JP5507328B2 - Battery case - Google Patents

Description

  The present invention relates to a battery case for housing a battery mounted on an electric vehicle, a hybrid electric vehicle, or the like.

  Conventionally, in a vehicle such as an electric vehicle, a large number of batteries such as battery modules and battery packs are mounted on the floor surface of the vehicle body, and each battery is electrically connected by a cable and is also made of iron or aluminum. It is attached to the vehicle body in a state of being housed in a battery case made of metal such as. For example, Patent Document 1 discloses a publication relating to this type of battery case.

JP 2009-302036 A

  However, in such a battery case, the case main body in which the battery is accommodated is formed of metal for the purpose of shielding (shielding) electromagnetic waves generated from the battery, so that a predetermined electromagnetic shielding property can be secured. However, since the weight of the battery case itself is heavy, it is difficult to reduce the weight of the vehicle, and it is difficult to improve the fuel efficiency of the vehicle required for environmental measures. Also, since the battery case is made of metal, the battery case itself can be secured to a certain degree of rigidity (strength). However, the battery case may be deformed or corroded by impact, so that it has sufficient impact resistance and resistance. It is difficult to obtain corrosiveness.

  The present invention has been made in view of such circumstances, and the object thereof is to reduce the weight while ensuring sufficient electromagnetic shielding properties, and is excellent in impact resistance, corrosion resistance, and the like. To provide a battery case.

In order to achieve such an object, the invention according to claim 1 of the present invention is a battery case having a pair of case bodies that are openably and closably connected by hinges, and a battery is accommodated inside the case body. there are, the pair of case body, by a multilayer blow molding, the inner surface of the resin material outside the resin layer formed on the outer surface side of the case body, wherein a conductive material is kneaded in a resin material outer resin layer A conductive material layer formed on the side, an outer wall and an inner wall each having a resin material and an inner resin layer formed inside the conductive material layer , and a hollow layer formed in a sealed state between the outer wall and the inner wall. And the conductive material layer is formed thinner than the outer resin layer and the inner resin layer .

The invention according to claim 2 is characterized in that the inner resin layer is formed of a return material . The invention described in claim 3 is characterized in that a binder layer is provided between the conductive material layer and the outer resin layer or the inner resin layer . The invention described in claim 4 is characterized in that the battery is a battery mounted on an electric vehicle or a hybrid electric vehicle .

According to the first aspect of the present invention, the pair of case main bodies in which the battery is housed are formed of an outer resin layer formed on the outer surface side of the case main body by multilayer blow molding and the resin layer. Since it has a resin-made conductive material layer formed on the inner surface side and an inner resin layer formed on the inner surface side of the conductive material layer, the case body is made of resin while ensuring sufficient electromagnetic shielding properties with the conductive material layer. Making it can reduce the weight and improve impact resistance, corrosion resistance, and the like.

Further, since the case body has a double wall structure having an outer wall and an inner wall and a hollow layer formed in a sealed state between the outer wall and the inner wall, the impact resistance of the case body is further improved by the hollow layer. Can do.

Further, since the outer wall and the inner wall have the outer resin layer, the inner resin layer, and the conductive material layer formed between the two resin layers, the outer wall and the inner wall may have a sandwich structure of a pair of resin layers and the conductive material layer. This can further improve the impact resistance of the case body.

Furthermore, since the conductive material layer is formed thinner than the outer resin layer and the inner resin layer , the conductive material layer can be set to an optimum amount that can ensure a predetermined electromagnetic wave shielding property while suppressing the amount of the conductive material used. Cost can be reduced.

Further, according to the invention described in claim 2 , in addition to the effect of the invention described in claim 1 , since the inner resin layer is formed of a return material, as an end material generated during blow molding of the case body The return material can be effectively used to improve the yield of the resin, and an inexpensive battery case can be obtained.

According to the invention described in claim 3 , in addition to the effect of the invention described in claim 1 or 2 , the binder layer is provided between the conductive material layer and the outer resin layer or the inner resin layer. The conductive material layer can be reliably adhered to each resin layer with a binder layer made of a predetermined adhesive depending on the type of the conductive material, and stable electromagnetic shielding properties can be ensured over a long period of time.

According to the invention described in claim 4 , in addition to the effects of the invention described in claims 1 to 3 , the battery is a battery mounted on an electric vehicle or a hybrid electric vehicle. A large number of mounted batteries can be attached to the vehicle body in a stable state while ensuring good electromagnetic shielding properties, and it is possible to contribute to environmental measures such as improving the fuel efficiency of the vehicle.

The perspective view which shows one Embodiment of the battery case concerning this invention The longitudinal section 2 is an enlarged sectional view of part A in FIG. Sectional drawing which expanded the B section of FIG. 2 which shows the basic concept of the same invention Sectional view similar to FIG. 4 showing an embodiment of the case body Sectional view similar to FIG. 4 showing a modification of the case body Sectional view similar to FIG. 4 showing another modification of the case body 2 is a longitudinal sectional view similar to FIG. 2 showing a reference example of a battery case according to the present invention. FIG. 8 is an enlarged sectional view of part C of FIG.

DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings.
1 to 3 show an embodiment of a battery case according to the present invention. As shown in FIGS. 1 and 2, the battery case 1 has side walls 1a to 1d, a ceiling wall 1e, and a bottom wall 1f (hereinafter, these walls are referred to as side walls 1a to 1f). It has a pair of case main bodies 2 and 3 which are formed in a hollow rectangular parallelepiped shape having a width W and a height H and which are divided into upper and lower portions having substantially the same height. Each case body 2, 3 has one long side wall 1 a connected by a hinge 4, and the other long side wall 1 b connected by a sliding hook 5 so that it can be locked (opened / closed). Has been.

  Each case body 2, 3 has housing recesses 2 a, 3 a in which a battery 19, which will be described later, is housed. For example, one side wall 1 c on the short side of the lower case body 3 is connected to a battery. A plurality of cable lead-out holes 6 through which the cable (not shown) is drawn out are formed. Furthermore, recessed portions 7 and 8 that are recessed inward are provided in the middle of the side wall 1b to which the hooks 5 of the case bodies 2 and 3 are attached in a state of being adjacent (continuous) in the vertical direction.

  A locking protrusion 10 is provided over the entire length in the upper end of the recess 8 of the lower case body 3, and one of the longitudinal directions is provided at the lower end of the recess 7 of the upper case body 2. A locking protrusion 9 having a predetermined length is provided on the side. A pair of upper and lower locking recesses 5 a and 5 b provided on the back surface side of the hook 5 are locked to the locking protrusions 9 and 10.

  Further, the hook 5 is slidably locked to the locking protrusion 10 of the lower case body 3 so that the lower locking recess 5b is always slidable. In the position shown in FIG. The locked state of the main body 2 with the locking ridge 9 is released, and the upper and lower case main bodies 2 and 3 can be opened and closed around the hinge 4. Further, by sliding the hook 5 from the position shown in FIG. 1 as indicated by an arrow A, the upper locking recess 5a of the hook 5 is locked to the case protrusion 9 of the upper case body 2, and a pair of case main bodies is obtained. Opening a few is prohibited.

The side walls 1a to 1f of the battery case 1 thus configured are configured as shown in FIGS. 2 and 3 and FIG. 4 showing the basic concept of the case bodies 2 and 3, respectively. That is, the case main bodies 2 and 3 are formed by multi-layer blow molding to have a double-wall structure in which the side walls 1a to 1f are the outer wall 11 and the inner wall 12, and the hollow layer 13 provided between the outer wall 11 and the inner wall 12. Yes. At this time, as shown in FIG. 4, the outer wall 11 and the inner wall 12 are provided on the resin layer 14 provided on the outer surface side of each of the side walls 1 a to 1 f and on the hollow layer 13 side that is the inner side of each resin layer 14. The conductive material layer 15 is formed with a double wall structure.

  As the resin layer 14, for example, a resin material such as polypropylene (PP), high-density polyethylene (HDPE), nylon (PA), or the like is used. The conductive material layer 15 is made of a material obtained by kneading a conductive material such as carbon black, CFRP, or a metal filler with a predetermined resin material at a predetermined ratio. Electromagnetic shielding properties are ensured. Further, the thickness t1 of the resin layer 14 on the outer wall 11 and the inner wall 12 and the thickness t2 of the conductive material layer 15 are set to t1> t2, so that the conductive material layer 15 is thinned.

  In addition, the said hinge 4 which connects the said case main bodies 2 and 3 so that opening and closing is possible is formed with the integral flange integrally formed at the time of multilayer blow molding of the upper and lower case main bodies 2 and 3. FIG. Further, as shown in FIG. 3, a concave portion 16 and a convex portion 17 that can be engaged with each other are integrally formed at the end portions of the side walls 1b of the case main bodies 2 and 3 so as to be capable of being fitted and connected. At the same time, the outer peripheral ends of the outer walls 11 and the inner walls 12 of the case bodies 2 and 3 are connected by a connecting wall 18 (see FIG. 3) made of the same wall as the outer walls 11 and the inner walls 12. Is formed in a sealed space. In addition, the said recessed part 16 and the convex part 17 are not necessarily required, and can also be abbreviate | omitted.

As described above, the battery case 1 uses a multilayer blow molding machine, and uses two types of resin materials that can form the resin layer 14 and resin materials in which the conductive material is previously kneaded. By blow molding, the case bodies 2 and 3 and the hinge 4, the recesses 7 and 8 and the locking protrusions 9 and 10 are simultaneously molded. In addition, as a resin material used at the time of blow molding of the battery case 1, when the resin layer 14 is polypropylene, an olefin type is used as the conductive material of the conductive material layer 15, and when the resin layer 14 is nylon, the resin material is conductive. It is preferable to use a nylon material as a material, and this also applies to Examples and the like described later. Then, the battery case 1 is manufactured by engaging the molded recesses 5a and 5b of the hook 5 separately assembled with the molded case bodies 2 and 3 respectively.

The reason why the multilayer blow molding is used for molding the battery case 1 is as follows. In other words, in order to obtain an impact resistance superior to that of a metal with a resin molded product, a solution can be achieved by forming a monocoque structure by providing a hollow layer and increasing physical strength. In order to mold the case with resin, it is necessary to form the outer wall and the inner wall separately and combine them in injection molding. In that respect, if multi-layer blow molding is used, the outer wall, inner wall, hinge, etc. can be integrally molded at the same time, so the resin type of the resin layer 14 and the conductive material layer 15, the type of conductive material and the kneading rate into the resin, This is because by setting the parison temperature conditions, viscosity, and the like to a predetermined value, for example, the battery case 1 having an electromagnetic wave shielding property of 60 dB and a volume resistivity of 10 ⁻² to 10 ⁴ Ω · cm can be obtained.

  The battery case 1 manufactured in this way accommodates, for example, a battery 19 for an electric vehicle comprising three battery modules and a battery pack as shown in FIG. The terminals of the three batteries 19 are connected to each other with cables (not shown). Then, the end of the cable connecting the three batteries 19 is pulled out from the cable lead-out hole 6 of the case main body 3 and connected to the battery 19 of the other battery case 1 installed adjacent thereto or its cable. By applying this to a predetermined number of battery cases 1 and mounting each battery case 1 on the body of an electric vehicle, the battery 19 in each battery case 1 can be used as a battery for the electric vehicle.

  At this time, in the case of an electric vehicle, the current flowing through the electric control system by DC-AC conversion or brush control becomes a current with a large amount of ripple due to the system, and this also flows into the battery 19, so that electromagnetic waves are easily radiated from the battery 19. However, this electromagnetic wave is shielded by the conductive material layer 15 of the battery case 1, and radiation (leakage) to the outside of the battery case 1 is prevented. Further, the electromagnetic waves radiated from the cables connecting the batteries 19 are prevented from being radiated out of the cables by the shield structure provided on the cables themselves.

  That is, the conductive material layer 15 in which the conductive material is kneaded on the side of the hollow layer 13 inside the resin layer 14 of the side walls 1a to 1f while reducing the weight by making the side walls 1a to fd of the battery case 1 from resin. By providing this, it is possible to shield the electromagnetic wave radiated from the battery 19 and ensure a predetermined electromagnetic wave shielding property for the battery case 1.

  Thus, according to the battery case 1, the pair of upper and lower case bodies 2 and 3 having the housing recesses 2a and 3a in which the battery 19 is housed are formed on the outer surface of each case body 2 and 3 by multilayer blow molding. The resin layer 14 formed on the side and the resin conductive material layer 15 formed on the inner surface side of the resin layer 14 are radiated from the battery 19 by the conductive material layer 15 of each case body 2, 3. Can prevent radiation and leakage to the outside by shielding the electromagnetic wave, and can secure sufficient electromagnetic wave shielding property for the battery case 1, for example, to suppress the adverse effect of the electromagnetic wave on the vehicle control system and the human body. It becomes possible.

  In addition, since the pair of case bodies 2 and 3 of the battery case 1 are made of resin, the weight of the battery case 1 can be reduced by reducing the weight compared to a conventional metal case. In addition, the deformation of the battery case 1 can be prevented by the elastic force of the resin and its impact resistance can be improved, and the corrosion of the case bodies 2 and 3 can be prevented by the use of the resin. Thus, it is possible to obtain a highly reliable battery case 1.

  Further, since the pair of case bodies 2 and 3 are formed in a double wall structure having the outer wall 11 and the inner wall 12 and the hollow layer 13 formed in a sealed state between the outer wall 11 and the inner wall 12, the hollow layer 13. Thus, the impact resistance of the case bodies 2 and 3 can be further improved, and for example, leakage due to deformation of the battery case 1 when a vehicle accident occurs can be reliably prevented. Furthermore, since the conductive material layer 15 is formed thinner than the resin layer 14, it can be set to an optimal amount (minimum amount) while suppressing the amount of conductive material used, and the cost of the battery case 1 can be reduced.

  In addition, by mounting the battery case 1 on an electric vehicle, a hybrid electric vehicle, or the like, a large number of batteries 19 mounted on a vehicle such as an electric vehicle can be stably attached to the vehicle body, and a system unique to the electric vehicle. It is possible to contribute to environmental measures related to automobiles such as reducing the weight of the vehicle and improving the fuel efficiency while reliably shielding the above electromagnetic wave with the conductive material layer 15.

  Furthermore, since the battery case 1 has a pair of case bodies 2 and 3 that are connected so as to be openable up and down, the battery 19 can be easily stored in the case bodies 2 and 3 and By opening the case main body 2 by sliding the hook 5, the internal battery 19 can be easily replaced, and its maintainability can be improved. Further, since the hinge protrusions 9 and 10 for connecting the upper and lower case bodies 2 and 3 so as to be openable and closable can be integrally formed simultaneously by blow molding, the manufacturing cost of the case bodies 2 and 3 itself The battery case 1 can be obtained even more inexpensively.

By the way, in the basic concept shown in FIG. 4 of the case main bodies 2 and 3 of the embodiment , the outer wall 11 and the inner wall 12 of the side walls 1a to 1f of the battery case 1 are two layers of the resin layer 14 and the conductive material layer 15. Although the example which comprises is demonstrated, the Example of this invention is comprised by three or more layers, as shown in FIGS . Hereinafter, the same parts as those in the basic concept will be described with the same reference numerals. First, the battery case 1 of the embodiment shown in FIG. 5 has a three-layer structure of the outer wall 11 and the inner wall 12 of the side walls 1a to 1f. By providing the resin layer 21 inside the conductive material layer 15, The outer wall 11 and the inner wall 12 have a sandwich structure of a resin layer 14 as an outer resin layer , a conductive material layer 15, and a resin layer 21 as an inner resin layer .

  In the case of the side walls 1a to 1f, the resin and the conductive material similar to those of the above embodiment are used as the resin layer 14 and the conductive material layer 15, and the resin layer 21 on the inner surface side of the outer wall 11 and the inner wall 12 is a return. Material is used. The return material is an end material generated on the outer peripheral side of the molded product when the battery case 1 is molded. Further, the thicknesses t1 to t3 of the resin layer 14, the conductive material layer 15, and the resin layer 21 are set to, for example, about t1 = 1.1 mm, t2 = 0.2 mm, and t3 = 1.2 mm. Thinning of the wall is planned.

Also in this embodiment , the following operational effects can be obtained in addition to the same operational effects as the above-described embodiment, such as ensuring a predetermined electromagnetic wave shielding property by the conductive material layer 15. That is, since the outer wall 11 and the inner wall 12 have a sandwich structure, the conductive material layer 15 can be positioned at a predetermined position in the thickness direction of the side walls 1a to 1f, and a stable electromagnetic shielding property can be ensured. A few impact resistances and the like can be further improved. Further, since the resin layer 21 inside the conductive material layer 15 that is not exposed to the outside is formed of a return material, the return material as an end material generated at the time of blow molding of the case main bodies 2 and 3 is effectively used, The yield can be improved, and a cheaper battery case 1 can be obtained.

  The battery case 1 shown in FIG. 6 has a four-layer structure of the outer wall 11 and the inner wall 12 of the side walls 1a to 1f, and a binder layer (adhesive layer) between the resin layer 14 and the conductive material layer 15. 22 is provided. In the case of the side walls 1a to 1f, the resin and conductive material similar to those of the above embodiment are used as the resin layer 14 and the conductive material layer 15, and the return layer is used as the resin layer 21 on the inner surface side of the outer wall 11 and the inner wall 12. Is used. Furthermore, the battery case 1 shown in FIG. 7 is provided with a resin layer 23 similar to the resin layer 14 on the inner surface side of the resin layer 21 made of the return material of the battery case 1 shown in FIG. 6, and the outer walls 11 of the side walls 1a to 1f. The inner wall 12 has a five-layer structure.

In each of these modified examples, in addition to the same effects as the above-described embodiment , since the binder layer 22 is provided between the resin layer 14 and the conductive material layer 15, the type of conductive material Accordingly, the conductive material layer 15 can be reliably adhered to the resin layer 14 with the binder layer 22 made of a predetermined adhesive, and a more stable electromagnetic shielding property can be secured. Note that the position of the binder layer 22 in FIGS. 6 and 7 is not limited to the illustrated example, and may of course be provided, for example, between the conductive material layer 15 and the resin layer 21. As described above, in the case of the battery case 1 according to the embodiment of the present invention, the outer wall 11 and the inner wall 12 of the side walls 1a to 1f only need to be configured in a multilayer structure. A structure can be adopted as appropriate.

8 and 9 show a reference example of the battery case according to the present invention. Hereinafter, the same parts as those in the above embodiment will be described with the same reference numerals. The battery case 1 of this reference example is characterized in that the side walls 1a to 1f of the case bodies 2 and 3 have a single wall structure, and the side walls 1a to 1f are positioned on the outer surface side as shown in FIG. It is formed by the resin layer 14 and the conductive material layer 15 located on the inner surface side, or as shown in FIG. 8B, it is formed by the resin layer 14 and the conductive material layer 15 and a resin layer 21 made of, for example, a return material. Is.

Although the battery case 1 of this reference example does not have the hollow layer 13, the conductive material layer 15 can ensure electromagnetic wave shielding properties, and can obtain substantially the same operational effects as the above embodiment in addition to weight reduction. In addition, the effect of simplifying the configuration of the case bodies 2 and 3 itself can be obtained. Also in the battery case 1 of this embodiment, various multilayer structures similar to the outer wall 11 and the inner wall 12 of each example of the above-described embodiment, such as providing a binder layer 22, can be adopted.

In the embodiment , the example in which three batteries 19 are accommodated in the battery case 1 in a stacked state has been described. However, for example, a plurality of batteries 19 are accommodated in a side-by-side state. The number and its accommodation form can be changed as appropriate, and the shape of the battery case 1 itself can also be changed as appropriate according to the form of the battery 19 to be accommodated. Moreover, in the said embodiment , although the battery case 1 was formed with a pair of substantially identical case main bodies 2 and 3 which have the same height, for example, the height of the lower case main body 3 is made high, etc. The case main bodies 2 and 3 can also be configured, and the upper and lower case main bodies 2 and 3 are not limited to the hooks 5 and can be configured appropriately.

  The present invention is not limited to application to a vehicle battery such as an electric vehicle or a hybrid electric vehicle, but can be applied to all devices using a battery such as an electric device.

DESCRIPTION OF SYMBOLS 1 ...... Battery case 1a-1d ... Side wall 1e ... Ceiling wall 1f ... Bottom wall 2 ... Case body 2a ··························································································································· Hook 5a, 5b ··· Locking recess 6 ······ Cable lead-out hole 9, 10 ··· Locking protrusion 11 ········ Outer wall 12 ··· ·························································································································・ Convex part 18 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ Connection wall 19 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ Battery 21 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ Resin layer 22 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ Binder layer 23 ・ ・ ・ ・ ・ ・ ・ ・ ・ ・ ・Resin layer

Claims (4)

A battery case having a pair of case bodies connected to each other by a hinge so as to be openable and closable, in which a battery is accommodated.
The pair of case bodies are formed on the inner surface side of the outer resin layer by a material obtained by kneading the outer resin layer formed of resin material on the outer surface side of the case body and a conductive material in the resin by multilayer blow molding. An outer wall and an inner wall each having an inner resin layer formed on the inner side of the conductive material layer and a resin material, and a hollow layer formed in a sealed state between the outer wall and the inner wall, The battery case, wherein the conductive material layer is formed thinner than the outer resin layer and the inner resin layer . The battery case according to claim 1, wherein the inner resin layer is formed of a return material . The battery case according to claim 1 , wherein a binder layer is provided between the conductive material layer and the outer resin layer or the inner resin layer . The battery case according to claim 1 , wherein the battery is a battery mounted on an electric vehicle or a hybrid electric vehicle .

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