The present invention relates to a battery and a battery pack integrating a plurality of batteries, as well as to methods for manufacturing the battery and the battery pack.
In recent years, accompanying the development of transportation equipment such as hybrid electric vehicles and electric vehicles and portable equipment such as personal computers, the roles of batteries have become increasingly important. There is fierce competition for development of equipment to be equipped with a battery, and smaller batteries capable of achieving higher output, as well as low-cost batteries, have been demanded in the market.
Also, batteries whose terminal portion is different from that of the battery shown in
In some applications (e.g., for use in vehicles) where a sufficient capacity, voltage, etc. cannot be achieved by a single battery, a battery pack in which a plurality of batteries are connect in series may be used. For example, one possible way to obtain a battery pack is connecting cylindrical batteries shown in
However, in the battery shown in
The batteries proposed in Patent Document 1 and Patent Document 2 also need a tab for collecting current. Besides, the terminal member shaped like a male thread is disposed so as to extend into a housing. Accordingly, a space for arranging the tab and the terminal member needs to be provided inside the batteries. Moreover, in order to form a battery pack by connecting batteries shown in
The present invention provides a battery and a battery pack that require a smaller space for accommodating a power generation component, as well as methods for manufacturing them.
A battery according to the present invention includes: a pair of cylindrical bottomed cans; a joint ring for joining an open end portion of one of the bottomed cans to an open end portion of the other bottomed can; and a power generation component including a pair of electrodes, which is accommodated in the joined bottomed cans. In this battery, one of the bottomed cans is electrically connected to one of the electrodes, the other bottomed can is electrically connected to the other electrode, and a region of the joint ring that is in contact with one of the bottomed cans is electrically insulated from a region of the joint ring that is in contact with the other bottomed can. Note here that the “bottomed can” as used herein refers to a can that includes a bottom, a sidewall(s), and an open end, and it may be constructed of either a single piece or multiple pieces.
A battery pack according to the present invention includes a plurality of the above-described batteries according to the present invention. In this battery pack, the batteries are connected in series.
A method for manufacturing a battery according to the present invention includes the steps of: (i) joining a joint ring to an open end portion of a first bottomed can; (ii) placing an electrode plate group including a pair of electrodes in the first bottomed can; and (iii) joining an open end portion of a second bottomed can to a portion of the joint ring on a side opposite to a side joined to the first bottomed can, so that the first bottomed can and the second bottomed can are joined to each other via the joint ring. The method further includes the steps of: (a) electrically connecting the first bottomed can to one of the electrodes; and (b) electrically connecting the second bottomed can to the other electrode.
A method for manufacturing a battery pack according to the present invention is a method for manufacturing a battery pack in which a plurality of batteries are connected in series. The method includes the steps of: (x) disposing a plurality of batteries so that end faces of adjacent batteries abut against each other; and (y) connecting the adjacent batteries in series by electrically connecting the end faces to each other. In this method, the batteries are the above-described batteries according to the present invention.
A battery according to the present invention includes: a pair of cylindrical bottomed cans; a joint ring for joining an open end portion of one of the bottomed cans to an open end portion of the other bottomed can; and a power generation component including a pair of electrodes, which is accommodated in the joined bottomed cans. One of the bottomed cans is electrically connected to one of the electrodes (e.g. a positive electrode), and the other bottomed can is electrically connected to the other electrode (e.g., a negative electrode). Furthermore, a region of the joint ring that is in contact with one of the bottomed cans is electrically insulated from a region of the joint ring that is in contact with the other bottomed can. Accordingly, it is possible to configure the battery in which the pair of bottomed cans and/or the joint ring serves as a battery case, one of the bottomed cans serves as a positive electrode, and the other bottomed can serves as a negative electrode, for example. In the battery of the present invention, any region in each of the bottomed cans can be used as a terminal portion. For example, the outer surface of the bottom of each bottomed can (i.e., the region corresponding to an end face of the battery) can be used as a terminal portion. The terminal portion refers to a portion provided for electric connection to the outside of the battery. Note here that a plurality of terminal portions may be provided.
In the battery with the foregoing configuration, the miniaturization of the battery can be realized easily because components such as a tab and a lead required in conventional batteries need not be provided. Thus, for example, the space inside the battery that is irrelevant to a charge/discharge capacity of the battery can be minimized, thereby increasing the energy density of the battery. Moreover, since the number of components provided between the electrode plate group and the terminal portion can be reduced, the internal resistance of the battery can be decreased so that the battery can achieve excellent output characteristics. Furthermore, the battery can achieve high productivity because the process steps required for manufacturing the battery can be reduced due to the reduction of the number of components. Besides, in the battery of the present invention, it is not necessary to provide a caulked portion as seen in the battery of
In the battery of the present invention, the configuration for joining the open end portions of the pair of bottomed cans to each other via the joint ring (i.e., the structure of the joint ring, the structure of the bottomed cans, the structure of the portions between the joint ring and the open end portions of the bottomed cans, etc.) is not particularly limited. Any configuration may be employed as long as the pair of bottomed cans serving as a battery case can be sealed hermetically when the finished product is used as a battery. For example, the configuration may be such that thread portions are formed on peripheral surfaces of the open end portions of the respective bottomed cans and on a peripheral surface of the joint ring, so that the pair of bottomed cans are joined to each other via the joint ring by threading the thread portions of the bottomed cans with the thread portion(s) of the joint ring. Alternatively, the configuration may be such that the peripheral surface of the joint ring and the peripheral surfaces of the open end portions of the bottomed cans are formed in predetermined shapes, so that the pair of bottomed cans are joined to each other via the joint ring by engaging the joint ring and the open end portions of the bottomed cans with each other. In this case, the open end portions of the bottomed cans may be engaged with the joint ring by contracting their diameter. When contracting the diameter of the bottomed cans, the diameter of at least the open end portions thereof may be contracted. Also, it is possible to use a configuration in which the above-described threaded engagement and other engagement are used in combination. For example, the configuration may be such that a thread portion(s) is formed on one peripheral surface of the joint ring while the other peripheral surface of the joint ring is formed in a predetermined shape, so that the joint ring is joined to one of the bottomed cans by threaded engagement, while the joint ring is joined to the other bottomed can by other engagement.
With regard to the joint ring, the configuration for maintaining electrical insulation between the region that is in contact with one of the bottomed cans and the region that is in contact with the other bottomed can is not particularly limited. For example, the joint ring may be configured so that the regions in contact with the pair of bottomed cans are made of resin or so that the entire joint ring is made of resin. Alternatively, the joint ring may be configured so as to include a metal layer and a resin layer, and the electrical insulation may be maintained by the resin layer. By configuring the joint ring so as to include a resin layer and a metal layer, it is possible to improve the strength of the joint ring. Note here that it is not always necessary to integrate the resin layer and the metal layer. For instance, during the manufacture of the battery, the resin layer and the metal layer may be disposed separately. The structure of the joint ring, the material used for the joint ring, etc. may be determined arbitrarily depending on the temperature range when the finished product is used as a battery, the required strength, etc.
The resin used for the joint ring is not particularly limited, and may be, for example, polyamide, polyolefin, polystyrene, polysulphone, fluororesin, or the like. Among them, fluororesin is preferable when the entire joint ring is made of resin, from the aspects of mechanical strength, resistance to moisture permeation, formability, etc. A metal used for the joint ring is not particularly limited, and may be, for example, stainless steel, iron-nickel plated steel, aluminum, or the like. In a resin portion of the joint ring, portions to be in contact with metal portions of the respective bottomed cans preferably are coated with a sealing agent. As the sealing agent, polybutene, blown asphalt, a fluorine-based coating agent, or the like can be used, for example.
The structure, material, constitution, etc. of the power generation component are not particularly limited as long as the power generation component includes a pair of electrodes (a positive electrode and a negative electrode). Any power generation component generally used for a battery can be used. For example, the power generation component may include an electrolyte and an electrode plate group including a separator and a positive electrode and a negative electrode that hold the separator therebetween. In this case, the electrode plate group may be wound, and the electrolyte may be an electrolytic solution having an ionic conductivity. The power generation component with such a configuration is similar to those used for general alkaline storage batteries, lithium batteries, etc. That is to say, the battery according to the present invention can be used as various batteries such as an alkaline storage battery, a nickel-metal hydride battery, a lithium primary battery, and a lithium secondary battery, by selecting the structure, material, constitution, etc. of the power generation component. More specifically, in the case where the battery of the present invention is used as a lithium secondary battery, the positive electrode and the negative electrode may be made of electrode materials that can store and release lithium reversibly (e.g., an electrode material for the positive electrode may be an oxide containing lithium and an electrode material for the negative electrode may be a carbon material or a material containing silicon) and the electrolyte may have a lithium conductivity (e.g., the electrolyte may be a nonaqueous solution of a lithium salt).
The configuration for maintaining the electric connection between the bottomed cans and the electrodes included in the power generation component is not particularly limited. For example, it is only necessary that inner surfaces of the bottoms of the bottomed cans are in contact with the electrodes stably enough to maintain the electroconductivity when the finished product is used as a battery. Moreover, between the bottomed can and the electrode, a conductive member (e.g., a current collector or the like) further may be provided. This configuration may be designed arbitrarily, depending on the required battery characteristics.
The material for the bottomed cans is not particularly limited. For example, any material generally used as a material for a battery case may be used. The material to be used varies depending on the kinds of the battery. In the case of a nickel-metal hydride battery, iron-nickel plated steel, stainless steel, or the like may be used, for example. In the case of a lithium battery, iron-nickel plated steel, stainless steel, aluminum, copper, or the like may be used, for example. The bottomed can to serve as a positive electrode and the bottomed can to serve as a negative electrode may be formed of different materials. In the case of the above-described lithium battery, the bottomed can to serve as a positive electrode (i.e., the bottomed can that is electrically connected to the positive electrode included in the power generation component) may be formed of aluminum, and the bottomed can to serve as a negative electrode (i.e., the bottomed can that is electrically connected to the negative electrode included in the power generation component) may be formed of copper, for example. Also, the material to be used may be determined depending on an electric potential caused in each bottomed can when the finished product is used as a battery.
The size of the bottomed cans is not particularly limited, and may be set, for example, depending on the battery capacity. For instance, when the desired battery capacity is 6000 mAh, the inner diameter of the bottomed cans may be, for example, about 30 mm φ to about 35 mm φ and the depth thereof measured as a total value of the depths of both the bottomed cans may be, for example, about 50 mm to about 55 mm. The wall thickness of the bottomed cans may be, for example, 0.2 mm to 0.6 mm.
A battery pack according to the present invention includes a plurality of the above-described batteries of the present invention, and these batteries are connected in series. This allows the miniaturization of the battery to be realized easily. Furthermore, such a battery pack can exhibit effects based on the above-described effects of the battery. More specifically, for example, it is possible to provide a battery pack with high energy density or a battery pack with excellent output characteristics. Furthermore, for example, by forming both end faces of adjacent batteries in a flat shape, it is possible to eliminate the necessity of providing a connector for connecting the adjacent batteries as disclosed in, for example, Patent Document 3. Note here that an end face of the battery refers to a portion corresponding to an outer surface of the bottom of the above-described bottomed can, for example.
A method for manufacturing a battery according to the present invention includes the steps of (i) joining a joint ring to an open end portion of a first bottomed can; (ii) placing an electrode plate group including a pair of electrodes in the first bottomed can; and (ii) joining an open end portion of a second bottomed can to a portion of the joint ring on a side opposite to a side joined to the first bottomed can, so that the first bottomed can and the second bottomed can are joined to each other via the joint ring. The method further includes the steps of: (a) electrically connecting the first bottomed can to one of the electrodes; and (b) electrically connecting the second bottomed can to the other electrode. According to such a manufacturing method, the above-described battery of the present invention can be obtained. It is to be noted here that the steps (a) and (b) may be performed at any time, as long as they are completed at the stage where the formation of the battery 1 is completed. For example, in the step (iii), the steps (a) and (b) can be completed by joining the first bottomed can and the second bottomed can to each other and bringing the first bottomed can into contact with one of the electrodes and the second bottomed can into contact with the other electrode. Materials and the like of the respective components are the same as those described above with regard to the battery of the present invention, and thus, the description thereof will be omitted here.
A method for manufacturing a battery pack according to the present invention is a method for manufacturing a battery pack in which a plurality of batteries are connected in series. The method includes the steps of: (x) disposing a plurality of batteries so that end faces of adjacent batteries abut against each other; and (y) connecting the adjacent batteries in series by electrically connecting the end faces to each other. The batteries connected in series are the above-described batteries of the present invention. According to such a manufacturing method, it is possible to obtain the above-described battery pack of the present invention.
Hereinafter, the present invention will be described by way of embodiments with reference to the drawings. Note here that in the following embodiments, the same components are denoted with the same reference numerals, and a duplicate description thereof may be omitted.
First, a battery of the present invention will be described with reference to the drawings.
The power generation component includes an electrolyte and an electrode plate group 4 including a separator 7 and a positive electrode 5 and a negative electrode 6 that hold the separator 7 therebetween. The electrode plate group 4 is wound. The electrolyte is accommodated in the bottomed cans 2 with a part thereof being held by the separator 7. Female thread portions are formed on an inner peripheral surface of the joint ring 3, and male thread portions are formed on outer peripheral surfaces of the open end portions of the respective bottomed cans 2. The bottomed can 2a and the bottomed can 2b are joined to each other via the joint ring 3 by threading the male thread portions with the female thread portions. The joint ring 3 has a structure in which a resin layer 8 and a metal layer 9 are laminated, with the resin layer 8 being an innermost layer. With this structure, on the inner peripheral surface of the joint ring 3, a region that is in contact with the bottomed can 2a is electrically insulated from a region that is in contact with the bottomed can 2b. Furthermore, the positive electrode 5 protrudes from one end face of the electrode plate group 4 so that the positive electrode 5 is electrically connected to an inner surface of the bottom of the bottomed can 2a, and the negative electrode 6 protrudes from the other end face of the electrode plate group 4 so that the negative electrode 6 is electrically connected to an inner surface of the bottom of the bottomed can 2b. The amount by which the positive electrode 5 and the negative electrode 6 protrude from the respective end faces (i.e., the amount of protrusion) may be about 0.5 mm to about 2.5 mm, for example.
With this configuration, it is possible to provide the battery 1 in which the bottomed can 2a serves as a positive electrode and the bottomed can 2b serves as a negative electrode. Furthermore, as shown in
Moreover, the manufacturing process of the battery 1 can be simplified as compared with that of conventional batteries. For example, for manufacturing the battery 101 shown in
In the battery 1 shown in
In the battery 1 shown in
Furthermore, in the battery 1 shown in
The structure of the thread portions formed in the bottomed cans 2 and the joint ring 3 (e.g., a pitch or the like of the thread portions) is not particularly limited. The thread portions formed in the respective bottomed can 2 and the thread portions formed in the joint ring 3 may be taper threads. By using the taper threads, the battery 1 with improved sealing can be obtained. Moreover, in this case, it is possible to improve the sealing of the battery 1 by, for example, controlling torque when rotating the bottomed cans 2 and/or the joint ring 3 during the manufacture of the battery 1.
The current collectors 11 and the bottomed cans 2 may be merely in contact with each other, as long as electric connection therebetween can be maintained for a required period. Alternatively, the current collectors 11 and the bottomed cans 2 may be electrically connected to each other by at least one selected from welding and brazing. By welding or brazing, the internal resistance of the battery 1 can further be decreased so that the battery 1 can achieve still more excellent output characteristics. Besides, the reliability of the battery 1 can be improved further. The type of welding is not particularly limited, and may be, for example, laser welding, resistance welding, or the like. Note here the above description also applies to the relationship between the current collectors 11 and the electrodes included in the electrode plate group 4.
The material for the current collector 11 is not limited as long as it is conductive and hardly subjected to corrosion and the like in the battery 1. In the case of an alkaline storage battery, nickel, nickel plated steel plate, or the like may be used, for example. In the case of a lithium battery, copper (for a current collector to be disposed on the negative electrode side) and aluminum (for a current collector to be disposed on the positive electrode side) may be used, for example. It is only necessary that the current collector 11 exhibits electrical conductivity as a whole, and thus an electrically insulating material may be contained therein. The structure of the current collector 11 is not particularly limited, and any generally used current collector may be used, for example. Examples of the current collector 11 are shown in
The through hole 12 may be sealed with a thin film. For example, when temperature rise or an increase in internal pressure occurs in the battery 1, the thin film breaks, thereby serving as a safety valve. The kind of the thin film is not particularly limited. For example, the thin film may be made of the same material as that for the bottomed cans 2 or may be made of resin. Alternatively, the thin film may include a plurality of layers made of different materials. The thickness of the thin film may be in the range from 10 μm to 100 μm, for example. The pressure range within which the thin film breaks can be set by changing the thickness or the material of the thin film. Note here that the through hole 12 may be sealed by using a thin film and a safety valve in combination. For example, a safety valve may be disposed in the through hole 12, and thereafter, the through hole 12 may be sealed with the thin film.
Although the through hole 12 is formed only in the bottomed can 2a in the example shown in
The material for the sealing member is not particularly limited, and may be, for instance, resin, rubber, a metal, or the like. However, because it is necessary to prevent the occurrence of an electric short circuit between the pair of bottomed cans 2, the sealing member preferably is electrically insulating in the case where the contact portion 10 is conductive. The type of the O-ring 13 used as a sealing member in the example shown in
Hereinafter, other variations of a battery according to the present invention will be described. The battery according to the present invention may have the following configurations, for example. Note here that the battery of the present invention can exhibit similar effects to those described above, even when it has the following configurations. The battery according to the present invention is by no means limited to the above-descried specific examples or to the variations described below.
According to the configurations shown in
Although a battery 1 as one aspect of the present invention has been specifically described above by way of embodiments, it is to be noted that the battery of the present invention is by no means limited to the above-described embodiments. For example, although in the above embodiments the battery has a joint ring with a round outer shape, the shape of the joint ring is not limited thereto. For example, the outer shape of the joint ring may be formed in a polygonal shape, such as a hexagonal shape or an octagonal shape. When a plurality of battery packs described later are formed, this allow the plurality of battery packs to be integrated with a certain distance being kept between adjacent battery packs and also allows the plurality of battery packs to be maintained stably. If a certain distance can be kept between the adjacent battery packs, it is possible to send cooling air between the adjacent battery packs during the use of the battery packs, for example.
Next, a battery pack according to the present invention will be described with reference to the drawings.
A battery pack 21 shown in
Although six batteries 1 are connected in series in the example shown in
The structure for connecting the batteries 1 in series (hereinafter referred to as the “connecting structure”) is not particularly limited, as long as electric connection between adjacent batteries 1 can be maintained. Note here that it is not necessary that all the batteries 1 in the battery pack 21 are connected by a common connecting structure, but the batteries 1 may be connected in series by a plurality of different connecting structures. In the battery pack 21 shown in
The battery 1 used in the battery pack 21 may be the battery 1 having projections 14 on an end face thereof as shown in
Although end faces of adjacent batteries 1 abut against each other directly in the battery pack 21 shown in
The material for the plate 24 is not particularly limited as long as it is conductive. For example, the plate 24 may be made of nickel, iron, a nickel plated steel plate, or the like. As in the case of the above-described current collector 11, it is only necessary that the plate 24 exhibits electrical conductivity as a whole, and thus an electrically insulating material may be contained therein. The size of the plate 24 is not particularly limited, and may be substantially the same as that of the end face of the battery 1, for example. The thickness of the plate 24 is not particularly limited, and may be, for example, in the range from 0.2 mm to 1.0 mm. Note here that a plurality of plates 24 may be disposed between end faces of each two adjacent batteries 1.
In the battery pack 21 shown in
In the battery pack 21 shown in
Still another example of a battery pack according to the present invention is shown in
Next, a method for manufacturing a battery according to the present invention will be described with reference to the drawings.
Next, as shown in
Next, as shown in
The battery 1 shown in
The bottomed cans 2a and 2b, the electrode plate group 4, and the joint ring 3 used in the manufacturing method of the present invention may be the same as the above-described bottomed cans, electrode plate group, and joint ring. For example, the electrode plate group 4 may include a separator and a positive electrode and a negative electrode that hold the separator therebetween, and may be wound.
In the step (i), the method of threading the bottomed can 2b with the joint ring 3 is not particularly limited. With regard to the degree of the threaded engagement to be achieved, note here that the threaded engagement may be achieved to the extent that the sealing of the battery 1 as a finished product can be maintained, for example. Moreover, the degree of the threaded engagement may be defined and controlled by the overall height of the battery 1 or the like, for example.
The method of placing the electrode plate group 4 in the step (ii) and the method of threading the bottomed can 2a with the joint ring 3 in the step (iii) are not particularly limited. In the case where it is necessary to place an electrolyte in addition to the electrode plate group 4 to compose a power generation component, the step of placing the electrolyte may be performed at any time. For example, when the electrolyte is solid, the electrode plate group 4 in which the electrolyte is inserted between the electrodes may be placed in the bottomed can 2b. When the electrolyte is liquid (i.e., an electrolytic solution), the electrolytic solution may be poured from a through hole that is formed beforehand in the bottom of the bottomed can 2a, for example, after performing the step (iii). The through hole may be sealed after the electrolytic solution has been poured.
The manufacturing method of the present invention may further include the step of: (c) disposing a current collector between the electrode plate group 4 and an interior of at least one bottomed can 2 selected from the bottomed can 2a and the bottomed can 2b. By disposing the current collector, electric connection between the interior of the bottomed can 2 and the electrode included in the electrode plate group 4 can be maintained more reliably. Thus, the battery 1 with excellent battery characteristics can be obtained. The current collector to be disposed may be the same as those described above. Furthermore, the inner region of the bottomed can 2 in which the current collector is to be disposed is not particularly limited. For example, as shown in
The methods of performing the step (a) and the step (b) are not particularly limited. For example, these steps can be accomplished by placing the electrode plate group 4 or joining the pair of bottomed cans 2a and 2b to each other in such a manner that the positive electrode (the negative electrode) is in contact with the interior of the bottomed can 2a (2b). Note here that the above-described step (c) of disposing the current collector may be a part of the step (a) and/or the step (b).
It is only necessary that the step (a) and the step (b) are completed at the stage where the formation of the battery 1 is completed (at the stage of
Hereinafter, the step (a) and the step (b) in the manufacturing method of the present invention will be described more specifically. In the following description, the positive electrode and the negative electrode included in the electrode plate group 4 may be inverted.
For example, in the step (ii), the electrode plate group 4 may be placed in such a manner that the negative electrode included therein is in contact with the bottomed can 2b. This allows the negative electrode to be electrically connected to the bottomed can 2b. In this case, for example, when the negative electrode protrudes from one end face of the electrode plate group 4 as shown in
Furthermore, the manufacturing method further may include the step of: (d) disposing a current collector in the bottomed can 2b, for example, before the step (ii), and in the step (ii), the electrode plate group 4 may be placed in such a manner that the current collector is in contact with the negative electrode included in the electrode plate group 4. According to such a manufacturing method, the negative electrode and the bottomed can 2b can be electrically connected to each other via the current collector. Furthermore, by disposing the current collector between the negative electrode and the bottomed can 2b, more reliable electric connection can be achieved.
Furthermore, as shown in, e.g.,
In the foregoing specific examples, for example, in the step (iii), the bottomed can 2a and the bottomed can 2b may be joined to each other in such a manner that the positive electrode included in the electrode plate group 4 is in contact with the interior of the bottomed can 2a. This allows the positive electrode to be electrically connected to the bottomed can 2a. In this case, for example, when the positive electrode protrudes from the end face of the electrode plate group 4 on the bottomed can 2a side as shown in
Furthermore, the manufacturing method further may include the step of: (e) disposing a current collector from an opening of the bottomed can 2b so as to be in contact with the positive electrode included in the electrode plate group 4, for example, between the step (ii) and the step (iii), and in the step (iii), the bottomed can 2a and the bottomed can 2b may be joined to each other in such a manner that the current collector disposed in the step (e) is in contact with the interior of the bottomed can 2a. According to such a manufacturing method, the positive electrode and the bottomed can 2a can be electrically connected to each other via the current collector.
Other than the above, the manufacturing method in which, for example, a first current collector is disposed beforehand on one end of the electrode plate group 4 so as to be in contact with the negative electrode included in the electrode plate group 4 and a second current collector is disposed beforehand on the other end of the electrode plate group 4 so as to be in contact with the positive electrode included in the electrode plate group 4 also is acceptable. In this case, in the step (ii), the electrode plate group 4 may be placed in the bottomed can 2b in such a manner that the first current collector that is in contact with the negative electrode is in contact with the interior of the bottomed can 2b, and in the step (iii), the bottomed can 2a and the bottomed can 2b may be joined to each other in such a manner that the second current collector that is in contact with the positive electrode is in contact with the interior of the bottomed can 2a. By so doing, the negative electrode and the bottomed can 2b can be electrically connected to each other via the first current collector, while the positive electrode and the bottomed can 2a can be electrically connected to each other via the second current collector.
In the manufacturing method of the present invention, at least one step selected from the step (a) and the step (b) may further include the step of (f) brazing the electrodes and the interiors of the bottomed cans 2. Alternatively, the above-described at least one step may include the step of: (g) welding the electrodes and the interiors of the bottomed cans 2. According to such a manufacturing method, it is possible to achieve more reliable electric connection between the electrodes included in the electrode plate group 4 and the interiors of the bottomed cans 2. The inner region of each bottomed can 2 to be subjected to the brazing or welding is not particularly limited, and may be, for example, the bottom of the bottomed can 2.
The step (f) and the step (g) may be performed at any time in the step (a) and the step (b). For example, the bottomed can 2b and bottomed can 2a may be joined to each other after the electrode plate group 4 has been placed in the bottomed can 2b and the negative electrode included in the electrode plate group 4 has been welded or brazed to the interior of the bottomed can 2b. Alternatively, the negative electrode included in the electrode plate group 4 may be welded or brazed to the interior of the bottomed can 2b after the electrode plate group 4 has been placed in the bottomed can 2b and the bottomed can 2b and the bottomed can 2a have been joined to each other. The same is applied with regard to the welding or brazing of the positive electrode to the interior of the bottomed can 2a. Note here that the step (f) and the step (g) may be performed with respect to both the pair of electrodes included in the electrode plate group 4 or either one of the electrodes.
In the step (f), the method of brazing the electrodes to the interiors of the bottomed cans 2 is not particularly limited, and any generally used method may be employed. Furthermore, in the step (g), the method of welding the electrodes to the interiors of the bottomed cans 2 is not particularly limited, and may be performed by, for instance, laser welding, resistance welding, or the like.
In the manufacturing method of the present invention, when a current collector is disposed between the electrode plate group 4 and the interior of at least one of the bottomed cans 2, at least one step selected from the step (a) and the step (b) may include the step of (h) brazing the current collector to the interior of the bottomed can 2 that holds the current collector between itself and the electrode plate group 4. Alternatively, the at least one step may include the step of: (j) welding the current collector to the interior of the bottomed can 2 that holds the current collector between itself and the electrode plate group 4. According to such a manufacturing method, it is possible to achieve reliable electric connection between the electrode included in the electrode plate group 4 and the interior of the bottomed can 2 via the current collector. The inner region of the bottomed can 2 to be subjected to the brazing or welding may be determined depending on the position where the current collector is disposed, and may be, for example, the bottom of the bottomed can 2.
Similarly to the step (f) and the step (g), the step (h) and the step (j) may be performed at any time in the step (a) and the step (b). In the case where the current collectors are disposed on both the positive electrode side and the negative electrode side, respectively, the step (h) and the step ( ) may be performed with respect to both the current collectors or either one of the current collectors.
In the step (h), the method of brazing the current collector to the interior of the bottomed can 2 is not particularly limited, and any generally used method may be employed. Furthermore, in the step (j), the method of welding the current collector to the interior of the bottomed can 2 is not particularly limited, and may be performed by, for instance, laser welding, resistance welding, or the like.
In the manufacturing method of the present invention, the winding direction of the electrode plate group 4 to be placed in the bottomed can 2b in the step (ii) may be the same as the rotating direction of the bottomed can 2a rotated in the step (iii). According to such a manufacturing method, it is possible to reduce the occurrence of an internal short circuit in the battery 1. During the manufacture of the battery 1, the possibility that an outermost layer of the electrode plate group 4 may be everted partially by the rotation of the bottomed can 2a cannot be denied completely. Regardless of whether the layer is an electrode or a separator, there is a possibility that the everted (or exposed) electrode resulting from the eversion of the outermost layer may be in contact with the bottomed can 2a. However, by setting the winding direction of the electrode plate group 4 to be the same as the rotating direction of the bottomed can 2a, it is possible to reduce the possibility that the layer may be everted. That is, it is possible to obtain a more reliable battery 1 in which the occurrence of an internal short circuit is reduced.
In the manufacturing method of the present invention, an electrode located at the outermost periphery of the electrode plate group 4 to be placed in the bottomed can 2b in the step (i) may be an electrode to be electrically connected to the bottomed can 2a in the step (b). According to such a manufacturing method, it is also possible to reduce the occurrence of an internal short circuit in the battery 1. As described above, during the manufacture of the battery 1, there is a possibility that an outermost layer of the electrode plate group 4 may be everted partially by the rotation of the bottomed can 2a so that the everted (or exposed) electrode may be in contact with the bottomed can 2a. In this case, however, by setting the everted (or exposed) electrode, i.e., the electrode located at the outermost periphery of the electrode plate group 4, to have the same polarity as the bottomed can 2a, it is possible to reduce the occurrence of an internal short circuit. It order to set the polarity of the electrode to be the same as that of the bottomed can 2a, the electrode located at the outermost periphery of the electrode plate group 4 may be set to be the electrode to be electrically connected to the bottomed can 2a. Note here that the electrode located at the outermost periphery of the electrode plate group 4 refers to an electrode that is located at the outermost periphery without giving consideration to the components (such as the separator) other than the electrodes. Thus, the electrode located at the outermost periphery is not necessarily the above-described outermost layer.
In the manufacturing method of the present invention, the outermost periphery of the electrode plate group 4 to be placed in the bottomed can 2b in the step (ii) may be the separator. According to such a manufacturing method, the possibility of an internal short circuit in the battery 1 can be reduced, thereby allowing a more reliable battery 1 to be obtained.
Furthermore, in the manufacturing method of the present invention, a peripheral surface of the joint ring 3 and a peripheral surface of an open end portion of each of the bottomed cans 2a and 2b may be formed in predetermined shapes. In such a manufacturing method, the step (i) may be a step for joining the bottomed can 2b and the joint ring 3 by engaging the open end portion of the bottomed can 2b with the joint ring 3, and the step (iii) may be a step for joining the bottomed can 2b and the bottomed can 2a to each other via the joint ring 3 by engaging the open end portion of the bottomed can 2a with the portion of the joint ring 3 on the side opposite to the side joined to the bottomed can 2b. According to such a manufacturing method, the battery 1 of the present invention in which the pair of bottomed cans 2a and 2b are joined to each other by being engaged with the joint ring 3 as shown in
In the above-described manufacturing method, the method of engaging the joint ring 3 and the bottomed cans 2a and 2b with each other is not particularly limited. For example, the shape of the peripheral surface of the joint ring 3 and the shape of the peripheral surface of the open end portion of each of the bottomed cans 2a and 2b may be set beforehand so as to engage with each other. Alternatively, the open end portion of the bottomed can 2a or the bottomed can 2b may be engaged with the joint ring 3 by contracting the diameter of the bottomed can 2a or the bottomed can 2b. Although the bottomed can whose diameter is to be contracted may be either the bottomed can 2a or the bottomed can 2b, it preferably is the bottomed can that is engaged with the joint ring 3 in the step (iii) (the bottomed can 2a in the example shown in
Next, an example of a method for manufacturing a battery pack according to the present invention will be described mainly with reference to
The manufacturing method of a battery pack according to the present invention includes the steps of: (x) disposing a plurality of batteries 1 so that end faces of adjacent batteries abut against each other; and (y) connecting the adjacent batteries in series by electrically connecting the end faces to each other.
In the step (x), the method of disposing the plurality of batteries 1 so that end faces of adjacent batteries 1 abut against each other is not particularly limited. Also, the number or the like of batteries 1 to be disposed may be set arbitrarily.
In the step (y), the method of electrically connecting the end faces of the adjacent batteries 1 to each other is not particularly limited. For example, the end faces of the adjacent batteries 1 may be electrically connected to each other by welding the end faces to each other.
Furthermore, in the manufacturing method of the present invention, in the step (x), a conductive plate 24 (see
In the step (y), the method of welding is not particularly limited, and may be performed by laser welding, for example. In the case where projections are formed on an end face of the battery 1 and/or a principal surface of the plate 24, projection welding may be used.
According to the present invention, a battery and a battery pack that can achieve high energy density and excellent output characteristics can be provided, for example. The battery and the battery pack of the present invention are applicable to various primary and secondary batteries, such as an alkaline-manganese battery, a nickel-cadmium battery, a nickel-metal hydride battery, and a lithium-ion battery, for example.
The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limiting. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
Number | Date | Country | Kind |
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2004-046772 | Feb 2004 | JP | national |