) has a resin intrusion prevention part (9).
The resin intrusion prevention part (9) and the mold (10) form a closed chamber, and pressurized resin is supplied to the closed resin intrusion prevention part (9) to mold the resin molding part (1). The method for manufacturing the battery pack according to claim 1. 7. The resin molding part (1) is molded by disposing a protective element (6) on the resin intrusion prevention part (9) of the holder (4).
A method for manufacturing a battery pack as described in. 8. The resin molding part (1) is molded by communicating the resin intrusion prevention part (9) of the holder (4) with the safety valve (21).
A method for manufacturing a battery pack as described in. 9. The method for manufacturing a battery pack according to claim 4, wherein the protection element (6) is any of a breaker, a PTC, a thermistor, a fuse, and a temperature sensor.