WO2022158367A1 - 電池パック用ケース及び電池パック - Google Patents
電池パック用ケース及び電池パック Download PDFInfo
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- WO2022158367A1 WO2022158367A1 PCT/JP2022/000920 JP2022000920W WO2022158367A1 WO 2022158367 A1 WO2022158367 A1 WO 2022158367A1 JP 2022000920 W JP2022000920 W JP 2022000920W WO 2022158367 A1 WO2022158367 A1 WO 2022158367A1
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- WIPO (PCT)
- Prior art keywords
- battery
- tray
- cover
- battery pack
- fiber
- Prior art date
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/244—Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K1/00—Arrangement or mounting of electrical propulsion units
- B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L50/00—Electric propulsion with power supplied within the vehicle
- B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
- B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
- B60L50/64—Constructional details of batteries specially adapted for electric vehicles
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- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L50/00—Electric propulsion with power supplied within the vehicle
- B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
- B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
- B60L50/66—Arrangements of batteries
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- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
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- H01M10/05—Accumulators with non-aqueous electrolyte
- H01M10/052—Li-accumulators
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- 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
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- 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
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- 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
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- H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/249—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders specially adapted for aircraft or vehicles, e.g. cars or trains
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- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
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- H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
- H01M50/271—Lids or covers for the racks or secondary casings
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- 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
- H01M50/271—Lids or covers for the racks or secondary casings
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- H01M50/28—Composite material consisting of a mixture of organic and inorganic materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K1/00—Arrangement or mounting of electrical propulsion units
- B60K1/04—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion
- B60K2001/0405—Arrangement or mounting of electrical propulsion units of the electric storage means for propulsion characterised by their position
- B60K2001/0438—Arrangement under the floor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
- B60Y2306/00—Other features of vehicle sub-units
- B60Y2306/01—Reducing damages in case of crash, e.g. by improving battery protection
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- 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
Definitions
- the present disclosure relates to battery pack cases and battery packs, and more particularly to battery pack cases used to form battery packs mounted on electric vehicles and battery packs mounted on electric vehicles.
- a battery pack case assembly for an electric vehicle comprising a case body in which a battery pack is housed and a cover assembled to the case body,
- the case body is made of a plastic composite material in which long fibers or a mixture of long fibers and continuous fibers are used as reinforcing fibers in a plastic base material,
- a separate reinforcing member made of a plastic composite material that uses long fibers, continuous fibers, or a mixture of long fibers and continuous fibers as reinforcing fibers is joined to the plastic base material.
- a battery pack case assembly for an electric vehicle is disclosed.
- a lightweight plastic composite material is used as the material of the case to reduce weight and improve rigidity, crashworthiness, and dimensional stability at the same time. Have been described.
- Patent document 1 JP 2013-201112
- An object of one aspect of the present disclosure is to provide a lightweight battery pack that can suppress battery damage in the event of an electric vehicle collision, and a battery pack case that can form the battery pack.
- a battery pack case used for forming a battery pack mounted on an electric vehicle a tray attached to the body of an electric vehicle; a battery holding member attached to at least a portion of the tray and holding a battery; a cover that covers the tray and the battery holding member; with at least two of the tray, the battery holding member, and the cover comprise fiber-reinforced plastic; Battery pack case.
- the tray includes a tray rear portion arranged under a rear seat of the electric vehicle, a tray extending portion extending in the vehicle front direction from the tray rear portion and having a shorter length in the vehicle width direction than the tray rear portion, including the battery retaining member includes a battery retaining member R attached to at least a portion of the tray rear;
- the cover includes a cover rear portion that covers the tray rear portion and the battery holding member R, and a cover extension portion that covers at least the tray extension portion,
- the cover reinforcing member includes a cover rear reinforcing member that reinforces at least a portion of the cover rear portion connected to the cover extension,
- the battery pack case according to ⁇ 2>.
- the tray further includes a tray front portion connected to an end portion of the tray extending portion in the front direction of the vehicle body and arranged under a front seat of the electric vehicle, Further comprising a tray front reinforcing member, which is a metal member or a fiber reinforced tape, for reinforcing the edge of the tray front,
- a tray front reinforcing member which is a metal member or a fiber reinforced tape
- the battery holding member includes a battery holding member M attached to at least a portion of the tray extension, the cover extension covers the tray extension and the battery holding member M;
- the cover reinforcing member includes a cover extending portion reinforcing member that reinforces at least a portion of a region of the cover extending portion that covers the battery holding member M,
- a tray extension portion reinforcing member which is a metal plate, is provided to reinforce a portion of the tray extension portion in the vehicle body length direction from one end to the other end in the vehicle width direction, at least part of the tray extension reinforcing member is embedded in the tray extension;
- At least one of the tray and the cover contains fiber-reinforced plastic containing two or more fibers selected from the group consisting of glass fiber, aramid fiber, carbon fiber, Zylon fiber, polyethylene fiber, and boron fiber.
- the battery pack case according to any one of ⁇ 1> to ⁇ 6>.
- the battery holding member is a battery module holding member holding a battery module formed by stacking a plurality of lithium secondary batteries in a thickness direction
- the battery module holding member is a pair of end plates for sandwiching the battery module from the outside of both ends in the thickness direction of the battery module; a pair of side plates for sandwiching the battery module from the outside of both ends of the battery module in a direction orthogonal to the thickness direction and the vertical direction; including wherein the pair of end plates and the pair of side plates contain the fiber-reinforced plastic;
- the battery pack case according to any one of ⁇ 1> to ⁇ 7>.
- the battery pack case according to ⁇ 8> wherein the pair of end plates is a plate-shaped member having a structure in which metal members are embedded in fiber-reinforced plastic.
- ⁇ 11> A battery pack mounted on an electric vehicle, a battery pack case according to any one of ⁇ 1> to ⁇ 10>; a battery held by the battery holding member in the battery pack case; a battery pack.
- a battery pack that can suppress battery damage in the event of a collision of an electric vehicle and is lightweight, and a battery pack case that can form the battery pack.
- FIG. 1 is a schematic perspective view of a vehicle body of an electric vehicle equipped with a battery pack according to an embodiment of the present disclosure
- FIG. 1 is a schematic perspective view of a battery pack according to an embodiment of the present disclosure
- FIG. 2 is an exploded perspective view conceptually showing how a cover is removed from a tray in a battery pack according to an embodiment of the present disclosure
- 1 is a schematic perspective view of a battery pack according to an embodiment of the present disclosure when a cover is indicated by dotted lines
- FIG. 1 is a schematic bottom view of a battery pack according to an embodiment of the present disclosure
- FIG. 4 is a schematic perspective view of a tray rear portion and a battery holding member attached on the tray rear portion in a battery pack according to an embodiment of the present disclosure
- FIG. 7 is a schematic perspective view showing a state in which the battery holding member shown in FIG. 6 holds battery modules;
- FIG. 4 is a schematic perspective view showing an end plate forming part of a battery holding portion in a battery pack according to an embodiment of the present disclosure;
- a numerical range represented by “to” means a range including the numerical values before and after “to” as lower and upper limits.
- the amount of each component in the composition refers to the total amount of the multiple substances present in the composition unless otherwise specified when there are multiple substances corresponding to each component in the composition. means
- the battery pack case of the present disclosure is a battery pack case used to form a battery pack mounted on an electric vehicle, a tray attached to the body of an electric vehicle; a battery holding member attached to at least a portion of the tray and holding the battery; a cover that covers the tray and the battery holding member; with at least two of the tray, the battery holding member, and the cover comprise fiber reinforced plastic; This is a battery pack case.
- the present inventors found that at least two of the tray, the battery holding member, and the cover in the battery pack case comprising the tray, the battery holding member, and the cover should contain fiber-reinforced plastic. As a result, the inventors have found that it is possible to effectively reduce the weight of the battery pack and suppress damage to the battery in the event of an electric vehicle collision. That is, according to the battery pack case of the present disclosure, it is possible to form a lightweight battery pack that can further suppress damage to the battery in the event of a collision of an electric vehicle.
- a battery pack formed by the battery pack case of the present disclosure exhibits an excellent effect of suppressing damage to the battery even in the event of a side collision of an electric vehicle.
- the side impact test in the examples described later is a new standard evaluation test established in June 2018 by the Ministry of Land, Infrastructure, Transport and Tourism of Japan (“Occupant protection standard for side impacts such as utility poles”).
- a battery pack formed by the battery pack case of the present disclosure exhibits an excellent effect of suppressing damage to the battery even in the side impact test, which is the new standard evaluation test (see Examples below).
- the battery pack case of the present disclosure preferably further includes a cover reinforcing member that reinforces at least a portion of the cover. This makes it possible to more effectively suppress damage to the battery when the electric vehicle collides. More preferably, the cover reinforcing member is a metal plate or a fiber reinforced tape.
- the tray in the battery pack case is The rear part of the tray placed under the rear seat of the electric vehicle, a tray extending portion extending in the front direction of the vehicle body from the rear portion of the tray and having a shorter length in the width direction of the vehicle body than the rear portion of the tray; can include In this mode (hereinafter referred to as "mode A"), a large tray rear portion can be arranged in a region below the large rear seat on the floor portion (floor panel) of the electric vehicle. A battery holding member having a large area can be arranged in the space. Therefore, according to Aspect A, the amount (volume) of batteries that can be accommodated in the battery pack increases.
- a battery holding member attached on the rear part of the tray is sometimes referred to as a battery holding member R. As shown in FIG.
- the tray rear portion and the tray extension portion do not need to be formed as separate members, and may be integrally formed as one member.
- a tray including a tray rear portion, a tray extension portion, and a tray front portion, which will be described later, may also be one integrally molded member.
- the battery holding member may be attached not only on the rear part of the tray but also on the extension part of the tray.
- the battery holding member attached on the tray extension may be referred to as a battery holding member M hereinafter.
- the tray may further include a tray front portion connected to an end portion of the tray extending portion in the front direction of the vehicle body.
- the tray front is preferably arranged under the front seat of the electric vehicle.
- the battery holding member may be attached not only on the tray rear portion but also on the tray front portion.
- the battery holding member attached on the tray front may be referred to as a battery holding member F hereinafter.
- the tray includes a rear part of the tray arranged under the rear seat of the electric vehicle, and a tray extending part extending in the front direction of the vehicle body from the rear part of the tray and having a shorter length in the vehicle width direction than the rear part of the tray, the battery retaining member includes a battery retaining member R mounted on at least a portion of the tray rear;
- the cover includes a cover rear portion that covers the tray rear portion and the battery holding member R, and a cover extension portion that covers at least the tray extension portion,
- the cover reinforcing member includes a cover rear reinforcing member that reinforces at least the connecting portion of the cover rear portion with the cover extension.
- the cover reinforcing member is the cover rear reinforcing member.
- the tray may further include a tray front portion connected to the end portion of the tray extending portion in the front direction of the vehicle body and arranged under the front seat of the electric vehicle.
- the battery pack case in this case preferably further includes a tray front reinforcing member, which is a metal member or a fiber reinforced tape, for reinforcing the edge of the tray front. This makes it possible to more effectively suppress damage to the battery when the electric vehicle collides.
- the battery retaining member includes a battery retaining member M attached to at least a portion of the tray extension;
- the cover extension covers the tray extension and the battery holding member M,
- the cover reinforcing member preferably includes a cover extending portion reinforcing member that reinforces at least a portion of the region of the cover extending portion that covers the battery holding member M.
- the battery pack case further includes a tray extension reinforcing member, which is a metal plate, which is a part of the tray extension in the vehicle body length direction and reinforces a region from one end to the other end in the vehicle width direction. is preferred.
- a tray extension reinforcing member which is a metal plate, which is a part of the tray extension in the vehicle body length direction and reinforces a region from one end to the other end in the vehicle width direction.
- the battery holding member in the battery pack case is preferably a battery module holding member that holds a battery module formed by stacking a plurality of lithium secondary batteries in the thickness direction.
- the battery module holding member is preferably a pair of end plates for sandwiching the battery module from the outside of both end portions in the thickness direction of the battery module (that is, the thickness direction (that is, stacking direction) of the plurality of lithium secondary batteries); a pair of side plates for sandwiching the battery module from outside of both ends of the battery module in a direction orthogonal to the thickness direction and the vertical direction; including.
- the pair of end plates and the pair of side plates preferably contain fiber-reinforced plastic.
- the pair of end plates are preferably plate-like members having a structure in which metal members are embedded in fiber-reinforced plastic.
- the battery pack case further comprises a shock absorbing layer disposed at least one between the pair of end plates and the battery module and between the battery module and the tray.
- a shock absorbing layer disposed at least one between the pair of end plates and the battery module and between the battery module and the tray.
- the tray and the cover are preferably joined directly or through a joining member.
- a joining member for example, a gasket
- the sealing member is preferably integrated with the tray or cover. As a result, the number of parts can be reduced, and the structure of the battery pack case can be simplified.
- a battery pack of the present disclosure is a battery pack mounted on an electric vehicle, a battery pack case of the present disclosure; a battery held by the battery holding member in the battery pack case; Prepare. According to the battery pack of the present disclosure, the same effects as those obtained by the battery pack case of the present disclosure are achieved.
- the battery pack of the present disclosure preferably includes a battery module that includes multiple batteries.
- the battery holding member is preferably a battery module holding member that holds the battery module.
- a preferred form of the battery module is as described in the section "battery pack case".
- the battery module including a plurality of batteries is preferably a battery module in which a plurality of lithium secondary batteries are stacked in the thickness direction.
- Each of the plurality of lithium secondary batteries may be a laminated lithium secondary battery in which the electrodes (positive electrode and negative electrode) are laminated, or a wound type in which the electrodes (positive electrode and negative electrode) are wound. may be a lithium secondary battery.
- known documents such as Japanese Patent No. 6751570 and Japanese Patent No. 6645500 can be referred to as appropriate.
- the battery pack of the present disclosure can be formed by holding batteries (preferably battery modules) in the battery pack case of the present disclosure.
- batteries preferably battery modules
- the batteries in the battery pack may be replaced. That is, the deteriorated battery may be removed from the battery pack case in the battery pack, and a new battery may be retained.
- Embodiments of the battery pack case of the present disclosure are obtained by removing the batteries from the battery packs according to the following embodiments.
- the battery pack and battery pack case of the present disclosure are not limited to the following embodiments. Elements common to each drawing are denoted by the same reference numerals, and redundant description may be omitted.
- FIG. 1 is a schematic perspective view of the vehicle body of an electric vehicle equipped with a battery pack according to this embodiment
- FIG. 2 is a schematic perspective view of the battery pack according to this embodiment.
- a battery pack 10 according to this embodiment is mounted in a vehicle body 100 of an electric vehicle.
- the battery pack 10 includes battery modules housed in a battery pack case including a tray 14 and a cover 12 .
- FIG. 3 is an exploded perspective view conceptually showing how the cover 12 is removed from the tray 14 in the battery pack.
- the battery pack case forming the battery pack 10 is: a tray 14 attached to the body 100 of the electric vehicle; battery holding members (18F, 18M, 18R) attached to at least a portion of the tray 14 to hold batteries; a cover 12 covering the tray 14 and the battery holding member; Prepare.
- the battery pack 10 is formed by holding batteries (in detail, battery modules 16F, 16M, and 16R, which will be described later) in battery holding members in the battery pack case.
- a sealing member for example, a gasket (not shown) is interposed at the junction between the tray 14 and the cover 12. As a result, the battery pack is sealed, and intrusion of water, dust, etc. into the battery pack is suppressed.
- the sealing member is integral with the tray or cover.
- the tray 14 includes a tray rear portion 14R, a tray extension portion 14M, and a tray front portion 14F.
- the tray rear portion 14R is arranged under the rear seat of the electric vehicle.
- the tray extending portion 14M is a portion extending from the tray rear portion 14R in the front direction of the vehicle body (the direction of the arrow FR in FIG. 1; the same shall apply hereinafter).
- the tray extending portion 14M is a member having a shorter length in the vehicle body width direction (direction of arrow W in FIG. 1) than the tray rear portion 14R.
- the tray front portion 14F is connected to the end of the tray extending portion 14M in the front direction of the vehicle body.
- the tray front part 14F is arranged under the front seat of the electric vehicle.
- a battery holding member 18R for holding the battery module 16R is attached on the tray rear part 14R
- a battery holding member 18M for holding the battery module 16M is mounted on the tray extension 14M
- a battery holding member 18F for holding the battery module 16F is attached on the tray front portion 14F.
- the battery holding member 18R, the battery holding member 18M, and the battery holding member 18F are members for holding the battery module 16R, the battery module 16M, and the battery module 16F, respectively.
- Each of the battery module 16R, the battery module 16M, and the battery module 16F is a battery module formed by stacking a plurality of lithium secondary batteries in the thickness direction. Detailed structures of the battery holding member 18R, the battery holding member 18M, and the battery holding member 18F will be described later.
- the cover 12 includes a cover rear portion 12R, a cover extension portion 12M, and a cover front portion 12F.
- the cover rear portion 12R is a portion of the cover 12 that covers the tray rear portion 14R, the battery holding members 18R, and the battery modules 16R.
- the cover extension 12M is a portion of the cover 12 that covers the tray extension 14M, the battery holding members 18M, and the battery modules 16M.
- the cover front portion 12F is a portion of the cover 12 that covers the tray front portion 14F, the battery holding members 18F, and the battery modules 16F.
- At least two of a tray, a battery holding member, and a cover contain fiber-reinforced plastic.
- a tray, a battery holding member, and a cover that is, a combination of a tray and a battery holding member, a combination of a battery holding member and a cover, a combination of a tray and a cover, or a tray and the combination of the battery holding member and the cover
- fiber-reinforced plastic that is, it is possible to effectively reduce the weight of the battery pack and prevent damage to the battery in the event of a collision of the electric vehicle.
- FIG. 4 is a schematic perspective view of the battery pack according to the present embodiment when the cover 12 is indicated by dotted lines, and is a view corresponding to FIG.
- the cover reinforcing members that is, the cover rear reinforcing member 20RF, the cover rear reinforcing member 20RS, the cover rear reinforcing member 20RR, the cover extension reinforcing member 20M, and the cover front reinforcing member 20F
- the cover 12 is indicated by dotted lines.
- each of the cover reinforcing members for reinforcing the cover covers at least part of the battery modules on the tray.
- These cover reinforcing members protect at least a portion of the battery modules on the tray, thereby effectively suppressing damage to the batteries in the event of a collision.
- Each of the cover reinforcing members is actually attached to the inner wall of the cover 12 or embedded in the cover 12 to reinforce a portion of the cover (specifically, the portion covering the battery).
- Each of the cover reinforcing members is preferably a metal plate or a fiber reinforced tape.
- a cover reinforcing member in the form of a fiber reinforced tape is preferably applied to the inner wall of cover 12 .
- the cover reinforcing member in the form of a metal plate may be attached to the inner wall of the cover 12 or embedded in the cover 12 .
- the cover reinforcing members include a cover rear reinforcing member 20RF, a cover rear reinforcing member 20RS, a cover rear reinforcing member 20RR, a cover extension reinforcing member 20M, and a cover front reinforcing member 20F.
- the cover rear reinforcing member 20RF is a member that reinforces at least the connection portion of the cover rear portion 12R with the cover extension portion 12M (in other words, the vehicle body front portion of the cover rear portion 12R).
- the cover rear reinforcing member 20RS is a member that reinforces both ends of the cover rear portion 12R in the vehicle width direction.
- the cover rear reinforcing member 20RR is a member that reinforces the vehicle body rear portion of the cover rear portion 12R.
- the cover extension reinforcing member 20M is a member that reinforces the cover extension 12M.
- the cover front portion reinforcing member 20F is a member that reinforces the cover front portion 12F.
- each cover reinforcing member contributes to suppressing damage to the battery in the event of a collision.
- the cover rear reinforcing member 20RF which reinforces at least the connection portion of the cover rear portion 12R with the cover extension portion 12M, is The effect of suppressing damage to the battery in the event of a collision (particularly during a side collision) is large.
- the battery pack 10 further includes a tray front reinforcing member 22F that reinforces the edge of the tray front 14F. This further suppresses damage to the batteries arranged on the tray front portion at the time of collision.
- the tray front reinforcement member 22F is preferably a metal member or fiber reinforced tape. At least part of the tray front reinforcing member 22F, which is a metal member, may be embedded in the tray front portion 14F.
- FIG. 5 is a schematic bottom view of the battery pack 10 (that is, a schematic bottom view of the tray).
- Battery pack 10 includes tray extension portion reinforcing member 30M embedded in the lower surface side of tray extension portion 14M.
- the tray extending portion reinforcing member 30M reinforces a portion of the tray extending portion 14M in the vehicle body length direction and extending from one end to the other end in the vehicle width direction. As a result, the effect of suppressing damage to the battery during a collision (particularly during a side collision) can be remarkably obtained.
- a metal plate is preferably used as the tray extending portion reinforcing member 30M.
- each structure of the battery holding member 18R and the battery module 16R will be described.
- the structure of each of the battery holding members 18M and 18F is similar to that of the battery holding member 18R, and the structure of each of the battery modules 16M and 16F is similar to that of the battery module 16R.
- the battery holding member 18R is a battery module holding member that holds a battery module 16R formed by stacking a plurality of lithium secondary batteries in the thickness direction.
- FIG. 6 is a schematic perspective view of the tray rear and battery holding members mounted on the tray rear. FIG. 6 shows a state in which the battery module 16R is removed from the tray rear portion 14 in FIGS. 3 and 4 in order to make the configuration of the battery holding member easier to see.
- 7 is a schematic perspective view showing a state in which the battery holding member shown in FIG. 6 holds the battery modules.
- FIG. FIG. 7 corresponds to an enlarged view of the tray rear side of the battery pack 10 in FIG.
- the battery holding member 18R which is a battery module holding member, includes a pair of end plates 18E and a pair of side plates 18S.
- the pair of end plates 18E sandwich the battery module 16R from the outside of both ends in the thickness direction of the plurality of lithium secondary batteries in the battery module 16R (that is, the stacking direction in which the plurality of lithium secondary batteries are stacked). do.
- the end plate 18E and the outermost lithium secondary battery may be adjacent to each other, or another layer (for example, a shock absorbing layer) may be provided between the end plate 18E and the outermost lithium secondary battery. may intervene.
- the function of the pair of end plates 18E is to sandwich the battery module 16R from the outside of the both end portions.
- Another function of the pair of end plates 18E is to suppress swelling of the battery module R due to repeated charge/discharge cycles.
- the swelling of the battery module R is caused by swelling in the thickness direction of the plurality of lithium secondary batteries.
- the pair of end plates 18E may also have other functions such as a shock absorbing function.
- the pair of side plates 18S sandwich the battery module 16R from the outside of both ends of the battery module in a direction perpendicular to the thickness direction and the vertical direction of the plurality of lithium secondary batteries (the width direction of the vehicle body in this example). do.
- the function of the pair of side plates 18S is to sandwich the battery module 16R from the outside of the both ends.
- Another function of the pair of side plates 18S is to suppress lateral slippage of the plurality of lithium secondary batteries in the battery module.
- the function of the pair of side plates 18S may include other functions such as a heat radiation function and a cooling function.
- As a method of imparting a heat dissipation function to the side plate 18S there is a method of providing a through hole penetrating the side plate in the plate thickness direction.
- As a method of imparting a cooling function to the side plate 18S there is a method of embedding a cooling member (for example, a pipe for circulating a cooling medium) in the side plate.
- one frame is formed by a pair of end plates 18E and a pair of side plates 18S, and battery modules are housed in this frame.
- the five frames are arranged in the width direction of the vehicle body, and adjacent frames share one side plate 18S. That is, the battery holding member 18R has six side plates 18S and ten end plates 18E.
- the number of side plates 18S and end plates 18E (in other words, the number of "frames") can be changed as appropriate.
- a shock absorbing layer 28 is arranged in the area where the battery module is held on the tray rear portion 14R (under the battery module when the battery module is held). As a result, the effect of suppressing damage to the battery at the time of collision is more effectively exhibited.
- FIG. 8 is a schematic perspective view showing an end plate forming part of the battery holding portion.
- the end plate 18E is preferably a plate member having a structure in which a cylindrical metal member 32 is embedded in fiber reinforced plastic.
- a metal bolt (not shown) may pass through the cylindrical metal member 32 .
- the metal member may be cylindrical.
- the battery pack and battery pack case of the present disclosure are not limited to the above embodiments. As long as each requirement of the battery pack and the battery pack case of the present disclosure is satisfied, various modifications of the above embodiment are also within the scope of the battery pack and the battery pack case of the present disclosure. .
- modifications of the battery pack of the above embodiment include the examples listed below.
- the tray front portion, the battery holding portion and the batteries on the tray front portion, and the cover front portion are omitted from the battery pack of the above-described embodiment to reduce the size.
- the battery holding member and the batteries on the tray extension portion and/or the battery holding member and the batteries on the tray front portion are omitted from the battery pack of the above embodiment. .
- a tray including a tray rear part and a tray extension part with different lengths in the width direction of the vehicle body for example, an example in which a rectangular tray is combined with a cover that matches the tray of this shape is also given. be done.
- the battery pack case of the present disclosure only needs to include a tray, a battery holding member, and a cover, and the shapes of members such as the tray and cover are not particularly limited.
- the fibers contained in the fiber-reinforced plastic are not particularly limited as long as they are fibers contained in ordinary fiber-reinforced plastics.
- the fiber-reinforced plastic may contain at least one fiber selected from the group consisting of glass fiber, aramid fiber, carbon fiber, Zylon fiber, polyethylene fiber, and boron fiber. preferable.
- At least one of the tray and the cover is It preferably contains fiber reinforced plastic, More preferably, it contains a fiber-reinforced plastic containing two or more types of fibers, More preferably, it contains fiber-reinforced plastic containing two or more fibers selected from the group consisting of glass fiber, aramid fiber, carbon fiber, Zylon fiber, polyethylene fiber, and boron fiber.
- the ratio of the fiber content to the total amount of the fiber-reinforced plastic is preferably 20% to 70% by mass, more preferably 30% to 60% by mass, relative to the total amount of the fiber-reinforced plastic.
- the preferable range of the ratio of the fiber content to the total amount of the member containing the fiber-reinforced plastic is also the same as the preferred range of the ratio of the fiber content to the total amount of the fiber-reinforced plastic.
- the resin (that is, the matrix resin) in the fiber-reinforced plastic is not particularly limited, and known resins can be applied.
- resins include polypropylene, polyester (that is, saturated polyester or unsaturated polyester), polyamide, polyetheretherketone, polycarbonate, polyphenylene sulfone, polyphenylene ether, thermoplastic polyurethane, and the like.
- the fiber-reinforced plastic may contain only one type of resin, or may contain two or more types.
- the ratio of the resin content to the total amount of the fiber-reinforced plastic is preferably 30% to 80% by mass, more preferably 40% to 70% by mass, relative to the total amount of the fiber-reinforced plastic.
- the preferable range of the ratio of the resin content to the total amount of the member containing the fiber-reinforced plastic is also the same as the preferred range of the ratio of the resin content to the total amount of the fiber-reinforced plastic.
- Fiber-reinforced plastics may contain components (additives, etc.) other than fibers and resins.
- additives include flame retardants (preferably brominated flame retardants).
- the content ratio of the flame retardant to the total amount of the fiber-reinforced plastic is preferably 10% to 30% by mass, more preferably 20% to 30% by mass, relative to the total amount of the fiber-reinforced plastic.
- the preferred range of the content ratio of the flame retardant to the total amount of the member containing the fiber-reinforced plastic is also the same as the preferred range of the content ratio of the flame retardant to the total amount of the fiber-reinforced plastic.
- Members containing fiber-reinforced plastic for example, trays, battery holding members, or covers
- injection molding SMC (Sheet Molding Compound) molding
- press molding press molding
- extrusion press molding extrusion press molding
- the battery pack case of the present disclosure may include reinforcing members (for example, cover reinforcing members, tray reinforcing members, etc.).
- the shape of the reinforcing member can be appropriately selected in consideration of the shape of the member to be reinforced by the reinforcing member, the strength of the reinforcement, and so on.
- Examples of the shape of the reinforcing member include plate-like, rod-like, cylindrical, sheet-like (for example, the shape of fiber reinforced tape), and the like.
- a metal member for example, a metal plate, a metal rod, etc.
- a fiber-reinforced tape is preferable as the reinforcing member.
- the material of the metal member is not particularly limited, and known materials such as aluminum, aluminum alloys, and stainless steel can be applied.
- the material of the fiber-reinforced tape is not particularly limited, and known materials can be applied. Examples of the material of the fiber-reinforced tape include materials similar to those of the above-described fiber-reinforced plastic.
- the battery pack case of the present disclosure preferably includes a sealing member (such as a gasket) interposed between the tray and the cover.
- a sealing member such as a gasket
- the sealing member preferably contains at least one thermoplastic elastomer.
- thermoplastic elastomers include olefinic elastomers (e.g., TPO, TPV, etc.), styrenic elastomers (e.g., SEEPS, SEPS, SEBS, etc.), urethane elastomer, polyvinyl chloride elastomer (e.g., TPVC), polyamide-based elastomers (e.g., PAER, TPAE, etc.), polyester elastomer (eg, TPEE), acrylic rubber, ethylene propylene rubber, etc.
- olefinic elastomers e.g., TPO, TPV, etc.
- styrenic elastomers e.g., SEEPS, SEPS, SEBS, etc.
- urethane elastomer e.g., polyvinyl chloride elastomer (e.g.
- the battery pack case further includes a shock absorbing layer (for example, the shock absorbing layer 28 ) is preferably provided.
- the impact absorbing layer preferably contains at least one thermoplastic elastomer. Materials for the shock absorbing layer include those similar to those for the sealing member described above.
- wt % and weight substantially mean mass % and mass.
- Examples 1 to 40, Comparative Examples 1 to 5 Regarding the battery pack 10 according to the above-described embodiment (see FIGS. 1 to 5), G-shock test Z when materials shown in Tables 1 and 2 are selected as materials for each of the cover, tray, and battery holding member. Simulations were performed for each of the axle, weight reduction rate, and side impact tests. The details of the materials shown in Tables 1 and 2 are as follows.
- the column of material for each of the cover, tray, and battery holding member includes the type of resin and the type and content of fiber (the content of fiber relative to the total content of resin and fiber).
- the notation "SMC GF 37 wt% + CF 2 wt%” means that when the total amount of resin and fiber is 100% by mass, 37% by mass of glass fiber (GF) is contained and 2% by mass of carbon fiber (CF). contained and the balance is resin (SMC).
- the cover reinforcing member the cover reinforcing member made of Al alloy was used throughout all the examples.
- the simulation was performed under MAT-24 conditions using the nonlinear structural analysis software LS-DYNA (manufactured by JSOL Co., Ltd.).
- the evaluation contents and evaluation criteria for each of the G-Shock test Z-axis, weight reduction rate, and side impact test are as follows.
- G-shock test Z-axis In the G-shock test Z-axis, an electric vehicle equipped with a battery pack was subjected to an acceleration impact of 18G in the X-axis direction, 15G in the Y-axis direction, and 25G in the Z-axis direction, and the battery pack case fractured. And the influence on the batteries in the battery pack was confirmed and evaluated according to the following evaluation criteria. In the following evaluation criteria, "A" is the most excellent rank in the effect of suppressing damage to the battery in the event of a collision of an electric vehicle.
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Abstract
Description
バッテリパックが収納されるケース本体と、ケース本体に組み立てられるカバーとを含んで構成される電気自動車用バッテリパックケースアセンブリであって、
ケース本体が、プラスチック基材に補強繊維として長繊維、または長繊維と連続繊維が混合使用されたプラスチック複合材料からなり、
ケース本体における車体締結のための両サイドブラケット部には、プラスチック基材に補強繊維として長繊維、連続繊維、または長繊維と連続繊維が混合使用されたプラスチック複合材料からなる別途の補強部材が接合されたことを特徴とする電気自動車用バッテリパックケースアセンブリが開示されている。
特許文献1には、上記電気自動車用バッテリパックケースアセンブリによれば、ケースの素材として軽量のプラスチック複合素材を用いて重量を減少させると共に剛性、衝突特性、及び寸法安定性を同時に向上できる、と記載されている。
一方、電池パックの軽量化が求められる場合もある。
<1> 電気自動車に搭載される電池パックの形成に用いられる電池パック用ケースであって、
電気自動車の車体に取り付けられるトレイと、
前記トレイ上の少なくとも一部分に取り付けられ、電池を保持する電池保持部材と、
前記トレイ上及び前記電池保持部材上を覆うカバーと、
を備え、
前記トレイ、前記電池保持部材、及び前記カバーのうちの少なくとも2つが、繊維強化プラスチックを含む、
電池パック用ケース。
<2> 更に、前記カバーの少なくとも一部分を補強する、金属板又は繊維強化テープであるカバー補強部材を備える、<1>に記載の電池パック用ケース。
<3> 前記トレイは、前記電気自動車のリアシート下に配置されるトレイ後部と、前記トレイ後部から車体前方向に延びる、前記トレイ後部よりも車体幅方向の長さが短いトレイ延出部と、を含み、
前記電池保持部材は、前記トレイ後部上の少なくとも一部分に取り付けられた電池保持部材Rを含み、
前記カバーは、前記トレイ後部上及び前記電池保持部材R上を覆うカバー後部と、少なくとも前記トレイ延出部上を覆うカバー延出部と、を含み、
前記カバー補強部材は、前記カバー後部の、少なくとも前記カバー延出部との接続部分を補強するカバー後部補強部材を含む、
<2>に記載の電池パック用ケース。
<4> 前記トレイは、更に、前記トレイ延出部における車体前方向の端部に接続され、前記電気自動車のフロントシート下に配置されるトレイ前部を含み、
更に、前記トレイ前部の縁部を補強する、金属部材又は繊維強化テープであるトレイ前部補強部材を備える、
<3>に記載の電池パック用ケース。
<5> 前記電池保持部材は、前記トレイ延出部上の少なくとも一部分に取り付けられた電池保持部材Mを含み、
前記カバー延出部が、前記トレイ延出部上及び前記電池保持部材M上を覆い、
前記カバー補強部材は、前記カバー延出部の前記電池保持部材M上を覆う領域の少なくとも一部分を補強するカバー延出部補強部材を含む、
<3>又は<4>に記載の電池パック用ケース。
<6> 更に、前記トレイ延出部の車体長さ方向の一部分であって車体幅方向の一端から他端までの領域を補強する、金属板であるトレイ延出部補強部材を備え、
前記トレイ延出部補強部材の少なくとも一部は、前記トレイ延出部中に埋め込まれている、
<3>に記載の電池パック用ケース。
<7> 前記トレイ及び前記カバーの少なくとも一方が、ガラス繊維、アラミド繊維、カーボン繊維、ザイロン繊維、ポリエチレン繊維、及びボロン繊維からなる群から選択される2種以上の繊維を含む繊維強化プラスチックを含む、<1>~<6>のいずれか1つに記載の電池パック用ケース。
<8> 前記電池保持部材は、複数のリチウム二次電池が厚さ方向に積層されてなる電池モジュールを保持する電池モジュール保持部材であり、
前記電池モジュール保持部材が、
前記電池モジュールの前記厚さ方向の両端部の外側から前記電池モジュールを挟持するための一対のエンドプレートと、
前記電池モジュールの前記厚さ方向及び鉛直方向に対して直交する方向の両端部の外側から、前記電池モジュールを挟持するための一対のサイドプレートと、
を含み、
前記一対のエンドプレート及び前記一対のサイドプレートが、前記繊維強化プラスチックを含む、
<1>~<7>のいずれか1つに記載の電池パック用ケース。
<9> 前記一対のエンドプレートは、繊維強化プラスチック中に金属部材が埋め込まれた構造を有する板状部材である、<8>に記載の電池パック用ケース。
<10> 更に、前記一対のエンドプレートと前記電池モジュールとの間、及び、前記電池モジュールと前記トレイとの間の少なくとも1か所に配置された衝撃吸収層を含む、<8>又は<9>に記載の電池パック用ケース。
<11> 電気自動車に搭載される電池パックであって、
<1>~<10>のいずれか1つに記載の電池パック用ケースと、
前記電池パック用ケースにおける前記電池保持部材に保持された電池と、
を備える、電池パック。
本明細書において、組成物中の各成分の量は、組成物中に各成分に該当する物質が複数存在する場合は、特に断らない限り、組成物中に存在する当該複数の物質の合計量を意味する。
本開示の電池パック用ケースは、電気自動車に搭載される電池パックの形成に用いられる電池パック用ケースであって、
電気自動車の車体に取り付けられるトレイと、
トレイ上の少なくとも一部分に取り付けられ、電池を保持する電池保持部材と、
トレイ上及び電池保持部材上を覆うカバーと、
を備え、
トレイ、電池保持部材、及びカバーのうちの少なくとも2つが、繊維強化プラスチックを含む、
電池パック用ケースである。
即ち、本開示の電池パック用ケースによれば、電気自動車の衝突時における電池の損傷をより抑制できる電池パックであって、軽量化された電池パックを形成できる。
特に、後述する実施例における側面衝突試験は、日本国国土交通省において、2018年6月に制定された新基準評価試験である(「電柱などの側面衝突時の乗員保護基準」)。本開示の電池パック用ケースによって形成された電池パックは、かかる新基準評価試験である側面衝突試験においても、電池の損傷抑制に対し、優れた効果を示す(後述の実施例参照)。
カバー補強部材は、金属板又は繊維強化テープであることがより好ましい。
電気自動車のリアシート下に配置されるトレイ後部と、
トレイ後部から車体前方向に延びる、トレイ後部よりも車体幅方向の長さが短いトレイ延出部と、
を含むことができる。
この態様(以下、「態様A」とする)では、電気自動車の床部分(フロアパネル)における、面積が広いリアシート下の領域に、面積が広いトレイ後部を配置することができ、かかるトレイ後部上に、面積が広い電池保持部材を配置することができる。従って、上記態様Aによれば、電池パックに収容できる電池の量(体積)が増大する。
トレイ後部上に取り付けられる電池保持部材を、電池保持部材Rと称することがある。
後述する、トレイ後部とトレイ延出部とトレイ前部とを含むトレイも、一体成形された一つの部材であってもよい。
後述する、カバー後部とカバー延出部とを含むカバー、カバー後部とカバー延出部とカバー前部とを含むカバーについても同様である。
トレイがトレイ前部を含む場合、トレイ後部上だけでなく、トレイ前部上にも、電池保持部材が取り付けられていてもよい。トレイ前部上に取り付けられる電池保持部材を、以下、電池保持部材Fと称することがある。
トレイが、電気自動車のリアシート下に配置されるトレイ後部と、トレイ後部から車体前方向に延びる、トレイ後部よりも車体幅方向の長さが短いトレイ延出部と、を含み、
電池保持部材が、トレイ後部上の少なくとも一部分に取り付けられた電池保持部材Rを含み、
カバーが、トレイ後部上及び電池保持部材R上を覆うカバー後部と、少なくともトレイ延出部上を覆うカバー延出部と、を含み、
カバー補強部材が、カバー後部の、少なくともカバー延出部との接続部分を補強するカバー後部補強部材を含むことが好ましい。
トレイは、トレイ延出部の車体前方向の端部に接続され、電気自動車のフロントシート下に配置されるトレイ前部を更に含んでいてもよい。
この場合の電池パック用ケースは、更に、トレイ前部の縁部を補強する、金属部材又は繊維強化テープであるトレイ前部補強部材を備えることが好ましい。これにより、電気自動車の衝突時における電池の損傷をより効果的に抑制できる。
電池保持部材は、トレイ延出部上の少なくとも一部分に取り付けられた電池保持部材Mを含み、
カバー延出部が、トレイ延出部上及び電池保持部材M上を覆い、
カバー補強部材は、カバー延出部の電池保持部材M上を覆う領域の少なくとも一部分を補強するカバー延出部補強部材を含むことが好ましい。
カバー補強部材が、カバー延出部補強部材を含む場合には、電気自動車の衝突時における電池の損傷がより効果的に抑制される。
トレイ延出部補強部材の少なくとも一部は、トレイ延出部中に埋め込まれていることが好ましい。
電池モジュール保持部材は、好ましくは、
電池モジュールの上記厚さ方向(即ち、複数のリチウム二次電池の厚さ方向(即ち、積層方向))の両端部の外側から電池モジュールを挟持するための一対のエンドプレートと、
電池モジュールの上記厚さ方向及び鉛直方向に対して直交する方向の両端部の外側から、上記電池モジュールを挟持するための一対のサイドプレートと、
を含む。
上記一対のエンドプレート及び上記一対のサイドプレートは、繊維強化プラスチックを含むことが好ましい。
これにより、電池パックの軽量化の効果及び衝突時における電池の損傷の抑制効果がより効果的に奏される。
これにより、衝突時における電池の損傷の抑制の効果及び軽量化の効果がより効果的に奏される。
これにより、衝突時における電池の損傷の抑制効果がより効果的に奏される。
上記効果がより効果的に得られる観点から、トレイとカバーとは、接合部材としての封止部材(例えばガスケット)を介して接合されていることがより好ましい。
本開示の電池パックは、電気自動車に搭載される電池パックであって、
本開示の電池パック用ケースと、
電池パック用ケースにおける上記電池保持部材に保持された電池と、
を備える。
本開示の電池パックによれば、本開示の電池パック用ケースによって得られる効果と同様の効果が奏される。
この場合、電池保持部材は、上記電池モジュールを保持する電池モジュール保持部材であることが好ましい。
電池モジュールの好ましい形態については、「電池パック用ケース」の項で説明したとおりである。
複数のリチウム二次電池の各々は、電極(正極及び負極)が積層されている積層型のリチウム二次電池であってもよいし、電極(正極及び負極)が巻回されている巻回型のリチウム二次電池であってもよい。
電池モジュールについては、例えば、特許第6751570号公報、特許第6645500号公報等の公知文献を適宜参照できる。
形成された電池パックにおける電池の充放電サイクルが繰り返され、電池が劣化した場合には、電池パックにおける電池を交換してもよい。即ち、電池パックにおける電池パック用ケースから劣化した電池を取り外し、新たな電池を保持させてもよい。
以下、本開示の電池パックの実施形態について、図面を参照しながら説明し、その説明の中で、本開示の電池パック用ケースの実施形態についても説明する。本開示の電池パック用ケースの実施形態は、下記実施形態に係る電池パックから電池を除いたものである。
本開示の電池パック及び電池パック用ケースは、以下の実施形態に限定されるものではない。
各図面に共通の要素については、同一の符号を付し、重複した説明を省略することがある。
図1及び図2に示されるように、本実施形態に係る電池パック10は、電気自動車の車体100中に搭載されるものである。電池パック10は、トレイ14及びカバー12を含む電池パック用ケースに、電池モジュールが収容されたものである。
図3は、電池パックにおけるトレイ14からカバー12を取り外した様子を概念的に示す分解斜視図である。
電気自動車の車体100に取り付けられるトレイ14と、
トレイ14上の少なくとも一部分に取り付けられ、電池を保持する電池保持部材(18F、18M、18R)と、
トレイ14上及び電池保持部材上を覆うカバー12と、
を備える。
トレイ後部14Rは、電気自動車のリアシート下に配置される。
トレイ延出部14Mは、トレイ後部14Rから車体前方向(図1中の矢印FRの方向。以下同じ)に延びる部分である。このトレイ延出部14Mは、トレイ後部14Rよりも車体幅方向(図1中の矢印Wの方向)の長さが短い部材である。
トレイ前部14Fは、トレイ延出部14Mにおける車体前方向の端部に接続されている。トレイ前部14Fは、電気自動車のフロントシート下に配置される。
トレイ延出部14M上には、電池モジュール16Mを保持するための電池保持部材18Mが取り付けられており、
トレイ前部14F上には、電池モジュール16Fを保持するための電池保持部材18Fが取り付けられている。
電池保持部材18R、電池保持部材18M、及び電池保持部材18Fは、それぞれ、電池モジュール16R、電池モジュール16M、及び電池モジュール16Fを保持するための部材である。
電池モジュール16R、電池モジュール16M、及び電池モジュール16Fは、それぞれ、複数のリチウム二次電池が厚さ方向に積層されてなる電池モジュールである。
電池保持部材18R、電池保持部材18M、及び電池保持部材18Fの詳細な構造については後述する。
カバー後部12Rは、カバー12のうち、トレイ後部14R、電池保持部材18R、及び電池モジュール16Rを覆っている部分である。
カバー延出部12Mは、カバー12のうち、トレイ延出部14M、電池保持部材18M、及び電池モジュール16Mを覆っている部分である。
カバー前部12Fは、カバー12のうち、トレイ前部14F、電池保持部材18F、及び電池モジュール16Fを覆っている部分である。
これにより、電池パックの軽量化と、電気自動車の衝突時における電池の損傷の抑制と、が効果的に実現される。
図4では、カバー補強部材(即ち、カバー後部補強部材20RF、カバー後部補強部材20RS、カバー後部補強部材20RR、カバー延出部補強部材20M、及びカバー前部補強部材20F)を見やすくするために、カバー12を点線で示している。
カバー補強部材の各々として、好ましくは、金属板又は繊維強化テープである。
繊維強化テープである態様のカバー補強部材は、好ましくはカバー12の内壁に貼り付けられる。
金属板である態様のカバー補強部材は、カバー12の内壁に貼り付けられていてもよいし、カバー12に埋め込まれていてもよい。
カバー後部補強部材20RFは、カバー後部12Rの、少なくともカバー延出部12Mとの接続部分(言い換えれば、カバー後部12Rにおける車体前方部分)を補強する部材であり、
カバー後部補強部材20RSは、カバー後部12Rの車体幅方向の両端部を補強する部材であり、
カバー後部補強部材20RRは、カバー後部12Rの車体後方部分を補強する部材であり、
カバー延出部補強部材20Mは、カバー延出部12Mを補強する部材であり、
カバー前部補強部材20Fは、カバー前部12Fを補強する部材である。
金属部材である態様のトレイ前部補強部材22Fの少なくとも一部分は、トレイ前部14Fに埋め込まれていてもよい。
電池パック10は、トレイ延出部14Mの下面側に埋め込まれたトレイ延出部補強部材30Mを備える。
トレイ延出部補強部材30Mは、トレイ延出部14Mの車体長さ方向の一部分であって車体幅方向の一端から他端までの領域を補強する。これにより、衝突時(特に側面衝突時)における電池の損傷抑制の効果が顕著に得られる。
トレイ延出部補強部材30Mとして、好ましくは金属板である。
電池保持部材18M及び電池保持部材18Fの各々の構造も電池保持部材18Rの構造と同様であり、電池モジュール16M及び電池モジュール16Fの各々の構造も電池モジュール16Rの構造と同様である。
図6は、トレイ後部及びトレイ後部上に取り付けられた電池保持部材の概略斜視図である。図6では、電池保持部材の構成を見やすくするために、図3及び図4におけるトレイ後部14上から電池モジュール16Rを除去した様子を示している。
図7は、図6に示す電池保持部材が電池モジュールを保持した状態を示す概略斜視図である。図7は、図3における電池パック10のトレイ後部側の拡大図に相当する。
一対のエンドプレート18Eは、電池モジュール16Rにおける複数のリチウム二次電池の厚さ方向(即ち、複数のリチウム二次電池が積層されている積層方向)の両端部の外側から、電池モジュール16Rを挟持する。ここで、エンドプレート18Eと最外層のリチウム二次電池とが隣接していてもよいし、エンドプレート18Eと最外層のリチウム二次電池との間に他の層(例えば、衝撃吸収層)が介在していてもよい。
一対のエンドプレート18Eの機能は、上記両端部の外側から電池モジュール16Rを挟持する機能である。
一対のエンドプレート18Eのもう一つの機能は、充放電サイクルの繰り返しによる電池モジュールRの膨れを抑え込む機能である。電池モジュールRの膨れは、複数のリチウム二次電池の厚さ方向の膨れに起因する。
一対のエンドプレート18Eは、更に、衝撃吸収機能等のその他の機能を有していてもよい。
一対のサイドプレート18Sの機能は、上記両端部の外側から電池モジュール16Rを挟持する機能である。一対のサイドプレート18Sのもう一つの機能は、電池モジュールにおける複数のリチウム二次電池の横ずれを抑制する機能である。
一対のサイドプレート18Sの機能は、放熱機能、冷却機能等のその他の機能を備えていてもよい。
サイドプレート18Sに放熱機能を持たせる方法としては、サイドプレートのプレート厚さ方向を貫通する貫通孔を設ける方法等が挙げられる。
サイドプレート18Sに冷却機能を持たせる方法としては、サイドプレートに冷却部材(例えば、冷却媒体を流通するためのパイプ)を埋め込む方法等が挙げられる。
サイドプレート18S及びエンドプレート18Eの数(言い換えれば、上記「枠」の数)は、適宜変更できる。
エンドプレート18Eは、繊維強化プラスチック中に、円筒形状の金属部材32が埋め込まれた構造を有する板状部材であることが好ましい。
これにより、衝突時における電池の損傷の抑制の効果(金属部材による効果)及び軽量化の効果(ベースである繊維強化プラスチックによる効果)がより効果的に奏される。
この場合、円筒形状の金属部材32の内部を、金属製のボルト(不図示)が貫通していてもよい。
また、金属部材は、円柱形状であってもよい。
以上、本開示の電池パック及び電池パック用ケースの実施形態について説明したが、本開示の電池パック及び電池パック用ケースは、上記実施形態に限定されるものではない。
本開示の電池パック及び電池パック用ケースの各々の要件を満足する限り、上記実施形態に対して様々な変更を加えた変形例も、本開示の電池パック及び電池パック用ケースの範囲内である。
変形例として、上記実施形態の電池パックに対し、トレイ前部と、トレイ前部上の電池保持部及び電池と、カバー前部と、が省略されて小型化された例が挙げられる。
また、変形例として、上記実施形態の電池パックに対し、トレイ延出部上の電池保持部材及び電池、並びに/又は、トレイ前部上の電池保持部材及び電池が省略されている例も挙げられる。
また、変形例として、車体幅方向の長さが異なるトレイ後部及びトレイ延出部を含むトレイではなく、例えば、長方形状のトレイに対し、この形状のトレイに合わせたカバーが組み合わせられる例も挙げられる。
次に、本開示の電池パック用ケースの各部材の好ましい材質等について説明する。
本開示の電池パック用ケースにおいて、トレイ、電池保持部材、及びカバーのうちの少なくとも2つは、繊維強化プラスチックを含む。
これにより、衝突時における電池の損傷抑制の効果と、電池パック用ケースの軽量化の効果と、が実現される。
電池の損傷をより抑制する観点から、繊維強化プラスチックは、繊維として、ガラス繊維、アラミド繊維、カーボン繊維、ザイロン繊維、ポリエチレン繊維、及びボロン繊維からなる群から選択される少なくとも1種を含むことが好ましい。
本開示の電池パック用ケースのうち、トレイ及びカバーの少なくとも一方が、
繊維強化プラスチックを含むことが好ましく、
2種以上の繊維を含む繊維強化プラスチックを含むことがより好ましく、
ガラス繊維、アラミド繊維、カーボン繊維、ザイロン繊維、ポリエチレン繊維、及びボロン繊維からなる群から選択される2種以上の繊維を含む繊維強化プラスチックを含むことが更に好ましい。
繊維強化プラスチックを含む部材の全量に対する繊維の含有量の比率の好ましい範囲も、繊維強化プラスチックの全量に対する繊維の含有量の比率の好ましい範囲と同様である。
樹脂として、例えば、ポリプロピレン、ポリエステル(即ち、飽和ポリエステル又は不飽和ポリエステル)、ポリアミド、ポリエーテルエーテルケトン、ポリカーボネート、ポリフェニレンスルホン、ポリフェニレンエーテル、熱可塑性ポリウレタン等が挙げられる。
繊維強化プラスチックは、樹脂を1種のみ含有してもよいし2種以上含有してもよい。
繊維強化プラスチックを含む部材の全量に対する樹脂の含有量の比率の好ましい範囲も、繊維強化プラスチックの全量に対する樹脂の含有量の比率の好ましい範囲と同様である。
添加剤としては、難燃剤(好ましくは臭素系難燃剤)等が挙げられる。
繊維強化プラスチックを含む部材の全量に対する難燃剤の含有量の比率の好ましい範囲も、繊維強化プラスチックの全量に対する難燃剤の含有量の比率の好ましい範囲と同様である。
本開示の電池パック用ケースは、前述したとおり、補強部材(例えば、カバー補強部材、トレイ補強部材等)を備える場合がある。
金属部材の材質としては特に制限はなく、アルミニウム、アルミニウム合金、ステンレス鋼等、公知の材質を適用できる。
繊維強化テープの材質としても特に制限はなく、公知の材質を適用できる。繊維強化テープの材質として、例えば、前述の繊維強化プラスチックの材質と同様の材質が挙げられる。
前述の通り、本開示の電池パック用ケースは、トレイとカバーとの間に介在する封止部材(例えばガスケット)を備えることが好ましい。
熱可塑性エラストマーとしては、例えば、
オレフィン系エラストマー(例えば、TPO、TPV等)、
スチレン系エラストマー(例えば、SEEPS、SEPS、SEBS等)、
ウレタン系エラストマー、
ポリ塩化ビニル系エラストマー(例えば、TPVC)、
ポリアミド系エラストマー(例えば、PAER、TPAE等)、
ポリエステル系エラストマー(例えば、TPEE)、
アクリルゴム、
エチレンプロピレンゴム、
等が挙げられる。
前述したとおり、電池パック用ケースは、更に、一対のエンドプレートと電池モジュールとの間、及び、電池モジュールとトレイとの間の少なくとも1か所に配置された衝撃吸収層(例えば衝撃吸収層28)を備えることが好ましい。
衝撃吸収層は、熱可塑性エラストマーを少なくとも1種含むことが好ましい。
衝撃吸収層の材質としては、前述した封止部材の材質と同様のものが挙げられる。
上述した実施形態に係る電池パック10(図1~図5参照)について、カバー、トレイ、及び電池保持部材の各々の材質として表1及び表2に示す材質を選択した場合の、Gショック試験Z軸、軽量化率、及び側面衝突試験の各々に関するシミュレーションを行った。
表1及び表2に示す材質の詳細は以下の通りである。
・SMC … ジャパンコンポジット社製のSMC成形用樹脂(マトリックス樹脂として不飽和ポリエステル樹脂を含有)
・PP … ポリプロピレン
・GF … ガラス繊維(日東紡社製、繊維径φ17μm、繊維長さ1mm)
・LGF … ガラス長繊維(日東紡社製、繊維径φ17μm、繊維長さ8mm)
・CF … カーボン繊維(帝人社製、繊維径φ7μm、繊維長さ1mm)
・LCF … カーボン長繊維(帝人社製、繊維径φ7μm、繊維長さ9mm)
・アーレンM335 … 三井化学社製「アーレン」(登録商標)M335(変性ポリアミド6T)
例えば、「SMC GF37wt%+CF2wt%」との表記は、樹脂及び繊維の合計量を100質量%とした場合に、ガラス繊維(GF)が37質量%含有され、カーボン繊維(CF)が2質量%含有され、残部が樹脂(SMC)であることを意味する。
また、カバー補強部材としては、全例を通じ、上記のAl合金製のカバー補強部材を用いた。
・車体重量 … 1680kg
・電池の総重量 … 210kg
・電池パック用ケースの重量 … 1470kg(比較例1の場合)
Gショック試験Z軸では、電池パックを搭載した電気自動車に、X軸方向成分18G、Y軸方向成分15G、及びZ軸方向成分25Gの加速度の衝撃を与えた際の、電池パック用ケースの破断及び電池パック内の電池への影響を確認し、下記評価基準にて評価した。
以下の評価基準において、電気自動車の衝突時における電池の損傷抑制効果に最も優れるランクは「A」である。
A:電池パック用ケースの破断が無い。
B:電池パック用ケースが一部破断するが、電池パック内の電池への影響は無い。
C:電池パック用ケースの少なくとも一部が破断し、電池パック内の電池への影響がある。
比較例1における、カバー(Al合金製)、トレイ(Al合金製)、及び電池保持部材(Al合金製)の総質量に対する、各実施例のカバー、トレイ、及び電池保持部材の総質量の減少率(%)を求め、以下の評価基準により、電池パック用ケースの軽量化率を評価した。
以下の評価基準において、軽量化率に最も優れる(即ち、最も軽量化された)ランクは「A」である。
A:カバー、トレイ、及び電池保持部材の総質量の減少率(%)が、10%以上であった。
B:カバー、トレイ、及び電池保持部材の総質量の減少率(%)が、5%以上10%未満であった。
C:カバー、トレイ、及び電池保持部材の総質量の減少率(%)が、5%未満であった。
電池パックを搭載した電気自動車を、速度32km/h,衝突角度75°にて、直径254mmのポールに側面衝突させ、その際の電池パック用ケースの破断及び電池パック内の電池への影響を確認し、下記評価基準にて評価した。
A:電池パック用ケースの破断が無い。
B:電池パック用ケースが一部破断するが、電池パック内の電池への影響は無い。
C:電池パック用ケースの少なくとも一部が破断し、電池パック内の電池への影響がある。
また、実施例1~40では、ある程度優れたGショック試験Z軸及び側面衝突試験の結果が得られた。これにより、衝突時における電池の損傷を抑制できることが確認された。
本明細書に記載された全ての文献、特許出願、及び技術規格は、個々の文献、特許出願、及び技術規格が参照により取り込まれることが具体的かつ個々に記された場合と同程度に、本明細書中に参照により取り込まれる。
Claims (11)
- 電気自動車に搭載される電池パックの形成に用いられる電池パック用ケースであって、
電気自動車の車体に取り付けられるトレイと、
前記トレイ上の少なくとも一部分に取り付けられ、電池を保持する電池保持部材と、
前記トレイ上及び前記電池保持部材上を覆うカバーと、
を備え、
前記トレイ、前記電池保持部材、及び前記カバーのうちの少なくとも2つが、繊維強化プラスチックを含む、
電池パック用ケース。 - 更に、前記カバーの少なくとも一部分を補強する、金属板又は繊維強化テープであるカバー補強部材を備える、請求項1に記載の電池パック用ケース。
- 前記トレイは、前記電気自動車のリアシート下に配置されるトレイ後部と、前記トレイ後部から車体前方向に延びる、前記トレイ後部よりも車体幅方向の長さが短いトレイ延出部と、を含み、
前記電池保持部材は、前記トレイ後部上の少なくとも一部分に取り付けられた電池保持部材Rを含み、
前記カバーは、前記トレイ後部上及び前記電池保持部材R上を覆うカバー後部と、少なくとも前記トレイ延出部上を覆うカバー延出部と、を含み、
前記カバー補強部材は、前記カバー後部の、少なくとも前記カバー延出部との接続部分を補強するカバー後部補強部材を含む、
請求項2に記載の電池パック用ケース。 - 前記トレイは、更に、前記トレイ延出部における車体前方向の端部に接続され、前記電気自動車のフロントシート下に配置されるトレイ前部を含み、
更に、前記トレイ前部の縁部を補強する、金属部材又は繊維強化テープであるトレイ前部補強部材を備える、
請求項3に記載の電池パック用ケース。 - 前記電池保持部材は、前記トレイ延出部上の少なくとも一部分に取り付けられた電池保持部材Mを含み、
前記カバー延出部が、前記トレイ延出部上及び前記電池保持部材M上を覆い、
前記カバー補強部材は、前記カバー延出部の前記電池保持部材M上を覆う領域の少なくとも一部分を補強するカバー延出部補強部材を含む、
請求項3又は請求項4に記載の電池パック用ケース。 - 更に、前記トレイ延出部の車体長さ方向の一部分であって車体幅方向の一端から他端までの領域を補強する、金属板であるトレイ延出部補強部材を備え、
前記トレイ延出部補強部材の少なくとも一部は、前記トレイ延出部中に埋め込まれている、
請求項3に記載の電池パック用ケース。 - 前記トレイ及び前記カバーの少なくとも一方が、ガラス繊維、アラミド繊維、カーボン繊維、ザイロン繊維、ポリエチレン繊維、及びボロン繊維からなる群から選択される2種以上の繊維を含む繊維強化プラスチックを含む、請求項1~請求項6のいずれか1項に記載の電池パック用ケース。
- 前記電池保持部材は、複数のリチウム二次電池が厚さ方向に積層されてなる電池モジュールを保持する電池モジュール保持部材であり、
前記電池モジュール保持部材が、
前記電池モジュールの前記厚さ方向の両端部の外側から前記電池モジュールを挟持するための一対のエンドプレートと、
前記電池モジュールの前記厚さ方向及び鉛直方向に対して直交する方向の両端部の外側から、前記電池モジュールを挟持するための一対のサイドプレートと、
を含み、
前記一対のエンドプレート及び前記一対のサイドプレートが、前記繊維強化プラスチックを含む、
請求項1~請求項7のいずれか1項に記載の電池パック用ケース。 - 前記一対のエンドプレートは、繊維強化プラスチック中に金属部材が埋め込まれた構造を有する板状部材である、請求項8に記載の電池パック用ケース。
- 更に、前記一対のエンドプレートと前記電池モジュールとの間、及び、前記電池モジュールと前記トレイとの間の少なくとも1か所に配置された衝撃吸収層を含む、請求項8又は請求項9に記載の電池パック用ケース。
- 電気自動車に搭載される電池パックであって、
請求項1~請求項10のいずれか1項に記載の電池パック用ケースと、
前記電池パック用ケースにおける前記電池保持部材に保持された電池と、
を備える、電池パック。
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JP2012129074A (ja) * | 2010-12-15 | 2012-07-05 | Mitsubishi Motors Corp | バッテリケース |
JP2013201112A (ja) | 2012-03-23 | 2013-10-03 | Hyundai Motor Co Ltd | 電気自動車用バッテリパックケースアセンブリ及びその製造方法 |
JP2014022157A (ja) * | 2012-07-17 | 2014-02-03 | Mitsubishi Motors Corp | 電池モジュールの支持構造 |
WO2020202670A1 (ja) * | 2019-03-29 | 2020-10-08 | 三洋電機株式会社 | 電源装置とこの電源装置を備える電動車両及び蓄電装置、電源装置用締結部材 |
JP2021006442A (ja) | 2019-06-28 | 2021-01-21 | トヨタ自動車株式会社 | 車載ブレーキシステム |
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JPH0345500B2 (ja) | 1982-05-31 | 1991-07-11 | Matsushita Electric Works Ltd | |
JPH0451570B2 (ja) | 1990-08-31 | 1992-08-19 | Mitsubishi Petrochemical Co | |
JP2012129074A (ja) * | 2010-12-15 | 2012-07-05 | Mitsubishi Motors Corp | バッテリケース |
JP2013201112A (ja) | 2012-03-23 | 2013-10-03 | Hyundai Motor Co Ltd | 電気自動車用バッテリパックケースアセンブリ及びその製造方法 |
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WO2020202670A1 (ja) * | 2019-03-29 | 2020-10-08 | 三洋電機株式会社 | 電源装置とこの電源装置を備える電動車両及び蓄電装置、電源装置用締結部材 |
JP2021006442A (ja) | 2019-06-28 | 2021-01-21 | トヨタ自動車株式会社 | 車載ブレーキシステム |
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