US20240021860A1 - Pack case, battery pack, and method for manufacturing pack case - Google Patents
Pack case, battery pack, and method for manufacturing pack case Download PDFInfo
- Publication number
- US20240021860A1 US20240021860A1 US18/366,797 US202318366797A US2024021860A1 US 20240021860 A1 US20240021860 A1 US 20240021860A1 US 202318366797 A US202318366797 A US 202318366797A US 2024021860 A1 US2024021860 A1 US 2024021860A1
- Authority
- US
- United States
- Prior art keywords
- metal plate
- wall
- lateral
- stacking direction
- side wall
- 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.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims description 17
- 238000004519 manufacturing process Methods 0.000 title claims description 15
- 229910052751 metal Inorganic materials 0.000 claims abstract description 505
- 239000002184 metal Substances 0.000 claims abstract description 505
- 238000003825 pressing Methods 0.000 claims abstract 4
- 229920005989 resin Polymers 0.000 claims description 88
- 239000011347 resin Substances 0.000 claims description 88
- 238000005452 bending Methods 0.000 claims description 37
- 238000001746 injection moulding Methods 0.000 claims description 16
- 238000000465 moulding Methods 0.000 claims description 2
- 238000012986 modification Methods 0.000 description 54
- 230000004048 modification Effects 0.000 description 54
- 230000006835 compression Effects 0.000 description 28
- 238000007906 compression Methods 0.000 description 28
- 238000006243 chemical reaction Methods 0.000 description 7
- 229910052782 aluminium Inorganic materials 0.000 description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 6
- 239000004952 Polyamide Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 229920002647 polyamide Polymers 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 125000006850 spacer group Chemical group 0.000 description 5
- 229910001335 Galvanized steel Inorganic materials 0.000 description 3
- 239000008397 galvanized steel Substances 0.000 description 3
- 239000003365 glass fiber Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000000452 restraining effect Effects 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000003486 chemical etching Methods 0.000 description 1
- 239000011162 core material Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 229910001416 lithium ion Inorganic materials 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000011255 nonaqueous electrolyte Substances 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Images
Classifications
-
- 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
- H01M10/0481—Compression means other than compression means for stacks of electrodes and separators
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
- B29C45/14475—Joining juxtaposed parts of a single article, e.g. edges of a folded container blank
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14467—Joining articles or parts of a single article
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/204—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
- H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/218—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material
- H01M50/22—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by the material of the casings or racks
- H01M50/222—Inorganic material
- H01M50/224—Metals
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/233—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions
- H01M50/242—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by physical properties of casings or racks, e.g. dimensions adapted for protecting batteries against vibrations, collision impact or swelling
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/258—Modular batteries; Casings provided with means for assembling
-
- 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
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
- H01M50/505—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing comprising a single busbar
-
- 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
- H01M50/50—Current conducting connections for cells or batteries
- H01M50/502—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing
- H01M50/521—Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing characterised by the material
- H01M50/522—Inorganic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
- B29C2045/14245—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity using deforming or preforming means outside the mould cavity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3468—Batteries, accumulators or fuel cells
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/712—Containers; Packaging elements or accessories, Packages
- B29L2031/7146—Battery-cases
-
- 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
-
- 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
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Battery Mounting, Suspending (AREA)
Abstract
A pack case includes: a first wall pressing a battery stack toward a second side in a stacking direction; and a second wall pressing the battery stack toward a first side in the stacking direction. At least one of the first wall and the second wall is a panel structure wall including a first metal plate, a second metal plate located outward of the first metal plate in the stacking direction and faces the first metal plate, and an interposed member interposed between and fixed to the first metal plate and the second metal plate. The interposed member has a lower density than a metal forming the first metal plate and the second metal plate.
Description
- The disclosure of Japanese Patent Application No. 2019-021418 filed on Feb. 8, 2019 including the specification, drawings and abstract is incorporated herein by reference in its entirety.
- The present disclosure relates to a pack case that accommodates a battery stack in which a plurality of batteries are stacked, a battery pack in which the pack case houses the battery stack, and a method for manufacturing a pack case.
- As a battery pack accommodating a plurality of batteries, a battery pack may be required in which the batteries are restrained by applying in a stacking direction a predetermined compression force to a battery stack, in which the batteries are stacked. Examples of the battery pack of this type includes a battery pack in which bolts are provided to extend between end plates arranged at both ends of a battery stack in a stacking direction and fastened with nuts, and a compression force is applied to the battery stack (see, Japanese Unexamined Patent Application Publication No. 2005-339929 (JP 2005-339929 A)).
- A battery pack is also conceivable that is formed by inserting, in a pack case formed by aluminum die casting or the like to have a bottomed rectangular box shape, a battery stack compressed with a compression force larger than a desired compression force, and then, loosening the compression so that the battery stack is accommodated in the battery pack in a compressed state with the desired compression force using rigidity of the pack case.
- However, when the battery stack is restrained by using the bolts and the nuts, the size of the battery pack increases, and the weight of the battery pack as a whole increases due to the weights of the end plates, the bolts, and the like. On the other hand, the battery pack including the aluminum die-cast pack case accommodating the battery stack can be made relatively light. However, in order to maintain an appropriate compression force, the rigidity of each part must be increased by increasing a thickness of walls of the pack case. Thus, the pack case itself tends to be heavy.
- The present disclosure provides a pack case that is lightweight and can accommodate a battery stack while applying a compression force to the battery stack, a battery pack including the pack case accommodating the battery stack, and a method for manufacturing the pack case.
- A first aspect of the present disclosure relates to a pack case. The pack case accommodates a battery stack in which a plurality of batteries are stacked in a stacking direction, and compresses and restrains the battery stack in the stacking direction. The pack case includes a first wall that is located on a first side of the accommodated battery stack in the stacking direction, contacts a first end of the battery stack, and presses the battery stack toward a second side in the stacking direction, and a second wall that is located on the second side of the accommodated battery stack in the stacking direction, contacts a second end of the battery stack, and presses the battery stack toward the first side in the stacking direction. At least one of the first wall and the second wall is a panel structure wall including a first metal plate, a second metal plate, and an interposed member. The second metal plate is located outward of the first metal plate in the stacking direction and faces the first metal plate. The interposed member is interposed between the first metal plate and the second metal plate, is fixed to the first metal plate and the second metal plate, and has a density lower than that of a metal forming the first metal plate and the second metal plate.
- In the above pack case that accommodates the battery stack and compresses and restrains the battery stack in the stacking direction, at least one of the first wall and the second wall that press the battery stack in the stacking direction is the panel structure wall that includes the first metal plate, the second metal plate, and the interposed member interposed between and fixed to the first metal plate and the second metal plate, and that has a so-called sandwich panel structure. Thus, the first wall or the second wall that is the panel structure wall has higher flexural rigidity and higher torsional rigidity compared to the case where the wall is formed of only the first metal plate or the case where the wall is formed of only the first metal plate and the interposed member fixed thereto. Therefore, it is possible to suppress deformation of the panel structure wall (first wall or second wall) due to a reaction force with respect to a compression force that compresses the battery stack in the stacking direction, and thus, to suppress reduction of the compression force that compresses the battery stack in the stacking direction. Moreover, the interposed member interposed between the first metal plate and the second metal plate has the density lower than that of the metal forming the first metal plate and the second metal plate. Therefore, it is possible to make the panel structure wall lightweight compared to the case where a solid metal plate having the same thickness as the panel structure wall is used instead of the sandwich panel structure. Thus, it is also possible to make the pack case lightweight.
- The pack case may have a rectangular frame shape surrounding the battery stack from four sides, or may have a bottomed rectangular frame shape (bottomed rectangular box shape) having a bottom, for example. The pack case may have a U shape (shape of a rectangle with one open side) having no lateral side wall and having a bottom in addition to the first wall and the second wall. The first metal plate and the second metal plate forming the panel structure wall may be separate metal plates, or may be provided by bending one metal plate into a U-shape.
- As a material for the first metal plate and the second metal plate forming the panel structure wall (first wall or second wall), an appropriate metal plate may be used. Example of the material include a steel plate, a galvanized steel plate, a nickel plated steel plate, a stainless steel plate, an aluminum plate, etc.
- Further, as the interposed member, a resin material made from thermoplastic resin such as polyamide, thermosetting resin such as epoxy, fiber reinforced plastic such as glass fiber reinforced polyamide, or the like can be used. In this case, besides using a solid interposed member made from resin, the interposed member may be provided with a lightening portion such as a hole (lightening hole), in order to reduce a weight of the panel structure wall and further a weight of the pack case. Further, a foamed resin material made of urethane foam, foamed polyamide, etc., a honeycomb material for a core material, in which a metal such as aluminum or stainless steel, or resin such as polypropylene or aramid is formed in a honeycomb shape, can also be used for the interposed member. The interposed member may be formed of a single member extending over the entire panel structure wall. Alternatively, the interposed member may be formed of a plurality of members. For example, in the interposed member, a portion close to the four corners of the pack case having a rectangular frame shape and a central portion may be formed of different members.
- For fixing the interposed member to the first metal plate and the second metal plate of the panel structure wall, a primer is applied to the first metal plate and the second metal plate, to which the interposed member is fixed. Alternatively, after the first metal plate and the second metal plate are subjected to surface roughing such as chemical etching or laser processing, resin may be injected by injection molding between the first metal plate and the second metal plate to form the interposed member and bond the interposed member to the first metal plate and the second metal plate together.
- In the first aspect, the panel structure wall may include a first metal plate portion that is the first metal plate, a second metal plate portion that is the second metal plate, and a connecting portion connecting the first metal plate portion and the second metal plate portion. The first metal plate portion, the second metal plate portion and the connecting portion are formed by bending one metal plate into a U-shape.
- In the pack case, the first metal plate portion and the second metal plate portion that are the first metal plate and the second metal plate are provided by bending one metal plate into a U-shape. Therefore, it is possible to reduce the number of parts forming the pack case and to provide an inexpensive pack case. In addition, compared to the case where the first metal plate and the second metal plate are separate members, the first metal plate portion and the second metal plate portion are connected via the connecting portion (the first metal plate portion, the second metal plate portion, and the connecting portion connecting the first metal plate portion and the second metal plate portion are formed of one metal plate). Therefore, it is possible to further improve the flexural rigidity and the torsional rigidity of the panel structure wall (first wall, second wall).
- As a U-shaped bending form in the connecting portion of the metal plate, the connecting portion may have a semicircular (rounded) bending form. The connecting portion may have a bending form having the shape of a rectangle with one open side (form in which opposite ends of the flat connecting portion are bent at an angle of 90 degrees to extend in the same direction). This is because the flexural rigidity and the torsional rigidity of the panel structure wall (first wall, second wall) can be further improved by connecting the respective parts by bending at an angle of 90 degrees.
- In the first aspect, the pack case may include a third wall and a fourth wall that are each located on an outer side of the accommodated battery stack in a lateral direction orthogonal to the stacking direction, that form, together with the first wall and the second wall, a rectangular frame surrounding the battery stack from four sides, and that connects the first wall and the second wall. The third wall and the fourth wall may each include a lateral metal plate extending in the stacking direction, and the lateral metal plate may be connected to the first metal plate and the second metal plate via a corner connecting resin portion made from resin.
- In the pack case, each of the third wall and the fourth wall includes the lateral metal plate extending in the stacking direction, and the lateral metal plate is connected to the panel structure wall (first wall, second wall) via the corner connecting resin portion. Therefore, part of the reaction force with respect to a compression force applied by the panel structure wall (first wall, second wall) to the battery stack can be transmitted to the third wall and the fourth wall each including the lateral metal plate via the corner connecting resin portions to be carried by the third wall and the fourth wall as a tensile force in the stacking direction.
- The pack case may be configured such that the lateral metal plate is not directly connected to the first metal plate or the second metal plate forming the panel structure wall. That is, the pack case may be configured such that the lateral metal plate and the first and second metal plates are separate members or the lateral metal plate and the first metal plate are formed by individually bending at respective fold lines orthogonal to each other and raising upright from a bottom plate to which the lateral metal plate and the first plate are connected. Alternatively, the pack case may be configured such that one metal plate is bent so that the lateral metal plate is directly connected (continuous) to the first metal plate or the second metal plate forming the panel structure wall.
- In the pack case according to the first aspect, the lateral metal plate may have an extending portion extending outward of the first metal plate of the panel structure wall in the stacking direction, in which the panel structure wall is the first wall or the second wall. The extending portion may include a panel engagement portion that is located outward of the first metal plate in the stacking direction and inward of a lateral edge of the first metal plate in the lateral direction, and that engages with the first metal plate via the corner connecting resin portion.
- In the pack case, the panel engagement portion provided in the extending portion of the lateral metal plate is engaged with the first metal plate via the corner connecting resin portion. Thus, the lateral side wall including the lateral metal plate and the panel structure wall (first wall, second wall) can be more firmly connected, which enables the pack case to have higher rigidity and higher strength.
- Examples of the panel engagement portion include a bulging portion that is formed by bulging a part of the extending portion of the lateral metal plate in a plate thickness direction (inward in the lateral direction) so that the bulging portion is located inward of a lateral edge of the first metal plate in the lateral direction and engages with the first metal plate via the corner connecting resin portion. The examples of the panel engagement portion further include a bending protruding portion that is formed by protruding a part of the extending portion so that the bending protruding portion engages with the first metal plate via the corner connecting resin portion.
- In the pack case according to the above aspect, at least one of the third wall and the fourth wall may be a panel structure lateral side wall including the lateral metal plate, the second lateral metal plate, and a lateral interposed member. The second lateral metal plate may extend in the stacking direction and may be located outward or inward of the lateral metal plate in the lateral direction so as to face the lateral metal plate. The lateral interposed member may be interposed between the lateral metal plate and the second lateral metal plate, may be fixed to the lateral metal plate and the second lateral metal plate, and may have a density lower than that of a metal forming the lateral metal plate and the second lateral metal plate.
- In the pack case, at least one of the third wall and the fourth wall is the panel structure lateral side wall having the sandwich panel structure. The panel structure lateral side wall has high flexural rigidity and torsional rigidity, compared to the case of using a single lateral metal plate as the lateral side wall or using only the lateral metal plate and the lateral interposed member as the lateral side wall. Therefore, the rigidity and the strength of the rectangular frame-shaped pack case can be further improved.
- Here, the lateral metal plate and the second lateral metal plate may be separate metal plates, or may be formed by bending one metal plate into a U-shape for use. In addition, the sandwich panel structure composed of the lateral metal plate, the second lateral metal plate, and the lateral interposed member may be employed only in a part of the lateral side wall in the height direction that is orthogonal to the stacking direction and the lateral direction.
- In the pack case according to the first aspect, each of the third wall and the fourth wall may be the panel structure lateral side wall.
- In the pack case, each of the third wall and the fourth wall has the sandwich panel structure. Therefore, it is possible to provide the lightweight pack case having even higher rigidity.
- In the pack case according to the first aspect, each of the first wall and the second wall may be the panel structure wall.
- In the pack case, each of the first wall and the second wall has the sandwich panel structure. Therefore, it is possible to provide the lightweight pack case having even higher rigidity.
- A second aspect of the present disclosure relates to a battery pack. The battery pack includes the pack case according to the first aspect and the battery stack accommodated in the pack case so as to be compressed and restrained in the stacking direction.
- In the battery pack, at least one of the first wall and the second wall of the pack case compressing and restraining the battery stack is the panel structure wall having the sandwich panel structure with high flexural rigidity and high torsional rigidity. Therefore, it is possible to provide the battery pack that is lightweight but does not easily deform, at the first wall or the second wall that is the panel structure wall, with a reaction force to the compression force applied to the battery stack in order to compress and restrain the battery stack, while suppressing the reduction of the compression force due to deformation of the first wall or the second wall.
- A third aspect of the present disclosure relates to a method for manufacturing a pack case. The pack case accommodates a battery stack in which a plurality of batteries are stacked in a stacking direction, and compresses and restrains the battery stack in the stacking direction. The pack case includes a first wall and a second wall. The first wall is located on a first side of the accommodated battery stack in the stacking direction, contacts a first end of the battery stack, and presses the battery stack toward a second side in the stacking direction. The second wall is located on the second side of the accommodated battery stack in the stacking direction, contacts a second end of the battery stack, and presses the battery stack toward the first side in the stacking direction. At least one of the first wall and the second wall is a panel structure wall including a first metal plate, a second metal plate, and an interposed member. The second metal plate is located outward of the first metal plate in the stacking direction and faces the first metal plate. The interposed member is interposed between the first metal plate and the second metal plate, is fixed to the first metal plate and the second metal plate, and has a density lower than that of a metal forming the first metal plate and the second metal plate. The method includes: setting the first metal plate and the second metal plate in a mold; and performing an injection molding for forming the panel structure wall by charging resin between the set first metal plate and the set second metal plate and molding the interposed member.
- In the above method, the interposed member is formed by injection molding. Therefore, it is possible to easily manufacture the pack case including the panel structure wall (first wall, second wall). In the injection molding, besides using a solid interposed member made from resin, the interposed member may be provided with a lightening portion such as a lightening hole, in order to reduce the weight of the panel structure wall and further the weight of the pack case.
- The method according to the third aspect further includes, prior to the setting, bending one metal plate into a U-shape to form a first metal plate portion that is the first metal plate, a second metal plate portion that is the second metal plate, and a connecting portion connecting the first metal plate portion and the second metal plate portion.
- In the method, in the bending, the first metal plate portion that is the first metal plate and the second metal plate portion that is the second metal plate are formed by bending one metal plate into a U-shape. Thus, it is possible to reduce the number of parts of the panel structure walls, and therefore, reduce the number of parts of the pack case. Accordingly, it is possible to reduce man-hours required in the setting and the like, which facilitates the manufacture of the pack case. Further, the first metal plate portion and the second metal plate portion are connected. Therefore, it is possible to further improve the flexural rigidity and the torsional rigidity of the panel structure wall (first wall, second wall).
- In the method according to the third aspect, the pack case may include a third wall and a fourth wall that are each located on an outer side of the accommodated battery stack in a lateral direction orthogonal to the stacking direction, that form, together with the first wall and the second wall, a rectangular frame surrounding the battery stack from four sides, and that connects the first wall and the second wall. The third wall and the fourth wall each may include a lateral metal plate extending in the stacking direction. The lateral metal plate may be connected to the first metal plate and the second metal plate via a corner connecting resin portion made from resin. In the setting, the lateral metal plate forming the third wall and the lateral metal plate forming the fourth wall may also be set in the mold. In the injection molding, the panel structure wall may formed and the corner connecting resin portion may be formed.
- In the above method, the panel structure wall is formed and the corner connecting resin portion is formed in the injection molding, which further facilitates the manufacture of the pack case.
- Features, advantages, and technical and industrial significance of exemplary embodiments of the present disclosure will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:
-
FIG. 1 is an explanatory diagram illustrating a battery pack according to a first embodiment; -
FIG. 2 is a perspective view of a pack case according to the first embodiment and a first modification; -
FIG. 3 is an enlarged sectional perspective view of the pack case according to the first embodiment, taken along line inFIG. 2 ; -
FIG. 4 is a perspective view of a metal case member used for the pack case according to the first embodiment and the first modification; -
FIG. 5 is an enlarged perspective view of a corner (a part B inFIG. 4 ) of the metal case member used for the pack case according to the first embodiment and the first modification; -
FIG. 6 is a developed view of the metal case member used for the pack case according to the first embodiment and the first modification; -
FIG. 7 is a flowchart showing processes of manufacturing the pack case and the battery pack according to the first and second embodiments and the first to fourth modifications; -
FIG. 8 is a perspective view of the pack case according to the first modification, as viewed from a bottom side; -
FIG. 9 is an enlarged sectional perspective view of the pack case according to the first modification, taken along line IX-IX inFIG. 8 ; -
FIG. 10 is a perspective view of a metal case member used for the pack case according to the second modification; -
FIG. 11 is an enlarged perspective view of a corner (a part D inFIG. 10 ) of the metal case member used for the pack case according to the second modification; -
FIG. 12 is an enlarged sectional perspective view of the corner of the metal case member used for the pack case according to the second modification, taken along line XII-XII inFIG. 11 ; -
FIG. 13 is a perspective view of the pack case according to the second modification; -
FIG. 14 is an enlarged perspective view of a corner (a part F inFIG. 13 ) of the pack case according to the second modification; -
FIG. 15 is an enlarged sectional perspective view of the corner of the pack case according to the second modification, taken along line XV-XV inFIG. 14 ; -
FIG. 16 is a perspective view of the pack case according to the third modification; -
FIG. 17 is an enlarged sectional perspective view of a corner of the pack case according to the third modification, taken along line XVII-XVII inFIG. 16 ; -
FIG. 18 is a perspective view of a metal case member used for the pack case according to the third modification; -
FIG. 19 is an enlarged perspective view of a corner (a part I inFIG. 18 ) of the metal case member used for the pack case according to the third modification; -
FIG. 20 is a perspective view of a metal case member used for the pack case according to the fourth modification; -
FIG. 21 is an enlarged perspective view of a corner (a part J inFIG. 20 ) of the metal case member used for the pack case according to the fourth modification; -
FIG. 22 is a perspective view of the pack case according to the fourth modification; -
FIG. 23 is an enlarged perspective view of a corner (a part K inFIG. 22 ) of the pack case according to the fourth modification; -
FIG. 24 is a perspective view of the pack case according to the second embodiment; -
FIG. 25 is a sectional perspective view of the pack case according to the second embodiment, taken along line XXV-XXV inFIG. 24 ; and -
FIG. 26 is a perspective view of a metal case member used for the pack case according to the second embodiment. - Hereinafter, a first embodiment of the present disclosure will be described with reference to the drawings.
FIG. 1 shows abattery pack 1 according to the first embodiment. Thebattery pack 1 is an in-vehicle battery pack that is mounted on a vehicle such as a hybrid car, a plug-in hybrid car, and an electric vehicle. Thebattery pack 1 includes: abattery stack 5 in which batteries (cells) 2,spacers 3 andend plates 4 are stacked in a stacking direction SH (right-left direction inFIG. 1 ); and a pack case 10 accommodating thebattery stack 5 while compressing thebattery stack 5 in the stacking direction SH with a compression force KF. - Among these, the
battery stack 5 includes the rectangular (cuboid)batteries 2 and the rectangular plate-shapedspacers 3 stacked alternately, as well as the rectangular plate-shapedmetal end plates 4 arranged at the opposite ends in the stacking direction SH. - The
batteries 2 are sealed rectangular lithium ion secondary batteries. Thebatteries 2 are connected in series via a bus bar (not shown). Eachbattery 2 contains electrodes (not shown) together with a non-aqueous electrolyte solution in abattery case 2 a made of metal (aluminum in the first embodiment) and having a cuboid box shape. Apositive terminal member 2 b and anegative terminal member 2 c are fixed to anupper surface 2 au of thebattery case 2 a while being insulated from thebattery case 2 a. Theterminal members battery case 2 a, and pass through theupper surface 2 au of thebattery case 2 a to the upper part of the battery. - The
spacers 3 are rectangular plate-shaped members made from insulating resin. Eachspacer 3 is interposed between twobatteries 2 adjacent to each other in the stacking direction SH to insulate thebattery cases 2 a of thebatteries 2 and forms a heat dissipation path for eachbattery 2. Theend plates 4 are rectangular plate-shaped members made of metal (aluminum in the first embodiment), and disposed on the outer side of thebatteries 2 at the opposite ends in the stacking direction SH. - The pack case 10 (see also
FIG. 2 ) has the shape of a bottomed rectangular tube opening only on an upper side HHU in a height direction HH that is orthogonal to the stacking direction SH. The pack case 10 includes a rectangular plate-shapedbottom wall 11 and fourwalls 12 to 15 extending upright from four side edges of thebottom wall 11 toward the upper side HHU to form a rectangular frame shape. Among these, afirst side wall 12 is located on a first side SH1 (right side inFIG. 1 , lower right side inFIG. 2 ) in the stacking direction SH, and asecond side wall 13 is located on a second side SH2 (left side inFIG. 1 , upper left side inFIG. 2 ) in the stacking direction SH and faces thefirst side wall 12. A third side wall 14 and a fourth side wall 15 extend in the stacking direction SH so as to be orthogonal to a lateral direction YH orthogonal to the stacking direction SH and the height direction HH and so as to face each other, as shown inFIG. 2 . The fourwalls 12 to are connected to each other by corner connecting resin portions 36 (described later) located at the four corners. - The pack case 10 includes a metal case member 20 shown in
FIGS. 4 and 5 and aresin case member 30 provided so as to cover the metal case member 20 from outside. Theresin case member 30 is formed by resin injection molding, and is fixed to and integrated with the metal case member 20. - The metal case member 20 (see
FIGS. 4 and 5 ) is formed by bending aflat metal plate 20M made of a galvanized steel plate shown inFIG. 6 , and includes a rectangular bottommetal plate portion 21 and rectangular side wallmetal plate portions 22 to 25 extending upright from the four side edges of the bottommetal plate portion 21 to the upper side HHU. A first side wallmetal plate portion 22 is located on the first side SH1 (lower right side inFIG. 4 ) in the stacking direction SH, and a second side wallmetal plate portion 23 is located on the second side SH2 (upper left side inFIG. 4 ) in the stacking direction SH and faces the first side wallmetal plate portion 22. A third side wallmetal plate portion 24 and a fourth side wallmetal plate portion 25 extend in the stacking direction SH so as to be orthogonal to the lateral direction YH and to face each other, as shown inFIG. 4 . The four side wallmetal plate portions 22 to 25 are not directly connected to each other but are connected via the bottommetal plate portion 21 as shown inFIG. 4 . - As shown in
FIG. 5 , the first side wallmetal plate portion 22 is formed by bending onemetal plate 20M into a U shape (shape of a rectangle with one open side), and has an innermetal plate portion 22 a, a connectingportion 22 b, and an outermetal plate portion 22 c. The innermetal plate portion 22 a is formed by bending themetal plate 20M at an angle of 90 degrees so as to be connected to the bottommetal plate portion 21 and extend upright to the upper side HHU. The connectingportion 22 b has a plate shape and is formed by further bending themetal plate 20M at an angle of 90 degrees so as to be connected to the innermetal plate portion 22 a and extend to the first side SH1 in the stacking direction SH. The outermetal plate portion 22 c is formed by further bending themetal plate 20M at an angle of 90 degrees so as to be connected to the connectingportion 22 b and extend to a lower side HHD while facing the innermetal plate portion 22 a. The connectingportion 22 b connects the innermetal plate portion 22 a and the outermetal plate portion 22 c. - Similarly to the first side wall
metal plate portion 22, the second side wallmetal plate portion 23 has an innermetal plate portion 23 a, a connectingportion 23 b, and an outermetal plate portion 23 c. The innermetal plate portion 23 a is formed by bending themetal plate 20M at an angle of 90 degrees so as to be connected to the bottommetal plate portion 21 and extend upright to the upper side HHU. The connectingportion 23 b has a plate shape and is formed by further bending themetal plate 20M at an angle of 90 degrees so as to be connected to the innermetal plate portion 23 a and extend to the second side SH2 in the stacking direction SH. The outermetal plate portion 23 c is formed by further bending themetal plate 20M at an angle of 90 degrees so as to be connected to the connectingportion 23 b and extend to the lower side HHD while facing the innermetal plate portion 23 a. The connectingportion 23 b connects the innermetal plate portion 23 a and the outermetal plate portion 23 c. Further, the third side wallmetal plate portion 24 and the fourth side wallmetal plate portion 25 have their respective end portions bent at an angle of 90 degrees in order to increase their rigidity. - The
resin case member 30 is made from glass fiber reinforced polyamide and is formed in a bottomed rectangular tube shape so as to cover the metal case member 20 from outside, as shown inFIGS. 2 to 4 . That is, in thebottom wall 11, abottom plate portion 31 is formed on the lower side HHD of the bottommetal plate portion 21 so as to be fixed to the bottommetal plate portion 21. In the third side wall 14, a third side wall resin portion 34 is formed on a first side YH1 of the third side wallmetal plate portion 24 in the lateral direction YH so as to be fixed to the third side wallmetal plate portion 24. Similarly in the fourth side wall 15, a fourth side wall resin portion 35 is provided on a second side YH2 of the fourth side wallmetal plate portion 25 in the lateral direction YH so as to be fixed to the fourth side wallmetal plate portion 25. - In the
first side wall 12, a first sidewall resin portion 32 is formed outward SHO of the innermetal plate portion 22 a of the first side wallmetal plate portion 22 in the stacking direction SH (on the first side SH1 in the stacking direction SH) and inward SHI of the outermetal plate portion 22 c of the first side wallmetal plate portion 22 in the stacking direction SH (on a second side SH2 in the stacking direction SH) i.e., between the innermetal plate portion 22 a and the outermetal plate portion 22 c, so as to be fixed to the innermetal plate portion 22 a and the outermetal plate portion 22 c. In thesecond side wall 13, a second sidewall resin portion 33 is formed outward SHO of the innermetal plate portion 23 a of the second side wallmetal plate portion 23 in the stacking direction SH (on the second side SH2 in the stacking direction SH) and inward SHI of the outermetal plate portion 23 c of the second side wallmetal plate portion 23 in the stacking direction SH (on the first side SH1 in the stacking direction SH), i.e., between the innermetal plate portion 23 a and the outermetal plate portion 23 c, so as to be fixed to the innermetal plate portion 23 a and the outermetal plate portion 23 c. - The
bottom plate portion 31 and the four sidewall resin portions 32 to 35 are connected to each other by the corner connectingresin portions 36 located at the four corners. Thus, as described above, the fourwalls 12 to 15 including the four sidewall resin portions 32 to 35 are connected to each other by the corner connectingresin portions 36. - In the first embodiment, the above-mentioned portions of the metal case member 20 and the above-mentioned portions of the
resin case member 30 are fixed to each other by applying a primer (for example, VESTAMELT Hylink (registered trademark) manufactured by Daicel-Evonik, Ltd., etc.) to the portions of the metal case member 20, which serve as fixing surfaces to which the portions of theresin case member 30 are fixed, followed by injection molding such that resin adheres to the fixing surfaces of the metal case member 20. - As described above, the
first side wall 12 has a so-called sandwich panel structure, in which the first sidewall resin portion 32 is interposed between and fixed to the innermetal plate portion 22 a and the outermetal plate portion 22 c. Thus, compared to a case of using, instead of thefirst side wall 12, a wall including only the innermetal plate portion 22 a or a wall including only the innermetal plate portion 22 a and the first sidewall resin portion 32 fixed to the innermetal plate portion 22 a, flexural rigidity and torsional rigidity of thefirst side wall 12 are high. Thus, it is possible to suppress deformation of thefirst side wall 12 due to a reaction force RKF to the compression force KF that compresses thebattery stack 5 in the stacking direction SH thereby lowering the compression force KF that presses thebattery stack 5. In addition, the first side wall resin portion 32 (glass fiber reinforced polyamide, density: 1.35 g/cm3) interposed between the innermetal plate portion 22 a and the outermetal plate portion 22 c has a density lower than that of a metal (galvanized steel plate, density: 7.8 g/cm3) forming the innermetal plate portion 22 a and the outermetal plate portion 22 c. Therefore, thefirst side wall 12 can be made lightweight compared to the case of using a solid metal plate having the same thickness instead of the sandwich panel structure. Thus, the pack case 10 can be also made lightweight. Note that thesecond side wall 13 having the same sandwich panel structure provides the same effects as those of thefirst side wall 12 described above, and therefore description thereof will be omitted. - In the pack case 10, the first side wall
metal plate portion 22 that is a part of onemetal plate 20M is bent into a U shape (shape of a rectangle with one open side) to provide the innermetal plate portion 22 a and the outermetal plate portion 22 c functioning as a first metal plate and a second metal plate, respectively, to form thefirst side wall 12. Therefore, it is possible to form the pack case 10 with a small number of parts and make the pack case 10 inexpensive. In contrast to the case where the first metal plate and the second metal plate are formed as separate parts, the innermetal plate portion 22 a and the outermetal plate portion 22 c are connected via the connectingportion 22 b. That is, a part of onemetal plate 20M forms the innermetal plate portion 22 a, the outermetal plate portion 22 c, and the connectingportion 22 b connecting the innermetal plate portion 22 a and the outermetal plate portion 22 c. Therefore, it is possible to further improve the flexural rigidity and the torsional rigidity of thefirst side wall 12. In particular, in thefirst side wall 12 of the first embodiment, the innermetal plate portion 22 a, the connectingportion 22 b, and the outermetal plate portion 22 c are connected by bending at an angle of 90 degrees. Thus, it is possible to further improve the flexural rigidity and the torsional rigidity of thefirst side wall 12. Note that thesecond side wall 13 having the same sandwich panel structure provides the same effects as those of thefirst side wall 12 described above, and therefore description thereof will be omitted. - Moreover, in the pack case 10, both the
first side wall 12 and thesecond side wall 13 located on the first side SH1 and the second side SH2, respectively, in the stacking direction SH have the sandwich panel structure. Therefore, it is possible to provide the lightweight pack case 10 having even higher rigidity. - Further, in the
battery pack 1 of the first embodiment, which includes the pack case 10, thefirst side wall 12 and thesecond side wall 13 of the pack case 10 compressing and restraining thebattery stack 5 are panel structure walls each having the sandwich panel structure with high flexural rigidity and high torsional rigidity. Therefore, it is possible to provide thebattery pack 1 that is lightweight but does not easily deform with the reaction force RKF to the compression force KF applied to thebattery stack 5 in order to compress and restrain thebattery stack 5, while suppressing the reduction of the compression force KF due to deformation. - In the first embodiment, unlike the
first side wall 12 and thesecond side wall 13, each of the third side wall 14 and the fourth side wall 15 does not have the sandwich panel structure. However, the sandwich panel structure may be adopted that is similar to those of thefirst side wall 12 and thesecond side wall 13, or similar to those ofthird side walls 514A, 514B and afourth side wall 515 in apack case 510 of a second embodiment to be described later. In such a pack case, each of the third side wall and the fourth side wall has the sandwich panel structure. Therefore, it is possible to provide the lightweight pack case having even higher rigidity. - The pack case 10 of the first embodiment is manufactured by the following procedure (see
FIG. 7 ). First, in a stamping step S1, themetal plate 20M is formed by stamping from a hoop-shaped metal plate (not shown). Next, in an application step S2, a primer is applied to a portion of themetal plate 20M, which serves as a fixing surface that is fixed to resin, and is dried. Next, in a bending step S3, the metal case member 20 is formed by bending themetal plate 20M. Themetal plate 20M may be obtained by stamping in the stamping step, after the application step in which the primer is applied to the metal plate that has not been subjected to the stamping. - Next, in a setting step S4, the metal case member 20 is set at a predetermined position in a mold (not shown) provided in an injection molding apparatus (not shown). Subsequently, in an injection molding step S5, the injection molding apparatus is operated to inject resin and the
resin case member 30 is molded so as to be fixed to the metal case member 20. Thus, the pack case 10 is completed. - In the method for manufacturing the pack case 10 described above, the first side
wall resin portion 32 and the second sidewall resin portion 33 are formed by injection molding. Therefore, it is possible to easily manufacture the pack case 10 having thefirst side wall 12 and thesecond side wall 13 that are the panel structure walls. - Further, in the bending step S3, a part of one
metal plate 20M is bent into a U shape (shape of a rectangle with one open side) to form the innermetal plate portion 22 a, the outermetal plate portion 22 c, and the connectingportion 22 b of the first side wallmetal plate portion 22. The same applies to the second side wallmetal plate portion 23. Thus, it is possible to reduce the number of parts of the first side wallmetal plate portion 22 and the second side wallmetal plate portion 23 that are the panel structure walls, and therefore, to reduce the number of parts of the pack case 10. Accordingly, it is possible to reduce man-hours required in the subsequent setting step S4 and the like, which facilitates the manufacture of the pack case 10. In addition, the innermetal plate portion 22 a and the outermetal plate portion 22 c (the innermetal plate portion 23 a and the outermetal plate portion 23 c) are connected. Therefore, it is possible to further improve the flexural rigidity and the torsional rigidity of thefirst side wall 12 and thesecond side wall 13 that are the panel structure walls. - In addition, in the setting step S4, the metal case member 20 is set in the mold, whereby the third side wall
metal plate portion 24 and the fourth side wallmetal plate portion 25 that function as lateral side metal plates can be set in the mold. In the injection molding step S5, thefirst side wall 12 and thesecond side wall 13 that are the panel structure walls are formed, and the corner connectingresin portion 36 is formed at each corner. Thus, in this manufacturing method, the pack case 10 can be manufactured more easily. - Next, the manufacture of the
battery pack 1 will be described (seeFIGS. 1 and 7 ). First, in a battery stack forming step S11, thebattery stack 5 is formed. That is, thebatteries 2 and thespacers 3 that have been separately manufactured are alternately arranged to be stacked, and theend plates 4 are arranged outward SHO of theoutermost batteries 2 in the stacking direction SH (theoutermost battery 2 on the first side SH1 in the stacking direction SH and theoutermost battery 2 on the second side SH2 in the stacking direction SH). Thus, thebattery stack 5 is formed. - Next, in an insertion and restraint step S12, the
battery stack 5 is compressed in the stacking direction SH with a compression force larger than the compression force KF, which is applied by a compression tool (not shown), thebattery stack 5 is inserted into the pack case 10 withbattery stack 5 compressed in length (dimension in the stacking direction SH), and then, the compression force of the compression tool is released. Then, the length of thebattery stack 5 slightly increases, and thebattery stack 5 is restrained by the pack case with the compression force KF. Thereafter, the compression tool is removed from thebattery stack 5. - Thereafter, in a connection step S13, the
positive terminal member 2 b and thenegative terminal member 2 c of eachbattery 2 are connected to each other in a predetermined connection pattern (for example, in series) using a bus bar (not shown) or the like. Thus, thebattery pack 1 is completed.Pack cases - Next, the
pack case 110 according to the first modification will be described with reference toFIGS. 2, 8, and 9 . Thepack case 110 according to the first modification has the same appearance as the pack case 10 of the first embodiment (seeFIG. 2 ), and includes the metal case member 20 that is the same as that of the first embodiment (seeFIGS. 4 and 5 ). - However, in the pack case 10 of the first embodiment, the first side
wall resin portion 32 of thefirst side wall 12 that is the panel structure wall and the second sidewall resin portion 33 of thesecond side wall 13 that is the panel structure wall are formed as solid resin members (seeFIG. 3 ). - In contrast, in the
pack case 110 of the first modification, each of a first sidewall resin portion 132 of afirst side wall 112 and a second sidewall resin portion 133 of asecond side wall 113 has a number of lighteningportions FIGS. 8 and 9 ). - Thus, the
first side wall 112 has the innermetal plate portion 22 a, the outermetal plate portion 22 c, and the first sidewall resin portion 132 interposed between and fixed to the innermetal plate portion 22 a and the outermetal plate portion 22 c, and is the panel structure wall having the sandwich panel structure. In addition, since the first sidewall resin portion 132 has the lighteningportions 132 h, it is possible to reduce the weight of the first sidewall resin portion 132 by the weight of the lighteningportions 132 h, compared to the first sidewall resin portion 32 of the first embodiment. Therefore, it is possible to reduce the weight of thefirst side wall 112 and further, reduce the weight of thepack case 110. The same applies to thesecond side wall 113 having the lighteningportions 133 h. - When the first side
wall resin portion 132 and the second sidewall resin portion 133 are provided with the lighteningportions portions first side wall 112 and thesecond side wall 113 and the degree of degradation of the flexural rigidity and the torsional rigidity. Further, in forming thepack case 110 of the first modification by injection molding, the first sidewall resin portion 132 and the second sidewall resin portion 133 may be provided with the lighteningportions - Next, the
pack case 210 according to the second modification will be described with reference toFIGS. 10 to 15 . Thepack case 210 according to the second modification and a metal case member 220 included in thepack case 210 have substantially the same appearances as the pack case 10 and the metal case member 20, respectively, of the first embodiment (seeFIGS. 2, 4 and 5 ). - However, in the pack case 10 of the first embodiment, the
first side wall 12 and thesecond side wall 13 are connected with the third side wall 14 and the fourth side wall at the four corners of thebottom wall 11 with only the corner connectingresin portions 36 made from resin. Therefore, when thebattery stack 5 is inserted into the pack case 10 and the compression force KF is applied to thebattery stack 5 from thefirst side wall 12 and thesecond side wall 13, the reaction force RKF to the compression force KF is applied to thefirst side wall 12 and the second side wall 13 (seeFIG. 1 ). The reaction force RKF is further transmitted to the third side wall 14 and the fourth side wall 15 in addition to thebottom wall 11, and large stresses are also applied to portions that connect the first andsecond side walls resin portions 36 made from resin, creep or cracking is likely to occur, and it is difficult to maintain the compression force KF. - In contrast, as can be easily understood from
FIGS. 11, 12, and 15 , in thepack case 210 of the second modification, connection between first andsecond side walls 212, 213, and third andfourth side walls - Specifically, a third side wall
metal plate portion 224 of the metal case member 220 has an extendingportion 224A extending further outward SHO in the stacking direction SH (more toward the first side SH1 in the stacking direction SH, lower right side inFIGS. 11 and 12 ) than an innermetal plate portion 222 a of thefirst side wall 212. The extendingportion 224A has panel engagement portions 224Ak that are located outward SHO of the innermetal plate portion 222 a in the stacking direction SH (on the first side SH1 in the stacking direction SH) and inward YHI of anedge 222 at of the innermetal plate portion 222 a in the lateral direction YH (on the second side YH2 in the lateral direction YH, upper right side inFIGS. 11 and 12 ) and that engage with the innermetal plate portion 222 a via a corner connectingresin portion 236. - In the second modification, the panel engagement portions 224Ak are two bulging portions each formed by making parallel cuts extending in the height direction HH in the extending
portion 224A and bulging a portion between the cuts inward YHI in the lateral direction YH (on the second side YH2 in the lateral direction YH, upper right side inFIGS. 11 and 12 ). - Further, in the metal case member 220 of the pack case 210 (see
FIG. 10 ) according to the second modification, panel engagement portions are formed at the other three corners. That is, an extendingportion 224B of the third side wallmetal plate portion 224 is also provided with panel engagement portions 224Bk that are bulging portions similar to the panel engagement portions 224Ak. In addition, extendingportions metal plate portion 225 are also provided with panel engagement portions (not shown) formed of bulging portions similar to the panel engaging portions 224Ak. - Thus, in the
pack case 210 of the second modification, the panel engagement portions 224Ak etc. provided in the extendingportions metal plate portion 224 and the fourth side wallmetal plate portion 225 are engaged with the innermetal plate portions resin portions 236. Thus, thethird side wall 214 and thefourth side wall 215 including the third side wallmetal plate portion 224 and the fourth side wallmetal plate portion 225 can be more firmly connected with thefirst side wall 212 and the second side wall 213 that are the panel structure walls, which enables thepack case 210 to have higher rigidity and higher strength. - As shown in
FIG. 15 , in thepack case 210 of the second modification, a first sidewall resin portion 232 of thefirst side wall 212 is provided with lighteningportions 232 h as in the first modification. Therefore, it is possible to reduce the weight of thefirst side wall 212, and further, to reduce the weight of thepack case 210. Although not shown, a second side wall resin portion of the second side wall 213 is similarly provided with lightening portions. - Next, a
pack case 310 according to a third modification will be described with reference toFIGS. 16 to 19 . Thepack case 310 according to the third modification and themetal case member 320 included therein also have substantially the same appearances as the pack case 10 and the metal case member 20 (seeFIGS. 2, 4, and 5 ) of the first embodiment. - However, in the pack case 10 of the first embodiment, the
first side wall 12 and thesecond side wall 13 are connected with the third side wall 14 and the fourth side wall at the four corners of thebottom wall 11 with only the corner connectingresin portions 36 made from resin. - In contrast, as can be easily understood from
FIGS. 17 and 19 , in thepack case 310 of the third modification, connection between first andsecond side walls fourth side walls - Specifically, a third side wall
metal plate portion 324 of themetal case member 320 has an extendingportion 324A extending further outward SHO in the stacking direction SH (more toward the first side SH1 in the stacking direction SH, lower right side inFIGS. 17 and 19 ) than an innermetal plate portion 322 a of thefirst side wall 312. The extendingportion 324A has a panel engagement portion 324Ak that is located outward SHO of the innermetal plate portion 322 a in the stacking direction SH (on the first side SH1 in the stacking direction SH) and inward YHI of anedge 322 at of the innermetal plate portion 322 a in the lateral direction YH (on the second side YH2 in the lateral direction YH, upper right side inFIGS. 17 and 19 ) and that engages with the innermetal plate portion 322 a via a corner connectingresin portion 336. - In the third modification, the panel engagement portion 324Ak is a bending protruding portion formed by bending an end of the extending
portion 324A inward YHI in the lateral direction YH (toward the second side YH2 in the lateral direction YH, upper right side inFIGS. 17 and 19 ) and protruding the end inward YHI in the lateral direction YH (toward the second side YH2 in the lateral direction YH) between the innermetal plate portion 322 a and an outermetal plate portion 322 c. - Also in the
metal case member 320 of the pack case 310 (seeFIG. 18 ) according to the third modification, panel engagement portions are formed at the other three corners. That is, an extendingportion 324B of the third side wallmetal plate portion 324 is also provided with a panel engagement portion 324Bk that is a bending protruding portion similar to the panel engagement portion 324Ak. Also, extendingportions 325A, 325B of the fourth side wallmetal plate portion 325 are each provided with a panel engagement portion (not shown) formed of a bending protruding portion similar to the panel engagement portion 324Ak. - Thus, in the
pack case 310 of the third modification, the panel engagement portion 324Ak etc. provided in the extendingportions metal plate portion 324 and the fourth side wallmetal plate portion 325 are engaged with the innermetal plate portions resin portions 336. Thus, thethird side wall 314 and thefourth side wall 315 including the third side wallmetal plate portion 324 and the fourth side wallmetal plate portion 325 can be more firmly connected with thefirst side wall 312 and thesecond side wall 313 that are the panel structure walls, which enables thepack case 310 to have higher rigidity and higher strength. - Next, the pack case 410 according to the fourth modification will be described with reference to
FIGS. 20 to 23 . The pack case 410 according to the fourth modification and ametal case member 420 included therein also have substantially the same appearances as the pack case 10 and the metal case member 20 (seeFIGS. 2, 4 and 5 ) of the first embodiment. - However, in the pack case 10 of the first embodiment, the
first side wall 12 and thesecond side wall 13 are connected with the third side wall 14 and the fourth side wall 15 at the four corners of thebottom wall 11 with only the corner connectingresin portions 36 made from resin. - In contrast, as can be easily understood from
FIGS. 21 and 23 , in the pack case 410 of the fourth modification, connection between first andsecond side walls fourth side walls - Specifically, a third side wall
metal plate portion 424 of themetal case member 420 has an extendingportion 424A extending further outward SHO in the stacking direction SH (more toward the first side SH1 in the stacking direction SH, lower right side inFIGS. 21 and 23 ) than an innermetal plate portion 422 a of thefirst side wall 412. The extendingportion 424A has a panel engagement portion 424Ak that is located outward SHO of the innermetal plate portion 422 a in the stacking direction SH (on the first side SH1 in the stacking direction SH) and inward YHI of anedge 422 at of the innermetal plate portion 422 a in the lateral direction YH (on the second side YH2 in the lateral direction YH, upper right side inFIGS. 21 and 23 ) and that engages with the innermetal plate portion 422 a via a corner connectingresin portion 436. - In the fourth modification, the panel engagement portion 424Ak is a bending protruding portion formed by bending an end of the extending
portion 424A to the second side YH2 in the lateral direction YH (inward YHI in the lateral direction YH, upper right side inFIGS. 21 and 23 ) and protruding the end inward YHI in the lateral direction YH (toward the second side YH2 in the lateral direction YH) at the same position in the stacking direction SH as an outermetal plate portion 422 c. The outermetal plate portion 422 c is provided with a notch 422Ck that can accommodate the panel engagement portion 424Ak. - In the
metal case member 420 of the pack case 410 (seeFIG. 20 ) according to the fourth modification, panel engagement portions are formed at the other three corners. That is, the extendingportion 424B of the third side wallmetal plate portion 424 is also provided with a panel engagement portion 424Bk that is a bending protruding portion similar to the panel engagement portion 424Ak. Also, extendingportions metal plate portion 425 are each provided with a panel engagement portion 425Ak etc. formed of a bending protruding portion similar to the panel engagement portion 424Ak etc. - Thus, in the pack case 410 of the fourth modification, the panel engagement portion 424Ak etc. provided in the extending
portions metal plate portion 424 and the fourth side wallmetal plate portion 425 are engaged with the innermetal plate portions 422 a, 423 a via the corner connectingresin portions 436. Thus, thethird side wall 414 and thefourth side wall 415 including the third side wallmetal plate portion 424 and the fourth side wallmetal plate portion 425 can be more firmly connected with thefirst side wall 412 and thesecond side wall 413 that are the panel structure walls, which enables the pack case 410 to have higher rigidity and higher strength. - Next, the
pack case 510 according to the second embodiment will be described with reference toFIGS. 24 to 26 . Unlike the pack case 10 and the metal case member 20 (seeFIGS. 2, 4 and 5 ) of the first embodiment, thepack case 510 and themetal case member 520 included in thepack case 510 according to the second embodiment have a pair ofaccommodating portions battery stacks 5 can be accommodated therein while being arranged side by side. - As can be understood from
FIG. 26 , ametal case member 520 is also formed by bending a flat metal plate, and includes a pair of bottommetal plate portions metal plate portions metal plate portions - Among these, in the
accommodating portion 510A, the first side wallmetal plate portion 522A is located on the first side SH1 in the stacking direction SH (lower right side inFIG. 26 ), and the second side wallmetal plate portion 523A is located on the second side SH2 in the stacking direction SH (upper left side inFIG. 26 ) and faces the first side wallmetal plate portion 522A. The third side wallmetal plate portion 524A and a fourth side wallmetal plate portion 525A extend in the stacking direction SH so as to be orthogonal to the lateral direction YH and to face each other. - In the
accommodating portion 510B, the first side wallmetal plate portion 522B is located on the first side SH1 in the stacking direction SH (lower right side inFIG. 26 ), and the second side wallmetal plate portion 523B is located on the second side SH2 in the stacking direction SH (upper left side inFIG. 26 ) and faces the first side wallmetal plate portion 522B. The third side wallmetal plate portion 524B and a fourth side wallmetal plate portion 525B extend in the stacking direction SH so as to be orthogonal to the lateral direction YH and to face each other. However, in themetal case member 520 of the second embodiment, the fourth side wallmetal plate portions accommodating portions metal plate portions 522A to 524A, 525 arranged on the four sides are not directly connected to one another and are connected via the bottommetal plate portion 521A, and the side wallmetal plate portions 522B to 524B, 525 arranged on the four sides are not directly connected to one another and are connected via the bottommetal plate portion 521B. - Here, since the first side wall
metal plate portions metal plate portions metal plate portion 22 and the second side wallmetal plate portion 23 of the first embodiment (seeFIGS. 4 and 5 ), description thereof will be omitted. - The third side wall
metal plate portion 524A has, unlike the third side wallmetal plate portion 24 of the first embodiment, an inner metal plate portion 524Aa bent from a bottommetal plate portion 521A and standing upright, an outer metal plate portion 524Ac located outward YHO of the inner metal plate portion 524Aa in the lateral direction YH (on the first side YH1 in the lateral direction YH) and facing the inner metal plate portion 524Aa, and a connecting portion 524Ab connecting the inner metal plate portion 524Aa and the outer metal plate portion 524Ac. Similarly, the third side wallmetal plate portion 524B has an inner metal plate portion 524Ba bent from a bottommetal plate portion 521B and standing upright, an outer metal plate portion 524Bc located outward YHO of the inner metal plate portion 524Ba in the lateral direction YH (on the second side YH2 in the lateral direction YH) and facing the inner metal plate portion 524Ba, and a connecting portion 524Bb connecting the inner metal plate portion 524Ba and the outer metal plate portion 524Bc. - The
third side wall 514A of thepack case 510 has a third sidewall resin portion 534A interposed between and fixed to the inner metal plate portion 524Aa and the outer metal plate portion 524Ac and having a density lower than that of the metal forming the inner metal plate portion 524Aa and the outer metal plate portion 524Ac. Thus, thethird side wall 514A is a panel structure lateral side wall having the sandwich panel structure. Similarly, the third side wall 514B has a third sidewall resin portion 534B between the inner metal plate portion 524Ba and the outer metal plate portion 524Bc, and is the panel structure lateral side wall having the sandwich panel structure. - The fourth side wall
metal plate portion 525 has, unlike the fourth side wallmetal plate portion 25 of the first embodiment, the fourth side wallmetal plate portion 525A bent from the bottommetal plate portion 521A and standing upright, the fourth side wallmetal plate portion 525B located outward YHO of the fourth side wallmetal plate portion 525A in the lateral direction YH (on the second side YH2 in the lateral direction YH) and facing the fourth side wallmetal plate portion 525A while being bent from the bottommetal plate portion 521B and standing upright, and a connecting portion 525C connecting the fourth side wallmetal plate portion 525A and the fourth side wallmetal plate portion 525B. - The
fourth side wall 515 of thepack case 510 has a fourth sidewall resin portion 535 interposed between and fixed to the fourth side wallmetal plate portion 525A and the fourth side wallmetal plate portion 525B and having a density lower than that of the metal forming the fourth side wallmetal plate portion 525A and the fourth side wallmetal plate portion 525B. Thus, thefourth side wall 515 is the panel structure lateral side wall having the sandwich panel structure. - As described above, in the
pack case 510, all thethird side walls 514A, 514B and thefourth side wall 515 are the panel structure lateral side walls. Thus, compared to the case using, instead of thethird side walls 514A, 514B and thefourth side wall 515, only the inner metal plate portions 524Aa, 524Ba, 525Aa each formed of a single metal plate, or using only the inner metal plate portions 524Aa, 524Ba, 525Aa, the third sidewall resin portions wall resin portion 535, thethird side wall 514A, 514B and thefourth side wall 515 have higher flexural rigidity and torsional rigidity. Therefore, the rigidity and the strength of thepack case 510 can be further improved. In particular, in thepack case 510 of the second embodiment, both thethird side wall 514A and thefourth side wall 515, and both the third side wall 514B and thefourth side wall 515 are the panel structure lateral side walls having the sandwich panel structure. Therefore, it is possible to provide thepack case 510 that is lightweight but has even higher rigidity. - In the
pack case 510 of the second embodiment, as in the pack case 10 of the first embodiment, thefirst side walls second side walls pack case 510 that is lightweight but has even higher rigidity. - In the above, description has been made with the first and second embodiments and the first to fourth modifications. However, needless to say, the present disclosure is not limited to the embodiments and the like, and may be appropriately changed for application without departing from the scope of the present disclosure. For example, the first and second embodiments and the first to fourth modifications describe the pack case and the like, in which the metal case member 20 and the like are each formed by bending the
single metal plate 20M or the like. However, the present disclosure is not limited to this, and the metal case member constituting the pack case 10 and the like may be formed of a plurality of metal plates. - In the second to fourth modifications, the extending
portions metal plate portions metal plate portions third side wall 214 etc. may be the panel structure lateral side wall having the sandwich panel structure, with the panel engagement portion 224Ak provided in the extendingportion 224A etc. of the third side wallmetal plate portion 224 etc. Thereby, it is possible to provide a pack case with even higher rigidity and strength. - The first and second embodiments and the first to fourth modifications show examples in which the
first side wall 12 etc. and thesecond side wall 13 etc. have the innermetal plate portion 22 a etc. and the outermetal plate portion 22 c etc. with the same dimension in the height direction HH and have the sandwich panel structure over the entire length along the height direction HH. However, for example, in thepack case 510 of the second embodiment, the outer metal plate portions may have a dimension in the height direction HH shorter than that of the inner metal plate portions, as in thethird side walls 514A, 514B, so that each of the first side wall and the second side wall has the sandwich panel structure only at a part thereof in the height direction. Moreover, each of the third side wall and the fourth side wall may have the sandwich panel structure only at a part thereof in the height direction.
Claims (10)
1. A pack case that accommodates a battery stack in which a plurality of batteries are stacked in a stacking direction, the pack case compresses and restrains the battery stack in the stacking direction, the pack case comprising:
a first wall located on a first side of the accommodated battery stack in the stacking direction, the first wall contacts a first end of the battery stack and presses the battery stack toward a second side in the stacking direction; and
a second wall located on the second side of the accommodated battery stack in the stacking direction, the second wall contacts a second end of the battery stack and presses the battery stack toward the first side in the stacking direction, wherein
at least one of the first wall and the second wall is a panel structure wall including a first metal plate, a second metal plate, and an interposed member,
the second metal plate is located outward of the first metal plate in the stacking direction and faces the first metal plate, and
the interposed member is interposed between the first metal plate and the second metal plate, the interposed member is fixed to the first metal plate and the second metal plate, and the interposed member has a density lower than a density of a metal of the first metal plate and the second metal plate;
further comprising:
a third wall and a fourth wall each located on an outer side of the accommodated battery stack in a lateral direction orthogonal to the stacking direction, the third wall and the fourth wall connecting the first wall and the second wall, and the first wall, the second wall, the third wall and the fourth wall forming a rectangular frame surrounding the battery stack from four sides wherein
the third wall and the fourth wall each include a lateral metal plate extending in the stacking direction, and the lateral metal plate is connected to the first metal plate and the second metal plate via a corner connecting resin portion made from resin; and
wherein
the lateral metal plate has an extending portion extending outward of the first metal plate of the panel structure wall in the stacking direction, the panel structure wall being the first wall or the second wall, and
the extending portion includes a panel engagement portion that is located outward of the first metal plate in the stacking direction and inward of a lateral edge of the first metal plate in the lateral direction, and
the extending portion engages with the first metal plate via the corner connecting resin portion.
2. The pack case according to claim 1 , wherein
the panel structure wall is an one metal plate bended in a U-shape,
the panel structure wall includes a first metal plate portion that is the first metal plate, a second metal plate portion that is the second metal plate, and a connecting portion connecting the first metal plate portion and the second metal plate portion.
3-4. (canceled)
5. The pack case according to claim 1 , wherein
at least one of the third wall and the fourth wall is a panel structure lateral side wall including the lateral metal plate, a second lateral metal plate, and a lateral interposed member,
the second lateral metal plate extends in the stacking direction and is located outward or inward of the lateral metal plate in the lateral direction so as to face the lateral metal plate, and
the lateral interposed member is interposed between the lateral metal plate and the second lateral metal plate, the lateral interposed member is fixed to the lateral metal plate and the second lateral metal plate, and the lateral interposed member has a density lower than a density of a metal of the lateral metal plate and the second lateral metal plate.
6. The pack case according to claim 5 , wherein each of the third wall and the fourth wall is the panel structure lateral side wall.
7. The pack case according to claim 1 , wherein each of the first wall and the second wall is the panel structure wall.
8. (canceled)
9. A method for manufacturing a pack case that accommodates a battery stack in which a plurality of batteries are stacked in a stacking direction and the pack case compresses and restrains the battery stack in the stacking direction, the pack case including a first wall and a second wall, the first wall being located on a first side of the accommodated battery stack in the stacking direction, the first wall contacting a first end of the battery stack, and pressing the battery stack toward a second side in the stacking direction, the second wall being located on the second side of the accommodated battery stack in the stacking direction, the second wall contacting a second end of the battery stack and pressing the battery stack toward the first side in the stacking direction, at least one of the first wall and the second wall being a panel structure wall including a first metal plate, a second metal plate, and an interposed member, the second metal plate being located outward of the first metal plate in the stacking direction and facing the first metal plate, and the interposed member being interposed between the first metal plate and the second metal plate, the interposed member being fixed to the first metal plate and the second metal plate and having a density lower than a density of a metal of the first metal plate and the second metal plate,
the method comprising:
setting the first metal plate and the second metal plate in a mold; and
performing an injection molding to form the panel structure wall by charging resin between the first metal plate and the second metal plate set in the mold and molding the interposed member.
10. The method according to claim 9 , further comprising prior to the setting, bending one metal plate into a U-shape to form a first metal plate portion that is the first metal plate, a second metal plate portion that is the second metal plate, and a connecting portion connecting the first metal plate portion and the second metal plate portion.
11. The method according to claim 9 , wherein
the pack case includes a third wall and a fourth wall each located on an outer side of the accommodated battery stack in a lateral direction orthogonal to the stacking direction, the third wall and the fourth wall connecting the first wall and the second wall, and the first wall, the second wall, the third wall and the fourth wall forming a rectangular frame surrounding the battery stack from four sides,
the third wall and the fourth wall each include a lateral metal plate extending in the stacking direction,
the lateral metal plate is connected to the first metal plate and the second metal plate via a corner connecting resin portion made from resin;
in the setting, the lateral metal plate forming the third wall and the lateral metal plate forming the fourth wall are also set in the mold; and
in the injection molding, the corner connecting resin portion is formed together with forming the panel structure wall.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US18/366,797 US20240021860A1 (en) | 2019-02-08 | 2023-08-08 | Pack case, battery pack, and method for manufacturing pack case |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2019-021418 | 2019-02-08 | ||
JP2019021418A JP7111018B2 (en) | 2019-02-08 | 2019-02-08 | Pack case, battery pack, and method for manufacturing pack case |
US16/773,111 US11764393B2 (en) | 2019-02-08 | 2020-01-27 | Pack case, battery pack, and method for manufacturing pack case |
US18/366,797 US20240021860A1 (en) | 2019-02-08 | 2023-08-08 | Pack case, battery pack, and method for manufacturing pack case |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/773,111 Continuation US11764393B2 (en) | 2019-02-08 | 2020-01-27 | Pack case, battery pack, and method for manufacturing pack case |
Publications (1)
Publication Number | Publication Date |
---|---|
US20240021860A1 true US20240021860A1 (en) | 2024-01-18 |
Family
ID=71739052
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/773,111 Active 2041-04-27 US11764393B2 (en) | 2019-02-08 | 2020-01-27 | Pack case, battery pack, and method for manufacturing pack case |
US17/656,577 Active US11817544B2 (en) | 2019-02-08 | 2022-03-25 | Pack case, battery pack, and method for manufacturing pack case |
US18/366,797 Pending US20240021860A1 (en) | 2019-02-08 | 2023-08-08 | Pack case, battery pack, and method for manufacturing pack case |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/773,111 Active 2041-04-27 US11764393B2 (en) | 2019-02-08 | 2020-01-27 | Pack case, battery pack, and method for manufacturing pack case |
US17/656,577 Active US11817544B2 (en) | 2019-02-08 | 2022-03-25 | Pack case, battery pack, and method for manufacturing pack case |
Country Status (4)
Country | Link |
---|---|
US (3) | US11764393B2 (en) |
JP (1) | JP7111018B2 (en) |
CN (1) | CN111554839B (en) |
DE (1) | DE102020201361A1 (en) |
Families Citing this family (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112086597B (en) * | 2020-09-08 | 2022-04-29 | 合肥国轩高科动力能源有限公司 | Power battery module and system |
KR102466311B1 (en) * | 2020-11-19 | 2022-11-14 | 주식회사 성우하이텍 | Manufacturing method of battery module case for electric vehicle |
JP2022184500A (en) | 2021-06-01 | 2022-12-13 | トヨタ自動車株式会社 | Battery case and manufacturing method of battery case |
JP2022184503A (en) * | 2021-06-01 | 2022-12-13 | トヨタ自動車株式会社 | Battery case and manufacturing method of battery case |
JP2022189510A (en) * | 2021-06-11 | 2022-12-22 | トヨタ自動車株式会社 | battery case |
CN113745694B (en) * | 2021-08-24 | 2023-05-26 | 三一重工股份有限公司 | Battery module and vehicle |
DE102021121980A1 (en) * | 2021-08-25 | 2023-03-02 | Schuler Pressen Gmbh | battery |
JP2023038404A (en) | 2021-09-07 | 2023-03-17 | プライムプラネットエナジー&ソリューションズ株式会社 | power storage device |
DE102021129273A1 (en) * | 2021-11-10 | 2023-05-11 | Kautex Textron Gmbh & Co. Kg | Battery case shell with improved temperature resistance for a traction battery |
DE102021132283A1 (en) | 2021-12-08 | 2023-06-15 | Bayerische Motoren Werke Aktiengesellschaft | Energy storage housing, motor vehicle, electrical energy storage and series |
Family Cites Families (20)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6109380A (en) * | 1998-04-13 | 2000-08-29 | Ford Global Technologies, Inc. | Electric vehicle vertical wall construction battery tray |
JP4208403B2 (en) * | 2000-11-14 | 2009-01-14 | 三洋電機株式会社 | Solar cell module and method for installing solar cell module |
JP2002154582A (en) * | 2000-11-16 | 2002-05-28 | Toho Kogyo Kk | Transporting box for plate-like member |
JP4581481B2 (en) | 2004-05-26 | 2010-11-17 | トヨタ自動車株式会社 | Battery module manufacturing method |
CN201210210Y (en) * | 2008-06-13 | 2009-03-18 | 富港电子(东莞)有限公司 | Backlight module frame |
JP5013140B2 (en) | 2009-12-10 | 2012-08-29 | 三菱自動車工業株式会社 | Battery case |
KR20120044853A (en) * | 2010-10-28 | 2012-05-08 | 현대자동차주식회사 | Battery pack case assembly for electric vehicles using plastic composite |
KR101233615B1 (en) | 2011-02-09 | 2013-02-14 | 삼성에스디아이 주식회사 | Battery pack |
US8637173B2 (en) | 2011-02-21 | 2014-01-28 | Samsung Sdi Co., Ltd. | Battery pack |
DE102011076583A1 (en) | 2011-05-27 | 2012-11-29 | Bayerische Motoren Werke Aktiengesellschaft | Energy storage module of several particular prismatic memory cells and method for producing an energy storage module |
CN203151890U (en) * | 2013-03-11 | 2013-08-21 | 外商独资江苏领先电子有限公司 | Power supply box casing |
JP6264905B2 (en) | 2014-01-31 | 2018-01-24 | 住友電気工業株式会社 | Composite member and method of manufacturing composite member |
JP6686823B2 (en) * | 2016-09-23 | 2020-04-22 | トヨタ自動車株式会社 | Battery stack mounting method |
JP2018056098A (en) * | 2016-09-30 | 2018-04-05 | 株式会社Gsユアサ | Power storage device |
SE540811C2 (en) | 2016-12-15 | 2018-11-20 | Nilar Int Ab | A battery module casing, a battery module and a battery |
JP2018125182A (en) * | 2017-02-01 | 2018-08-09 | カルソニックカンセイ株式会社 | Assembled battery |
KR102178959B1 (en) * | 2017-04-06 | 2020-11-13 | 주식회사 엘지화학 | End plate, battery module, battery pack comprising the battery module and vehicle comprising the battery pack |
CN207097888U (en) * | 2017-06-09 | 2018-03-13 | 深圳市沃特玛电池有限公司 | A kind of battery case |
CN107958972A (en) * | 2017-11-16 | 2018-04-24 | 北京航空航天大学 | The battery shell structure and preparation process of a kind of metal and composite panel Mixed Design |
JP7061547B2 (en) * | 2018-10-02 | 2022-04-28 | 本田技研工業株式会社 | Battery module and method of manufacturing battery module |
-
2019
- 2019-02-08 JP JP2019021418A patent/JP7111018B2/en active Active
-
2020
- 2020-01-27 US US16/773,111 patent/US11764393B2/en active Active
- 2020-02-04 CN CN202010079534.3A patent/CN111554839B/en active Active
- 2020-02-05 DE DE102020201361.6A patent/DE102020201361A1/en active Pending
-
2022
- 2022-03-25 US US17/656,577 patent/US11817544B2/en active Active
-
2023
- 2023-08-08 US US18/366,797 patent/US20240021860A1/en active Pending
Also Published As
Publication number | Publication date |
---|---|
CN111554839A (en) | 2020-08-18 |
US11817544B2 (en) | 2023-11-14 |
US20220216552A1 (en) | 2022-07-07 |
US11764393B2 (en) | 2023-09-19 |
CN111554839B (en) | 2022-06-24 |
JP7111018B2 (en) | 2022-08-02 |
DE102020201361A1 (en) | 2020-08-13 |
US20200259139A1 (en) | 2020-08-13 |
JP2020129474A (en) | 2020-08-27 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11817544B2 (en) | Pack case, battery pack, and method for manufacturing pack case | |
JP7174923B2 (en) | power storage device | |
US9786965B2 (en) | Power source device | |
KR101794265B1 (en) | Battery pack having reinforcement bead | |
US9947958B2 (en) | Power source module | |
EP2826083B1 (en) | Large format electrochemical energy storage device housing and module | |
KR101126889B1 (en) | Battery pack | |
JP6306431B2 (en) | Battery module | |
JP5272629B2 (en) | Method for producing assembled battery structure | |
JP6826638B2 (en) | Battery modules, battery packs and vehicles | |
KR101117686B1 (en) | Battery module and battery pack having the same | |
CN109155380B (en) | Battery module including cover assembly | |
WO2018142809A1 (en) | Power storage device | |
CN209786004U (en) | Battery pack | |
EP3712980A1 (en) | Battery module and battery pack | |
JP2016219257A (en) | Power storage device | |
KR102389694B1 (en) | Method For Battery Module Having Bead Formed at Frame Structure and Battery Module Using the Same | |
WO2021192545A1 (en) | Battery module | |
CN212011061U (en) | End plate, battery module, battery pack, and device using battery module as power supply | |
KR20230114206A (en) | Battery pack | |
JP2022055798A (en) | Power storage module and manufacturing method thereof | |
KR20230102737A (en) | Rechargeable battery module | |
JPWO2019181411A1 (en) | Battery module and battery pack | |
JP2020149918A (en) | Binding member |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STPP | Information on status: patent application and granting procedure in general |
Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION |