US20160276637A1 - Battery module and method for manufacturing same - Google Patents

Battery module and method for manufacturing same Download PDF

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Publication number
US20160276637A1
US20160276637A1 US14/989,834 US201614989834A US2016276637A1 US 20160276637 A1 US20160276637 A1 US 20160276637A1 US 201614989834 A US201614989834 A US 201614989834A US 2016276637 A1 US2016276637 A1 US 2016276637A1
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United States
Prior art keywords
adhesive
battery
porous layer
adhesion
layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US14/989,834
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English (en)
Inventor
Kosuke KUSABA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyoda Gosei Co Ltd
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Toyoda Gosei Co Ltd
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Filing date
Publication date
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Assigned to TOYODA GOSEI CO., LTD. reassignment TOYODA GOSEI CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KUSABA, Kosuke
Publication of US20160276637A1 publication Critical patent/US20160276637A1/en
Priority to US15/962,140 priority Critical patent/US10847768B2/en
Abandoned legal-status Critical Current

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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
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H01M10/0404—Machines for assembling batteries
    • H01M2/1072—
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/213—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for cells having curved cross-section, e.g. round or elliptic
    • 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
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/291—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by their shape
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2220/00—Batteries for particular applications
    • H01M2220/20—Batteries in motive systems, e.g. vehicle, ship, plane
    • 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
    • H01M50/289—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs
    • H01M50/293—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by spacing elements or positioning means within frames, racks or packs characterised by the material
    • 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
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Definitions

  • the present invention relates to a battery module including a battery cell and a holder for holding the battery cell, and a method for manufacturing the battery module.
  • a battery cell in a battery module is generally adhered to a holder.
  • a battery module disclosed in JP2013008655 (A) is formed by integrally adhering multiple battery cells to a holder. This type of battery module is referred to as an assembled battery, and is applied in various use applications such as, for example, batteries for vehicles.
  • a conceivable method is to apply the adhesive on the outer circumferential surface of the battery cell, and insert, in the battery retention section of the holder, the battery cell having the adhesive applied thereon.
  • the adhesive has to fill a narrow gap.
  • the adhesive has a relatively high viscosity, the frictional resistance between the inner circumferential surface of the battery retention section and the adhesive is relatively large, and uniformly applying and spreading the adhesive are difficult.
  • uniformly spreading the adhesive throughout a narrow gap between the inner circumferential surface of the battery retention section and the outer circumferential surface of the battery cell has not been easy.
  • the size of an adhesion area between the solidified adhesive (i.e., adhesion part) and a counterpart material i.e., the inner circumferential surface of the battery retention section and/or the outer circumferential surface of the battery cell
  • the strength of adhesion between the adhesion part and the counterpart material cannot be improved easily, and integrally adhering the battery cell and the holder stably has been difficult.
  • the present invention has been made in view of the above described circumstances, and an objective is to provide a battery module in which a gap between a battery retention section of a holder and a battery cell is filled sufficiently with an adhesion part, and a method for manufacturing the battery module.
  • a first method for manufacturing a battery module of the present invention solving the above described problem includes:
  • a deformable porous layer is formed on the outer circumferential surface of the battery cell and the porous layer is impregnated with an adhesive to form an adhesion layer including the porous layer and the adhesive.
  • a second method for manufacturing a battery module of the present invention solving the above described problem includes:
  • a preparing step of preparing a battery cell and a holder having a battery retention section with a hole an adhesion layer-forming step of forming an adhesion layer on an outer circumferential surface of the battery cell; and an insertion step of inserting the battery cell in the battery retention section of the holder, wherein
  • a deformable porous layer is formed in a first area which is a part of the outer circumferential surface of the battery cell, and
  • an adhesive layer including an adhesive is formed on a second area located adjacent to the first area and on a back side thereof in an insertion direction for the battery cell to form an adhesion layer including the porous layer and the adhesive.
  • a battery module of the present invention solving the above described problem includes:
  • a holder having a battery retention section with a hole; a battery cell inserted in the battery retention section of the holder; and an adhesion part interposed between the holder and the battery cell, wherein
  • the adhesion part includes a porous layer, and an adhesive at least partially impregnating the porous layer.
  • the adhesive can sufficiently fill the gap between the battery retention section of the holder and the battery cell.
  • the battery module of the present invention has the gap between the battery retention section of the holder and the battery cell filled sufficiently with the adhesive.
  • FIG. 1 is a perspective view schematically showing a battery module of Example 1;
  • FIG. 2 is an exploded perspective view schematically showing the battery module of Example 1;
  • FIG. 3 is a cross sectional view schematically showing the battery module of Example 1 cut at X-X position in FIG. 1 ;
  • FIG. 4 is an illustrative diagram schematically showing an adhesion layer-forming step of the manufacturing method of Example 1;
  • FIG. 5 is an illustrative diagram schematically showing an insertion step of the manufacturing method of Example 1;
  • FIG. 6 is an illustrative diagram schematically showing an adhesion layer-forming step of a manufacturing method of Example 2;
  • FIG. 7 is an illustrative diagram schematically showing an insertion step of the manufacturing method of Example 2.
  • FIG. 8 is an illustrative diagram schematically showing an adhesion layer-forming step of a manufacturing method of Example 3.
  • FIG. 9 is an illustrative diagram schematically showing an insertion step of the manufacturing method of Example 3.
  • a numeric value range of “x to y” described in the present specification includes, in a range thereof, a lower limit “x” and an upper limit “y.”
  • a numeric value range can be formed by arbitrarily combining such upper limit values, lower limit values, and numerical values described in embodiments.
  • numerical values arbitrarily selected within the numeric value range can be used as upper limit and lower limit numerical values.
  • Example 1 relates to the first method for manufacturing the battery module of the present invention.
  • FIG. 1 is a perspective view schematically showing a battery module of Example 1.
  • FIG. 2 is an exploded perspective view of the battery module of Example 1 shown in FIG. 1 .
  • FIG. 3 is a cross sectional view schematically showing the battery module of the Example 1 cut at X-X position in FIG. 1 .
  • FIG. 4 is an illustrative diagram schematically showing an adhesion layer-forming step of the manufacturing method of Example 1.
  • FIG. 5 is an illustrative diagram schematically showing an insertion step of the manufacturing method of Example 1.
  • up, down, left, right, front, and back respectively refer to up, down, left, right, front, and back shown in FIG. 1 .
  • an axial direction Y of a battery cell refers to up-down direction shown in FIG. 1 .
  • the axial direction Y of a member other than a battery cell refers to a direction that matches the axial direction Y in an assembled state shown in FIG. 1 .
  • an insertion direction for a battery cell refers to a direction that matches the axial direction Y.
  • the method for manufacturing the battery module of Example 1 is a method for manufacturing a battery module having battery cells 1 , adhesion parts 42 , and a holder 5 (cf., FIGS. 1 and 2 ).
  • each of the battery cells 1 is inserted in a penetration hole of a battery retention section 50 of the holder 5 .
  • each of the adhesion parts 42 is a layer including a porous layer 40 and a solidified adhesive, and is interposed between an inner circumferential surface 51 of a battery retention section 50 and an outer circumferential surface 11 of each of the battery cells 1 to bind the two.
  • the method for manufacturing the battery module of Example 1 includes a preparing step, an adhesion layer-forming step, and an insertion step.
  • the battery cells 1 and the holder 5 are prepared.
  • the battery cells 1 are substantially columnar, and each of the battery retention sections 50 of the holder 5 has a penetration hole with a slightly larger diameter than the outer diameter of each of the battery cells 1 .
  • each of the battery cells 1 has a portion disposed inside the battery retention section 50 in the holder 5 , and other portions, i.e., portions disposed outside the battery retention section 50 .
  • each of the outer circumferential surfaces 11 of the battery cells 1 has an area (referred to as binding area Z) facing the inner circumferential surface 51 of the battery retention section 50 of the holder 5 , and other areas.
  • a binding area Z is formed of an area that is a part of the outer circumferential surface 11 of each of the battery cells 1 in the axial direction Y.
  • the binding area Z is continuously formed on the whole circumference in the circumferential direction of each of the battery cells 1 .
  • a gap between the inner circumferential surface 51 of the battery retention section 50 and the outer circumferential surface 11 of each of the battery cells 1 is referred to as an adhesion space 20 .
  • the porous layer 40 which is cylindrical, is disposed on the outer circumferential surface 11 of each of the battery cells 1 .
  • the porous layer 40 is formed by winding, around the outer circumferential surface 11 of each of the battery cells 1 , a sponge tape obtained by laminating an adhesive layer (not shown) for tapes on the back surface of a tape made from sponge.
  • the tape of the porous layer 40 i.e., the sponge portion, is made of an open-cell type foamed urethane resin and is elastically deformable.
  • the porous layer 40 is impregnated with a fluid adhesive.
  • the method for impregnating the porous layer 40 with the adhesive is not particularly limited, and a known method may be appropriately selected depending on the type of the adhesive, and the diameter of the fine pores of the porous layer 40 , etc.
  • the porous layer 40 can be impregnated with the adhesive by simply applying the adhesive on the porous layer 40 .
  • the porous layer 40 can be impregnated with the adhesive by disposing the porous layer 40 on each of the battery cells 1 , applying the adhesive on the surface of the porous layer 40 , and placing each of the battery cells 1 in a reduced pressure atmosphere such as in a vacuum chamber.
  • the method for impregnating the porous layer 40 with the adhesive is not limited to those described above, and various methods may be used.
  • an adhesion layer 4 formed of the porous layer 40 and the adhesive can be formed on the outer circumferential surface 11 of each of the battery cells 1 .
  • the adhesion layer 4 obtained by impregnating the porous layer 40 with the adhesive is formed.
  • Each of the adhesion parts 42 of the battery module of Example 1 is formed when the adhesion layer 4 is left still and solidified.
  • the outer diameter of the adhesion layer 4 before insertion is larger than the hole diameter of the battery retention section 50 of the holder 5 .
  • the thickness of the adhesion layer 4 at this moment is larger than the distance between the outer circumferential surface 11 of each of the battery cells 1 and the inner circumferential surface 51 of the battery retention section 50 in the assembled state.
  • an outer circumferential surface 41 of the cylindrical adhesion layer 4 is positioned outward in the radial direction from the inner circumferential surface 51 of the battery retention section 50 .
  • the internal diameter of the substantially cylindrical adhesion layer 4 is smaller than the hole diameter of the battery retention section 50 .
  • the inner circumferential surface of the adhesion layer 4 is positioned inward in the radial direction from the inner circumferential surface 51 of the battery retention section 50 .
  • the thickness of the porous layer 40 is about 1.0 to 2.0 mm, and the thickness of the adhesion layer 4 is about 0.4 to 1.0 mm.
  • the width of the adhesion space 20 is about 0.1 to 0.4 mm.
  • the difference between the thickness of the adhesion layer 4 and the width of the adhesion space 20 is about 0 to 0.4 mm.
  • the thickness of the porous layer 40 and the thickness of the adhesion layer 4 both refer to an average of thicknesses of each of the layers, and the width of the adhesion space 20 refers to an average of the distance between the outer circumferential surface 11 of each of the battery cells 1 and the inner circumferential surface 51 of the battery retention section 50 .
  • each of the battery cells 1 having the adhesion layer 4 formed thereon is aligned with the battery retention section 50 of the holder 5 using respective axes, and each of the battery cells 1 is inserted in the battery retention section 50 .
  • the battery cells 1 are moved along the axial direction Y with respect to the holder 5 that is fixed, and, as shown in the central portion in FIG. 5 , the battery cells 1 are inserted in the respective battery retention sections 50 .
  • the battery cells 1 have moved relative to the holder 5 upward from below in FIG. 1 .
  • the adhesion layer 4 is disposed on the outer circumferential surface 11 of each of the battery cells 1 .
  • the thickness of the adhesion layer 4 is larger than the width of the adhesion space 20 .
  • the adhesion layer 4 includes the porous layer 40 having a large number of fine pores, and the porous layer 40 is deformable.
  • the porous layer 40 in the adhesion layer 4 is deformed and is pressed toward the adhesion space 20 . Since the porous layer 40 can retain its own shape by itself, the porous layer 40 penetrates the adhesion space 20 as a whole while being accompanied by a certain degree of compressive deformation as shown in the central portion in FIG. 5 .
  • one portion of the adhesive impregnating the fine pores of the porous layer 40 leaks outside the porous layer 40 , and moves to the surface of the porous layer 40 , i.e., the surface of the adhesion layer 4 .
  • the adhesive is a fluid and can deform more easily than the porous layer 40 and the battery retention section 50 , the adhesive functions as a lubricant for the porous layer 40 .
  • the porous layer 40 since the porous layer 40 is able to retain shape, the porous layer 40 functions as a pressing material for applying and spreading the adhesive.
  • the adhesive held in the porous layer 40 also penetrates the adhesion space 20 , the adhesive is applied and spread within the adhesion space 20 along the inner circumferential surface 51 of the battery retention section 50 , and the porous layer 40 further advances forward in the insertion direction due to lubricative action of the adhesive. In this manner, the adhesion layer 4 fills the adhesion space 20 without leaving any gaps.
  • a complex formed of the battery cells 1 , the holder 5 , and the adhesion layers 4 and obtained when the battery cells 1 are inserted in the battery retention section 50 and the adhesion space 20 is filled with the adhesion layer 4 , is left still to enable the liquid adhesive to harden into a solid state to obtain the battery module of Example 1 including the adhesion parts 42 , the battery cells 1 , and the holder 5 .
  • the length of the porous layer 40 in the axial direction after the insertion step is substantially identical to the length of the binding area Z in the axial direction, and the length of the adhesion parts 42 in the battery module in the axial direction is also substantially identical to the length of the binding area Z in the axial direction.
  • the adhesion layer 4 being formed of two elements, i.e., the porous layer 40 and the adhesive, and causing the porous layer 40 and the adhesive to affect each other in the insertion step; the battery module in which the adhesion layer 4 sufficiently fills the gap between the battery retention section 50 of the holder 5 and each of the battery cells 1 can be manufactured easily.
  • the adhesion layer 4 including the porous layer 40 and the adhesive fills the gap between the battery retention section 50 of the holder 5 and each of the battery cells 1 , and an excellent adhesive strength is obtained for each of the adhesion parts 42 formed through solidification of the adhesion layer 4 .
  • the manufacturing method of the present invention is achieved as long as, as described above, the porous layer 40 is deformable, and the adhesive has a fluidity higher than the porous layer 40 and is more easily deformed than the porous layer 40 .
  • the porous layer 40 is a deformable solid and the adhesive is a fluid.
  • the solid porous layer 40 does not break even when being deformed, and the fluid adhesive has fluidity and conforms to the shape of a counterpart.
  • the porous layer 40 is disposed over the whole circumference of the outer circumferential surface 11 of each of the battery cells 1 ; in the adhesion layer-forming step of the manufacturing method of the present invention, the porous layer 40 does not have to be disposed over the whole circumference of the outer circumferential surface 11 of each of the battery cells 1 .
  • the porous layer 40 may be provided with one or more slits extending in the axial direction Y. In this case, when the amount of deformation of the porous layer 40 is sufficiently large and the width of the slit is sufficiently small, the slit closes at the insertion step when the porous layer 40 deforms. Since the adhesive follows the porous layer 40 and fills the slit, the adhesion layer 4 is formed practically on the whole circumference of the outer circumferential surface 11 of each of the battery cells 1 .
  • the adhesive preferably impregnates the whole porous layer 40
  • a portion not impregnated with the adhesive may partially exist in the porous layer 40 at the adhesion layer-forming step.
  • the part of the porous layer 40 not impregnated with the adhesive at the adhesion layer-forming step may also be provided with the adhesive at the insertion step depending on the amount of deformation of the porous layer 40 .
  • the adhesion layer 4 preferably contains a large amount of the adhesive, and the adhesive preferably impregnates the porous layer 40 at a level where the surface of the porous layer 40 is soaked at the adhesion layer-forming step.
  • the porous layer 40 is elastically deformable in the manufacturing method of Example 1; the manufacturing method of the present invention is achieved as long as the porous layer 40 is deformable and may deform plastically.
  • the porous layer 40 which has elastically deformed due to being pressed against the inner circumferential surface 51 of the battery retention section 50 and/or the insertion edge 52 of the holder 5 at the insertion step, fills the adhesion space 20 because of its own elasticity.
  • the adhesive that has leaked from the porous layer 40 at the time of deformation is absorbed again by the porous layer 40 when the porous layer 40 returns to its original shape through elasticity.
  • the adhesion space 20 is filled with the porous layer 40 holding the adhesive sufficiently, i.e., the adhesion layer 4 .
  • the adhesive absorbed by the porous layer 40 again, leakage of the adhesive from the battery cells 1 at an end in the axial direction Y can be suppressed.
  • loss of the adhesive can be suppressed, and formation of an insulation part by any leaked adhesive near an end of any one of the battery cells 1 , i.e., near a terminal section of one of the battery cells 1 , in the axial direction Y can be suppressed.
  • the porous layer 40 may be electrically conductive as long as the porous layer 40 does not touch the terminal section, obviously, the porous layer 40 is preferably electrically insulative.
  • materials for the electrically insulative porous layer 40 include resins, rubbers, elastomers, and glass fibers, etc. These materials may be formed into a three dimensional shape of, for example, a sponge, a nonwoven fabric, a woven fabric, a net, a coil, and/or a brush to be used as the porous layer 40 .
  • the number, shape, and degree of porosity of the fine pores in the porous layer 40 are not particularly limited.
  • the porous layer 40 is preferably an open-cell type, considering the porous layer 40 is to be impregnated with the adhesive.
  • An open-cell type porous layer 40 refers to a porous layer 40 whose fine pores are interconnected cells, and, more specifically, refers to a porous layer 40 in which at least one portion of fine pores are communicatively connected with each other to form penetration holes.
  • a closed-cell type porous layer 40 refers to a porous layer 40 whose fine pores are isolated cells, and, more specifically, refers to a porous layer 40 in which fine pores are independent from each other and are not communicatively connected.
  • the porous layer 40 used in the first method for manufacturing the battery module has to be an open-cell type.
  • the porous layer 40 used in the second method for manufacturing the battery module may be an open-cell type or a closed-cell type, but an open-cell type is preferable.
  • the average pore size of the fine pores in the porous layer 40 is preferably not smaller than 100 ⁇ m and more preferably not smaller than 1000 ⁇ m.
  • the average pore size can be measured with a nitrogen gas adsorption method.
  • an angle of contact with respect to the porous layer 40 before solidification is preferably small. Specifically the angle of contact is preferably not larger than 30° and more preferably not larger than 15°.
  • a battery module of Example 1 is obtained through the method for manufacturing a battery module of Example 1. As shown in FIGS. 1 and 2 , the battery module of Example 1 includes the battery cells 1 , the adhesion parts 42 , the holder 5 , a separator 90 , and bus bars 91 .
  • the battery module of Example 1 holds sixteen of the battery cells 1 .
  • the battery cells 1 are cylindrical cells having substantially the same shape, and each have terminals 19 (positive electrode terminal and negative electrode terminal) on both ends in the axial direction Y.
  • the holder 5 has a substantially plate-like shape, and holds sixteen of the battery retention sections 50 .
  • Each of the battery retention sections 50 is formed with a penetration hole, and the internal diameter of each of the battery retention sections 50 is slightly larger than the outer diameter of each of the battery cells 1 .
  • the battery cells 1 are inserted in the respective battery retention sections 50 .
  • four of the battery cells 1 are connected in series by one of the bus bars 91 as one set.
  • a conductive material layer which is not shown in the figures, is disposed between the bus bars 91 and the battery cells 1 .
  • the conductive material layer is a layer for electrically connecting the bus bars 91 and the terminals 19 of the battery cells 1 .
  • the shape of the conductive material layer is not particularly limited, and may be formed using a known method such as tab welding, wire bonding, and brazing, etc.
  • the separator 90 is locally interposed between the bus bars 91 and the battery cells 1 .
  • the separator 90 is a member for connecting the battery cells 1 through the bus bars 91 while preventing short circuiting by partially blocking electric connection between the battery cells 1 and the bus bars 91 .
  • the separator 90 may be formed of an insulating material, and is made of an insulation resin in the present example.
  • Each of the adhesion parts 42 is a layer that is formed of the hardened adhesive and the porous layer 40 , interposed between the inner circumferential surface 51 of the battery retention section 50 formed on the holder 5 and the outer circumferential surface 11 of each of the battery cells 1 , and bound to the inner circumferential surface 51 of the battery retention section 50 and the outer circumferential surface 11 of each of the battery cells 1 .
  • each of the adhesion parts 42 has a two-phase structure formed of the porous layer 40 and the adhesive impregnating the porous layer 40 .
  • the adhesive is dispersed in a matrix formed by the porous layer 40 .
  • each of the adhesion part 42 is disposed throughout the whole binding area Z of each of the battery cells 1 .
  • each of the adhesion parts 42 is interposed between the outer circumferential surface 11 of each of the battery cells 1 and the inner circumferential surface 51 of the battery retention section 50 over the whole circumference of each of the battery cells 1 .
  • each of the adhesion parts 42 in Example 1 has a substantially cylindrical shape as shown in FIG. 2 .
  • the inner circumferential surface of each of the adhesion parts 42 is in contact with the outer circumferential surface 11 of each of the battery cells 1
  • the outer circumferential surface 41 of each of the adhesion parts 42 is in contact with the inner circumferential surface 51 of the battery retention section 50 .
  • each of the adhesion parts 42 is spread throughout the gap between the outer circumferential surface 11 of each of the battery cells 1 and the inner circumferential surface 51 of the battery retention section 50 , and is loaded over the whole circumference in the circumferential direction and the full length in the axial direction without leaving any gaps.
  • Example 2 relates to the second method for manufacturing the battery module of the present invention.
  • a manufacturing method of Example 2 is roughly identical to the manufacturing method of Example 1 except for the adhesion layer-forming step.
  • a battery module of Example 2 is roughly identical to the battery module of Example 1 except for the adhesion layer.
  • the preparing step and the cell binding step in the manufacturing method of Example 2 are roughly identical to those in the manufacturing method of Example 1.
  • FIG. 6 is an illustrative diagram schematically showing the adhesion layer-forming step of the manufacturing method of Example 2.
  • FIG. 7 is an illustrative diagram schematically showing the insertion step of the manufacturing method of Example 2.
  • a porous layer 40 whose length in the axial direction is smaller than that of Example 1 is formed on the outer circumferential surface 11 of each of the battery cells 1 , and this porous layer 40 is impregnated with the same adhesive as in Example 1.
  • An area where the porous layer 40 is formed on the outer circumferential surface 11 of each of the battery cells 1 is referred to as a first area I.
  • the first area I is an area located forward in the insertion direction on the outer circumferential surface 11 of each of the battery cells 1 .
  • an adhesive having a higher viscosity than the adhesive impregnating the porous layer 40 is applied to form the adhesive layer.
  • the adhesive having a high viscosity can also be rephrased as “an adhesive capable of maintaining a relative position between a battery cell and holder to enable easy retention of shape also in the insertion step,” or “an adhesive having low fluidity compared to a low viscosity adhesive.”
  • “low viscosity adhesive” can also be rephrased as “an adhesive capable of functioning as a lubricant at the insertion step,” or “an adhesive having high fluidity compared to a high viscosity adhesive.”
  • the adhesive forming the adhesive layer is referred to as a high viscosity adhesive
  • the adhesive impregnating the porous layer 40 is referred to as a low viscosity adhesive.
  • a layer including the porous layer 40 and the adhesive impregnating the porous layer 40 is referred to as a front part 45
  • a layer including a high viscosity adhesive is referred to as a back part 46 .
  • the adhesion layer 4 is formed from the front part 45 and the back part 46 .
  • the back part 46 in the manufacturing method of Example 2 corresponds to the adhesive layer in the manufacturing method of the present invention.
  • the front part 45 is, except for its length in the axial direction, roughly identical to the adhesion layer 4 in the manufacturing method of Example 1.
  • the thickness of the front part 45 and the thickness of the back part 46 are substantially identical, and these thicknesses are substantially identical to the thickness of the adhesion layer 4 in Example 1.
  • An insertion-direction front edge 47 of the back part 46 is in contact with an insertion-direction back edge 48 of the front part 45 .
  • the front part 45 and the back part 46 are both disposed over the whole circumference of the outer circumferential surface 11 of each of the battery cells 1 .
  • the outer circumferential surface of the front part 45 and the outer circumferential surface of the back part 46 having a cylindrical shape are positioned outward in the radial direction from the inner circumferential surface 51 of the battery retention section 50 .
  • the thickness of the porous layer 40 is about 1.0 to 2.0 mm
  • the thickness of the adhesion layer 4 is about 0.4 to 1.0 mm.
  • the width of the adhesion space 20 is about 0.1 to 0.4 mm. The difference between the thickness of the adhesion layer 4 and the width of the adhesion space 20 is about 0 to 0.4 mm.
  • each of the battery cells 1 having the adhesion layer 4 formed thereon is aligned with the battery retention section 50 of the holder 5 using respective axes, and each of the battery cells 1 is inserted in the battery retention section 50 .
  • the thickness of the adhesion layer 4 disposed on the outer circumferential surface 11 of each of the battery cells 1 is larger than the width of the adhesion space 20 .
  • the front part 45 that forms the forward portion of the adhesion layer 4 in the insertion direction includes, similarly to the adhesion layer 4 of Example 1, the deformable porous layer 40 , and an adhesive having a higher fluidity than the porous layer 40 and capable of deforming easier than the porous layer 40 .
  • the front part 45 penetrates, similarly to the adhesion layer 4 of Example 1, the adhesion space 20 without leaving any gaps through interaction between the porous layer 40 and the adhesive.
  • the back part 46 located adjacent to the front part 45 does not include the porous layer 40 , the back part 46 is drawn by the front part 45 and penetrates the adhesion space 20 .
  • the adhesive included in the back part 46 is a high viscosity adhesive whose viscosity is higher than that of the low viscosity adhesive included in the front part 45 , similarly to the porous layer 40 of the front part 45 , the back part 46 slides into the adhesion space 20 through lubricative action of the low viscosity adhesive, and applies and spreads the low viscosity adhesive over the inner circumferential surface 51 of the battery retention section 50 . As a result, similarly to the front part 45 , the back part 46 also fills the adhesion space 20 without leaving any gaps. Thus, at the insertion step, the adhesion layer 4 fills the adhesion space 20 without leaving any gaps over the whole circumference in the circumferential direction and the full length in the axial direction.
  • the battery module in which the adhesion layer 4 sufficiently fills the gap between the battery retention section 50 of the holder 5 and each of the battery cells 1 can be manufactured easily.
  • the ratio of the length of the front part 45 in the axial direction with respect to the length of the back part 46 in the axial direction is not particularly limited, as long as the shape of the front part 45 can be sufficiently retained.
  • the viscosities before the adhesion layer-forming step and after the insertion step are not particularly limited.
  • Example 2 although the back part 46 includes the high viscosity adhesive and the front part 45 includes the low viscosity adhesive; the adhesive included in the back part 46 and the adhesive included in the front part 45 may be the same. In addition, the adhesive included in the front part 45 may be the high viscosity adhesive and the adhesive included in the back part 46 may be the low viscosity adhesive.
  • the front part 45 penetrates the adhesion space 20 based on interaction between the porous layer 40 and the adhesive, and the back part 46 in contact with the front part 45 is also drawn into the adhesion space 20 by the front part 45 ; the adhesion space 20 is filled with the adhesion layer 4 without leaving any gaps over the whole circumference in the circumferential direction and the full length in the axial direction.
  • the front part 45 and the back part 46 are preferably disposed so as to make contact with each other at the adhesion layer-forming step, for example, the front part 45 and the back part 46 may be slightly spaced at the adhesion layer-forming step. In this case, when the front part 45 that has deformed at the insertion step and has swelled at the back in the insertion direction makes contact with the back part 46 , the back part 46 is drawn by the front part 45 and penetrates the adhesion space 20 similarly.
  • An adhesive in the present invention refers to a composition that can change from a fluid into a solid, and can bind, when changing from a fluid into a solid, at least the outer circumferential surface 11 of each of the battery cells 1 and the inner circumferential surface 51 of the battery retention section 50 .
  • the adhesive may be a fluid at the insertion step, i.e., when each of the battery cells 1 is being inserted in the battery retention section 50 .
  • any adhesive may be used as long as, at the cell binding step, i.e., after each of the battery cells 1 is inserted in the battery retention section 50 , the adhesive can harden because of a chemical reaction, evaporation of a solvent, or the like, change into a solid from a fluid, and bind the inner circumferential surface 51 of the battery retention section 50 and the outer circumferential surface 11 of each of the battery cells 1 .
  • a fluid refers to a state of capable of flowing, and is a concept including forms such as liquid, gel, sol, and slurry.
  • Specific examples of the adhesive include reactive-type adhesives, solvent based adhesives, emulsion adhesives, hot-melt adhesives, and synthetic rubber based adhesives, etc.
  • any high viscosity adhesive can be used as long as the high viscosity adhesive has a higher viscosity than that of the low viscosity adhesive, and the high viscosity adhesive and the low viscosity adhesive may be formed from different materials, or may be formed from the same material.
  • the viscosity of the adhesive can be adjusted using various methods. For example, the viscosity can be adjusted by appropriately setting molecular weights of resin components such as oligomers and polymers included in the adhesive. Generally, a resin component with a low molecular weight is regarded to have low viscosity when compared to a resin component with a high molecular weight. Alternatively the viscosity of the adhesive can be adjusted by blending various fillers to the adhesive.
  • the viscosity of the adhesive can also be adjusted by appropriately setting the type and amount of the filler.
  • the viscosity of the adhesive is generally said to increase as the blended amount of the filler increases.
  • the viscosity of the adhesive can be adjusted by appropriately adjusting the blending ratio of the solvent or dispersion medium (i.e., solid content concentration of the adhesive). The viscosity of the adhesive increases when the solid content concentration is higher.
  • the viscosity of the adhesive can also be adjusted by appropriately changing the mixing ratio of a main agent and a curing agent, and the type of the main agent and/or the curing agent.
  • the battery module of Example 2 obtained by the manufacturing method of Example 2 is roughly identical to the battery module of Example 1 except for the adhesion parts 42 , and is largely different from the battery module of Example 1 regarding that the porous layer 40 exists only at the front part 45 and the porous layer 40 does not exist at the back part 46 .
  • Example 3 relates to the second method for manufacturing the battery module of the present invention.
  • a manufacturing method of Example 3 is also roughly identical to the manufacturing method of Example 1 except for the adhesion layer-forming step.
  • a battery module of Example 3 is roughly identical to the battery module of Example 1 except for the adhesion part.
  • FIG. 8 is an illustrative diagram schematically showing the adhesion layer-forming step of the manufacturing method of Example 3.
  • FIG. 9 is an illustrative diagram schematically showing the insertion step of the manufacturing method of Example 3.
  • a porous layer 40 whose length in the axial direction is shorter than that of Example 2 is formed at the first area I on the outer circumferential surface 11 of each of the battery cells 1 , and the porous layer 40 is not impregnated with the adhesive.
  • the high viscosity adhesive identical to that in Example 2 is applied on the second area II to form an adhesive layer.
  • the front part 45 does not include the adhesive
  • the length L 1 of the front part 45 in the axial direction is shorter than that in Example 2
  • the length L 2 of the back part 46 in the axial direction is longer than that in Example 2.
  • a sum of the length L 1 of the front part 45 in the axial direction and the length L 2 of the back part 46 in the axial direction, i.e., the length of the adhesion layer 4 in the axial direction, is identical to that in Example 2.
  • the thickness of the adhesion layer 4 is also identical to that in Example 2.
  • the insertion-direction front edge 47 of the back part 46 is in contact with the insertion-direction back edge 48 of the front part 45 .
  • the front part 45 and the back part 46 are both disposed over the whole circumference of the outer circumferential surface 11 of each of the battery cells 1 .
  • the outer circumferential surface of the front part 45 and the outer circumferential surface of the back part 46 having a cylindrical shape are positioned outward in the radial direction from the inner circumferential surface 51 of the battery retention section 50 .
  • the thickness of the porous layer 40 is about 1.0 to 2.0 mm
  • the thickness of the adhesion layer 4 is about 0.4 to 1.0 mm.
  • the width of the adhesion space 20 is about 0.1 to 0.4 mm. The difference between the thickness of the adhesion layer 4 and the width of the adhesion space 20 is about 0 to 0.4 mm.
  • each of the battery cells 1 having the adhesion layer 4 formed thereon is aligned with the battery retention section 50 of the holder 5 using respective axes, and each of the battery cells 1 is inserted in the battery retention section 50 .
  • the thickness of the adhesion layer 4 disposed on the outer circumferential surface 11 of each of the battery cells 1 is larger than the width of the adhesion space 20 .
  • the front part 45 of the adhesion layer 4 consists only of the deformable porous layer 40 .
  • the porous layer 40 penetrates the adhesion space 20 without leaving any gaps by its own shape retention force.
  • the back part 46 located adjacent to the front part 45 does not include the porous layer 40 ; similarly to Example 2, the back part 46 is drawn by the front part 45 and penetrates the adhesion space 20 . Since the back part 46 includes the adhesive, the back part 46 slides in the adhesion space 20 through its own lubricative action and the adhesive is applied and spread over the inner circumferential surface 51 of the battery retention section 50 .
  • the insertion-direction front edge 47 of the back part 46 being in contact with the front part 45 can be rephrased as the back part 46 being adhered to the front part 45 .
  • the back part 46 is drawn by the front part 45 as a whole and fills the adhesion space 20 without leaving any gaps.
  • the adhesion space 20 is filled with the adhesion layer 4 without leaving any gaps over the whole circumference in the circumferential direction and the full length in the axial direction.
  • the length L 2 of the back part 46 in the axial direction is set to be larger than the length L 1 of the front part 45 in the axial direction.
  • the ratio of the length L 2 of the back part 46 in the axial direction with respect to the length L 1 of the front part 45 in the axial direction is not particularly limited in the manufacturing method of the present invention.
  • the length L 2 of the back part 46 in the axial direction may be smaller than the length L 1 of the front part 45 in the axial direction.
  • the length L 2 of the back part 46 in the axial direction is set to be larger than the length L 1 of the front part 45 in the axial direction in order to increase the proportion of the adhesive in the adhesion layer 4 and increase the adhesive strength of the adhesion layer 4 .
  • the length L 2 of the back part 46 in the axial direction is preferably larger than the length L 1 of the front part 45 in the axial direction. More specifically, the length L 2 of the back part 46 in the axial direction is preferably at least two times, more preferably three times, larger than the length L 1 of the front part 45 in the axial direction.
  • the porous layer 40 used in the manufacturing method of Example 3 does not have to be impregnated with the adhesive.
  • a closed-cell type porous layer 40 can be used.
  • the adhesive included in the back part 46 adheres to the front part 45 at a boundary portion with respect to the back part 46 .
  • fine pores having an opening at the boundary portion are impregnated with the adhesive.
  • at least one portion of the front part 45 can be considered to be impregnated with the adhesive.
  • the front part 45 is preferably adhered to the back part 46 firmly at the adhesive layer-forming step.
  • the surface area of the front part 45 at a boundary portion with respect to the back part 46 is preferably large, and the front part 45 is preferably formed of the porous layer 40 that is an open-cell type.
  • the front part 45 is formed from the porous layer 40 that is an open-cell type, the whole front part 45 is in some cases impregnated with the adhesive at the insertion step, depending on the viscosity of the adhesive, and the ratio of lengths of the front part 45 and the back part 46 in the axial direction, etc.
  • the battery module of Example 3 obtained by the manufacturing method of Example 3 is roughly identical to the battery module of Example 2 except for the adhesion parts 42 , but is largely different from the battery module of Example 2 regarding the adhesive almost not existing at the front part 45 .
  • the battery module of the present invention is not particularly limited in terms of its use application, and can be disposed in various devices and equipment, etc. Specific examples thereof include assembled batteries to be mounted on vehicles.
  • the method for manufacturing the battery module of the present invention can be expressed as described in the following.
  • a method for manufacturing a battery module including: a preparing step of preparing a battery cell 1 and a holder 5 having a battery retention section 50 with a hole; an adhesion layer-forming step of forming an adhesion layer 4 on an outer circumferential surface 11 of the battery cell 1 ; and an insertion step of inserting the battery cell 1 in the battery retention section 50 of the holder 5 , wherein
  • a deformable porous layer 40 is formed on the outer circumferential surface 11 of the battery cell 1 and the porous layer 40 is impregnated with an adhesive to form an adhesion layer including the porous layer and the adhesive.
  • a method for manufacturing a battery module including: a preparing step of preparing a battery cell 1 and a holder 5 having a battery retention section 50 with a hole; an adhesion layer-forming step of forming an adhesion layer 4 on an outer circumferential surface 11 of the battery cell 1 ; and an insertion step of inserting the battery cell 1 in the battery retention section 50 of the holder 5 , wherein
  • a deformable porous layer 40 is formed in a first area I which is a part of the outer circumferential surface 11 of the battery cell 1 , and
  • an adhesion layer including an adhesive is formed on a second area II located adjacent to the first area I and on a back side thereof in an insertion direction for the battery cell 1 to form an adhesive layer including the porous layer and the adhesive.
  • the adhesion layer 4 is formed on a whole circumference of the outer circumferential surface 11 of the battery cells 1 .
  • a battery module including: a holder 5 having a battery retention section 50 with a hole; a battery cell 1 inserted in the battery retention section 50 of the holder 5 ; and an adhesion part 42 interposed between the holder 5 and the battery cell 1 , wherein
  • the adhesion part 42 includes a porous layer 40 , and an adhesive impregnating at least one part of the porous layer 40 .

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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)
  • Battery Mounting, Suspending (AREA)
  • Cell Separators (AREA)
US14/989,834 2015-03-16 2016-01-07 Battery module and method for manufacturing same Abandoned US20160276637A1 (en)

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US11217839B2 (en) 2018-02-12 2022-01-04 Airbus Defence and Space GmbH Battery arrangement for structurally integrating batteries in a vehicle
US11302979B2 (en) * 2018-02-12 2022-04-12 Airbus Defence and Space GmbH Battery arrangement for the structural integration of batteries in a vehicle
US11316224B2 (en) 2018-03-22 2022-04-26 Airbus Defence and Space GmbH Battery arrangement for the load-bearing structural integration of batteries into a vehicle

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KR20220072503A (ko) * 2020-11-25 2022-06-02 삼성에스디아이 주식회사 이차 전지

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US11217839B2 (en) 2018-02-12 2022-01-04 Airbus Defence and Space GmbH Battery arrangement for structurally integrating batteries in a vehicle
US11302979B2 (en) * 2018-02-12 2022-04-12 Airbus Defence and Space GmbH Battery arrangement for the structural integration of batteries in a vehicle
US11316224B2 (en) 2018-03-22 2022-04-26 Airbus Defence and Space GmbH Battery arrangement for the load-bearing structural integration of batteries into a vehicle

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US20180248158A1 (en) 2018-08-30
CN105990540A (zh) 2016-10-05
DE102016001636B4 (de) 2022-03-17
US10847768B2 (en) 2020-11-24
JP2016173903A (ja) 2016-09-29
DE102016001636A1 (de) 2016-09-22
JP6394448B2 (ja) 2018-09-26

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