Patent Application
20230344013
The present invention relates to a bipolar battery and a method of manufacturing the same.
In recent years, power generation facilities using natural energy such as sunlight and wind power have been increasing. In such a power generation facility, an amount of power generation cannot be controlled, and thus a power load is leveled using a storage battery. That is, when the amount of power generation is larger than a consumption, a difference is charged into the storage battery, and when the amount of power generation is smaller than a consumption, a difference is discharged from the storage battery. As the above-described storage battery, lead-acid batteries are frequently used for economic efficiency, safety, and the like. Among them, bipolar lead-acid batteries have been attracting attention from the viewpoint of energy density.
This bipolar lead-acid battery is formed by connecting in series a plurality of cell members assembled by alternately stacking the plurality of cell members, in each of which an electrolyte layer is interposed between a positive electrode having a positive active material layer and a negative electrode having a negative active material layer, and a plurality of frame units made of resin incorporating the cell members.
In this bipolar lead-acid battery, the electrolyte layer constituting the cell member in a cell is impregnated with an electrolytic solution. Therefore, it is necessary to prevent electrolytic solution leakage out of the cell.
For example, a conventional sealed bipolar battery assembly disclosed in JP Patent Publication No. 6571091 B2 is known as a battery assembly having a seal structure for preventing electrolytic solution leakage to the outside.
The sealed bipolar battery assembly disclosed in JP Patent Publication No. 6571091 B2 includes a casing frame in which a first current collector and a second current collector are arranged. Further, two end caps are attached to mate with a top and a bottom of the casing frame. An electrolytic solution region is defined by the first current collector, the second current collector, the casing frame, and the end caps.
In order to prevent the electrolytic solution leakage to the outside, a plurality of plastic seals and adhesive seals are placed around each of the first current collector and the second current collector between the casing frame and the end caps, and the casing frame and the end caps are joined by welding joints using hot-plate welding or other welding technology.
However, the conventional sealed bipolar battery assembly disclosed in JP Patent Publication No. 6571091 B2 has the following problem.
That is, in the sealed bipolar battery assembly disclosed in JP Patent Publication No. 6571091 B2, as the seal structure for sealing the electrolytic solution leakage to the outside from between the casing frame and the end caps, it is necessary to place the plurality of plastic seals and adhesive seals around each of the first current collector and the second current collector between the casing frame and the end caps, and to join together the casing frame and the end caps by the welding joints using hot-plate welding or other welding technology. Thus, a problem is that the seal structure is complicated.
In view of such a problem, an object of the present invention is to provide a bipolar battery and a method of manufacturing the same capable of reliably preventing electrolytic solution leakage out of a cell by means of a simple seal structure.
To solve the above-described problem, the present invention provides embodiments of a bipolar battery having the following configurations.
The present invention also provides embodiments of a method of manufacturing a bipolar battery having the following configurations.
With a bipolar battery according to embodiments of the present invention, the plurality of frame units includes the frame unit made of a light transmissive resin material and the frame unit made of a light absorbing resin material being alternately arranged in the stacking direction of the cell members. The frame unit made of a light transmissive resin material and the frame unit made of a light absorbing resin material adjacent in the stacking direction of the cell members are welded and joined together. As a result, it is possible to reliably prevent electrolytic solution leakage out of the cell by means of the simple seal structure.
In addition, because the frame unit made of the light transmissive resin material and the frame unit made of the light absorbing resin material adjacent in the stacking direction of the cell members are welded and joined together, increased airtightness is achieved compared to joining using an adhesive method, and electrolytic solution sealing performance can be further improved. Moreover, because the frame unit made of the light transmissive resin material and the frame unit made of the light absorbing resin material are welded and joined together, burrs are less likely to be generated at a joining place, and a possibility that foreign matter, such as burrs generated by joining, enters the cell can be avoided.
In addition, with a bipolar battery according to embodiments of the present invention, the frame unit made of a light transmissive resin material and the frame unit made of a light absorbing resin material each include a joining surface extending along a direction perpendicular to the stacking direction. As a result, the joining surfaces of the frame unit made of the light transmissive resin material and the frame unit made of the light absorbing resin material can be welded and joined together, so that it is possible to reliably prevent the electrolytic solution leakage out of the cell.
In addition, with a bipolar battery according to embodiments of the present invention, the frame unit made of a light transmissive resin material and the frame unit made of a light absorbing resin material each include a joining surface extending along the stacking direction, and the joining surfaces are welded and joined together. As a result, a width of the joining surface extending along the stacking direction can be made larger than a width of the joining surface extending along the direction perpendicular to the stacking direction. Thus, a creepage distance of the electrolytic solution leakage out of the cell can be made larger than a creepage distance when using the joining surface extending along the direction perpendicular to the stacking direction, and electrolytic solution sealing performance can be further improved.
In addition, with a bipolar battery according to embodiments of the present invention, a resin component of the light transmissive resin material serving as a base material is a thermoplastic resin, and a resin component of the light absorbing resin material serving as a base material is a thermoplastic resin and contains a light absorbing agent. The frame unit made of the light transmissive resin material, the resin component of the light transmissive resin material serving as the base material being the thermoplastic resin, and the frame unit made of the light absorbing resin material, the resin component of the light absorbing resin material serving as the base material being the thermoplastic resin and containing the light absorbing agent, are welded and joined together. Thus, it is possible to reliably prevent the electrolytic solution leakage out of the cell by means of the simple seal structure.
In addition, with a bipolar battery according to embodiments of the present invention, the light transmissive resin material uses as a base material a thermoplastic resin exhibiting a transmittance between 50% and 95% inclusive with respect to light having a wavelength selected from a range between 380 nm and 2000 nm inclusive. The light absorbing resin material contains a light absorbing agent in a thermoplastic resin as a base material, to exhibit an absorbance between 5% and 60% inclusive with respect to light having a wavelength selected from a range between 380 nm and 2000 nm inclusive. The frame unit made of the light transmissive resin material as described and the frame unit made of the light absorbing resin material as described are welded and joined together. Thus, it is possible to reliably prevent electrolytic solution leakage out of the cell by means of the simple seal structure.
In addition, with a bipolar battery according to embodiments of the present invention, the thermoplastic resin contains at least one of an acrylonitrile-butadiene-styrene resin or a polypropylene resin. As a result, the frame unit made of the light transmissive resin material using as the base material the thermoplastic resin containing at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin and the frame unit made of the light absorbing resin material containing the light absorbing agent in the thermoplastic resin containing at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin are welded and joined together. Thus, it is possible to reliably prevent electrolytic solution leakage out of the cell by means of the simple seal structure.
In addition, the bipolar battery according to embodiments of the present invention is a bipolar lead-acid battery in which the positive electrode has a positive-electrode lead layer and the negative electrode has a negative-electrode lead layer, so that it is possible to reliably prevent electrolytic solution leakage out of the cell by means of the simple seal structure.
In addition, a method of manufacturing a bipolar battery according to embodiments of the present invention includes the frame unit arranging step of arranging the plurality of frame units to cause the frame unit made of a light transmissive resin material and the frame unit made of a light absorbing resin material to be alternately arranged in the stacking direction of the cell members, and the joining step of joining together, at the welded portion, the frame unit made of a light transmissive resin material and the frame unit made of a light absorbing resin material adjacent in the stacking direction of the cell members. The welded portion is formed by emitting the light to pass through the frame unit made of a light transmissive resin material to the frame unit made of a light absorbing resin material, and by causing the frame unit made of a light absorbing resin material and the frame unit made of a light transmissive resin material to be melted and solidified.
As a result, it is possible to reliably prevent electrolytic solution leakage out of the cell by means of a simple seal method using laser welding and a simple seal structure.
In addition, by joining the frame unit made of the light transmissive resin material and the frame unit made of the light absorbing resin material adjacent in the stacking direction of the cell members at the welded portion by laser welding, increased airtightness is achieved compared to joining using an adhesive method, and electrolytic solution sealing performance can be further improved. Moreover, by joining the frame unit made of the light transmissive resin material and the frame unit made of the light absorbing resin material at the welded portion, burrs are less likely to be generated at a joining place, and a possibility that foreign matter, such as burrs generated by joining, enters the cell can be avoided.
In addition, with a method of manufacturing a bipolar battery according to embodiments of the present invention, in the joining step, a joining surface of the frame unit made of a light transmissive resin material, the joining surface extending along a direction perpendicular to the stacking direction, and a joining surface of the frame unit made of a light absorbing resin material are joined at the welded portion. The joining surface extends along the direction perpendicular to the stacking direction.
As a result, the joining surfaces of the frame unit made of the light transmissive resin material and the frame unit made of the light absorbing resin material, the joining surfaces extending along the direction perpendicular to the stacking direction, are joined at the welded portion by laser welding, so that it is possible to reliably prevent the electrolytic solution leakage out of the cell.
In addition, with a method of manufacturing a bipolar battery according to embodiments of the present invention, in the joining step, a joining surface of the frame unit made of a light transmissive resin and a joining surface of the frame unit made of a light absorbing resin material, where each of the joining surfaces extend along the stacking direction, are joined at the welded portion. As a result, a width of the joining surface extending along the stacking direction can be made larger than a width of the joining surface extending along the direction perpendicular to the stacking direction. Thus, a creepage distance of the electrolytic solution leakage out of the cell can be made larger than a creepage distance when using the joining surface extending along the direction perpendicular to the stacking direction, and the electrolytic solution sealing performance can be further improved.
Although embodiments of a bipolar battery according to the present invention will be described based on the drawings, the present invention is not limited to the following embodiments described based on the drawings.
A bipolar battery and a method of manufacturing the same according to a first embodiment of the present invention will be described with reference to
A bipolar battery 100 (also referred to as a bipolar storage battery) according to the first embodiment of the present invention illustrated in
The plurality of cell members 150 are arranged to be stacked at intervals in a stacking direction (vertical direction in
The plurality of internal frame units 110, the first end frame unit 120, and the second end frame unit 130 respectively form a plurality of cells 160 (also called spaces) respectively incorporating the plurality of cell members 150.
Each of the internal frame units 110 includes a substrate 111 (also called a bipolar plate) having a rectangular planar shape, and a rim 112 having a quadrangular frame shape provided on an outer periphery of the substrate 111. The substrate 111 of each of the internal frame units 110 is arranged between the cell members 150 adjacent in the stacking direction (vertical direction in
The substrate 111 is integrated with the inside of the rim 112. The substrate 111 is positioned at one end (e.g., a lower end) of the rim 112 in a thickness direction (vertical direction in
The first end frame unit 120 includes a first end plate 121 having a rectangular planar shape, and a rim 122 having a quadrangular frame shape is provided on an outer periphery of the first end plate 121. The first end frame unit 120 surrounds the negative electrode 152 of the cell member 150 and a side surface of the cell member 150, on one end side (e.g., the lower end side in
The first end plate 121 of the first end frame unit 120 is arranged in parallel with the substrates 111 of the internal frame units 110, and the rim 122 is arranged to be in contact with the rim 112 of the internal frame unit 110 positioned adjacent thereto. That is, the rim 122 includes a joining surface 122a facing the rim 112 of the internal frame unit 110 in the stacking direction (vertical direction in
The second end frame unit 130 includes a second end plate 131 having a rectangular planar shape, and a rim 132 having a quadrangular frame shape is provided around the second end plate 131. The second end plate 131 is integrated with the inside of the rim 132. The second end frame unit 130 surrounds the positive electrode 151 of the cell member 150 on the other end side (e.g., the upper end side in
The second end plate 131 is arranged in parallel with the substrates 111 of the internal frame units 110, and the rim 132 is arranged to contact the rim 112 of the internal frame unit 110 positioned adjacent thereto. That is, the rim 132 includes a joining surface 132a facing the rim 112 of the internal frame unit 110 in the stacking direction (vertical direction in
The second end plate 131 has a thickness larger than the thickness of the substrate 111. The rim 132 has the same thickness as the thickness of the second end plate 131.
The positive-electrode lead layer 101 is disposed on one surface of the substrate 111. The negative-electrode lead layer 102 is disposed on the other surface of the substrate 111. A positive active material layer 103 is disposed on the positive-electrode lead layer 101. A negative active material layer 104 is disposed on the negative-electrode lead layer 102.
An electrolyte layer 105 made of a glass fiber mat or the like impregnated with an electrolytic solution such as sulfuric acid is disposed between the positive active material layer 103 and the negative active material layer 104 facing each other.
The negative-electrode lead layer 102 is disposed on the other surface of the first end plate 121. The negative active material layer 104 is disposed on the negative-electrode lead layer 102 on the first end plate 121. The electrolyte layer 105 made of a glass fiber mat or the like impregnated with an electrolytic solution such as sulfuric acid is disposed between the negative active material layer 104 on the first end plate 121 and the facing positive active material layer 103 of the substrate 111.
The positive-electrode lead layer 101 is disposed on one surface of the second end plate 131. The positive active material layer 103 is disposed on the positive-electrode lead layer 101 on the second end plate 131. The electrolyte layer 105 made of a glass fiber mat or the like impregnated with an electrolytic solution such as sulfuric acid is disposed between the positive active material layer 103 on the second end plate 131 and the facing negative active material layer 104 of the substrate 111.
The negative-electrode lead layer 102 on the first end plate 121 is provided with a negative electrode terminal 107 that is electrically connected with the outside of the first end plate 121. The positive-electrode lead layer 101 on the second end plate 131 is provided with a positive electrode terminal 106 that is electrically connected with the outside of the second end plate 131.
That is, the bipolar battery 100 according to the first embodiment includes the plurality of cell members 150, each including the positive electrode 151 having the positive active material layer 103, the negative electrode 152 having the negative active material layer 104, and the electrolyte layer 105 interposed between the positive electrode 151 and the negative electrode 152. The plurality of cell members 150 are arranged to be stacked at intervals. The plurality of frame units (the plurality of internal frame units 110, the first end frame unit 120, and the second end frame unit 130) respectively forming the plurality of cells 160 respectively incorporate the plurality of cell members 150.
The cell members 150 adjacent in the stacking direction are electrically connected in series. Therefore, the substrate 111 interposed between the cell members 150 adjacent in the stacking direction includes means of electrically connecting the positive-electrode lead layer 101 and the negative-electrode lead layer 102.
In the bipolar battery 100 according to the first embodiment, the plurality of frame units (the plurality of internal frame units 110, the first end frame unit 120, and the second end frame unit 130) include a frame unit made of a light transmissive resin material and a frame unit made of a light absorbing resin material being alternately arranged in the stacking direction of the cell members 150.
Specifically, the first end frame unit 120 at one end (the lower end in
Here, a resin component of the light transmissive resin material serving as a base material is a thermoplastic resin. A thermoplastic resin that exhibits a transmittance between 50% and 95% inclusive with respect to light having a wavelength (approximately between 380 nm and 2000 nm inclusive) selected from a range of visible light (approximately between 380 nm and 780 nm inclusive) and near-infrared light (approximately between 780 nm and 2000 nm inclusive) may be used as the base material.
In addition, a resin component of the light absorbing resin material serving as a base material is a thermoplastic resin that contains a light absorbing agent. The thermoplastic resin serving as the base material may contain the light absorbing agent to exhibit an absorbance between 5% and 60% inclusive with respect to light having a wavelength (approximately between 380 nm and 2000 nm inclusive) selected from a range of visible light (approximately between 380 nm and 780 nm inclusive) and near-infrared light (approximately between 780 nm and 2000 nm inclusive).
Examples of the thermoplastic resin applicable as the light transmissive resin material and the light absorbing resin material include acrylonitrile butadiene styrene (ABS) resin, polycarbonate (PC), polystyrene (PS), acrylic resin (PMMA), cyclic polyolefin (COP), polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polybutylene terephthalate (PBT), polyacetal (POM), and polyphenylene sulfide (PPS), and combinations thereof. PP and ABS resin are particularly preferable.
Although the light transmissive resin material and the light absorbing resin material may use different thermoplastic resins as their base materials, it is preferable to use the same thermoplastic resin because there is no difference in melting point and thermal expansion coefficient, and joining reliability is increased.
As the light absorbing agent, for example, conventionally known dyes, pigments, and the like can be used. Examples include a cyanine compound, a phthalocyanine compound, a dithiol metal complex, a naphthoquinone compound, a diimmonium compound, an azo compound, a naphthalocyanine compound, a nickel dithiolene complex, a squarylium dye, a quinone-based compound, quinacridone, dioxane, benzimidazolone, carbon black, titanium oxide, a ferrite compound such as nickel-iron ferrite, manganese-zinc ferrite, nickel-zinc ferrite, or copper-zinc ferrite, nickel, iron particles, gold particles, and copper particles. One of these components can be used singly, or two or more of them can be used in combination.
In particular, in a case where light (e.g., a laser beam) in a visible light region (approximately between 380 nm and 780 nm inclusive) is used, for example, a phthalocyanine compound, quinacridone, dioxane, benzimidazolone, titanium oxide, gold particles, copper particles, or the like is preferably applied as the light absorbing agent. In a case where light in a near-infrared region (approximately between 780 nm and 2000 nm inclusive) is used, for example, a phthalocyanine compound, nickel, iron particles, manganese-zinc ferrite, nickel-zinc ferrite, copper-zinc ferrite, titanium oxide, or the like is preferably applied as the light absorbing agent.
As the light absorbing agent, any shape such as a spherical form, a powdery form, or a granular form can be used as well as a particulate form. An average particle size of the light absorbing agent is preferably within a range of approximately 0.01 μm to 2 μm. For measurement of the average particle size, for example, a primary particle size of the light absorbing agent in an observation sample may be measured at a predetermined magnification (for example, 100,000 times) using a transmission electron microscope, and an average value thereof may be used. In a case where the shape of the light absorbing agent is not spherical, a major axis and a minor axis may be measured, and a value calculated as (a sum of the major axis and the minor axis)/2 may be used as the average particle size.
The reason why the plurality of frame units (the plurality of internal frame units 110, the first end frame unit 120, and the second end frame unit 130) include the second end frame unit 130 and internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and first end frame unit 120 made of the light absorbing resin material being alternately arranged in the stacking direction of the cell members 150 is as follows. That is, as will be described later, when the frame units adjacent in the stacking direction are joined by laser welding, the frame unit made of the light absorbing resin material and the frame unit made of the light transmissive resin material are melted and solidified by emitting a laser beam to pass through a frame unit made of the light transmissive resin material to a frame unit made of the light absorbing resin material.
In the bipolar battery 100 according to the first embodiment, the second end frame unit 130 and internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and first end frame unit 120 made of the light absorbing resin material adjacent in the stacking direction of the cell members 150 are joined at welded portions 140.
Specifically, in order from top to bottom in
In addition, the joining surface 112a provided on the rim 112 of the internal frame unit 110 (a frame unit made of the light absorbing resin material), the joining surface 112a extending along the direction perpendicular to the stacking direction, and the joining surface 112a provided on the rim 112 of the internal frame unit 110 (a frame unit made of the light transmissive resin material) adjacent to the internal frame unit 110 (a frame unit made of the light absorbing resin material) in the stacking direction, the joining surface 112a extending along the direction perpendicular to the stacking direction, are joined at the welded portion 140. The welded portion 140 is formed over an entire periphery of the rims 112 and 112.
Furthermore, the joining surface 112a provided on the rim 112 of the internal frame unit 110 (a frame unit made of the light transmissive resin material), the joining surface 112a extending along the direction perpendicular to the stacking direction, and the joining surface 122a provided on the rim 122 of the first end frame unit 120 (a frame unit made of the light absorbing resin material) adjacent to the internal frame unit 110 (a frame unit made of the light transmissive resin material) in the stacking direction, the joining surface 122a extending along the direction perpendicular to the stacking direction, are joined at the welded portion 140. The welded portion 140 is formed over an entire periphery of the rims 112 and 122.
Here, the respective welded portions 140 are formed by melting and solidifying the internal frame unit 110 and first end frame unit 120 made of the light absorbing resin material and the second end frame unit 130 and internal frame unit 110 made of the light transmissive resin material.
When the bipolar battery 100 is manufactured, particularly when the second end frame unit 130 and internal frame unit 110 made of the light absorbing resin material and the internal frame unit 110 and first end frame unit 120 made of the light transmissive resin material are joined at the welded portions 140, first, as illustrated in
Specifically, the first end frame unit 120 (a frame unit made of the light absorbing resin material), the internal frame unit 110 (a frame unit made of the light transmissive resin material), the internal frame unit 110 (a frame unit made of the light absorbing resin material), and the second end frame unit 130 (a frame unit made of the light transmissive resin material) are arranged in this order from a lower side to an upper side in
Next, the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material, and the second end frame unit 130 and internal frame unit 110 made of the light transmissive resin material are joined together by generating the welded portions 140 by laser welding. That is, as illustrated in
Specifically, as illustrated in
Note that it is preferable that a region irradiated with the laser beam A in the direction perpendicular to the stacking direction is substantially an entire region of a width W1 of each of the joining surfaces 112a and 122a.
Moreover, the laser beam A preferably has a wavelength selected from the range between 380 nm and 2000 nm inclusive (furthermore, between 380 nm and 1200 nm inclusive, and particularly between 380 nm and 500 nm inclusive, and between 1000 nm and 1200 nm inclusive).
In addition, as illustrated in
Note that it is preferable that a region irradiated with the laser beam B in the direction perpendicular to the stacking direction is substantially an entire region of the width W1 of each of the joining surfaces 112a and 112a similarly to the laser beam A.
Moreover, the laser beam B also preferably has a wavelength selected from the range between 380 nm and 2000 nm inclusive (furthermore, between 380 nm and 1200 nm inclusive, and particularly between 380 nm and 500 nm inclusive, and between 1000 nm and 1200 nm inclusive).
In addition, although not illustrated in the drawings, a laser beam is emitted to pass through the second end frame unit 130 (a frame unit made of the light transmissive resin material) to the joining surface 112a provided on the rim 112 of the internal frame unit 110 (a frame unit made of the light absorbing resin material), the joining surface 112a extending along the direction perpendicular to the stacking direction. As a result, the vicinity of the joining surface 112a of the internal frame unit 110 (a frame unit made of the light absorbing resin material) and the vicinity of the joining surface 132a of the second end frame unit 130 (a frame unit made of the light transmissive resin material) are melted by generated heat and are cooled and solidified to generate the welded portion 140 (see
Note that it is also preferable that a region irradiated with the laser beam in the direction perpendicular to the stacking direction is substantially an entire region of the width W1 of each of the joining surfaces 112a and 132a similarly to the laser beams A and B.
Moreover, the laser beam also preferably has a wavelength selected from the range between 380 nm and 2000 nm inclusive (furthermore, between 380 nm and 1200 nm inclusive, and particularly between 380 nm and 500 nm inclusive, and between 1000 nm and 1200 nm inclusive).
As described above, with the bipolar battery 100 according to the first embodiment, the plurality of frame units (the plurality of internal frame units 110, the first end frame unit 120, and the second end frame unit 130) include the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material being alternately arranged in the stacking direction of the cell members 150.
The second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material adjacent in the stacking direction of the cell members 150 are joined at the welded portions 140.
As a result, it is possible to reliably prevent electrolytic solution leakage out of the cells 160 by means of a simple seal structure.
In addition, because the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material adjacent in the stacking direction of the cell members 150 are joined at the welded portions 140, increased airtightness is achieved compared to joining using an adhesive method, and an electrolytic solution sealing performance can be further improved. Moreover, because the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material are joined at the welded portions 140, burrs are less likely to be generated at a joining place, and a possibility that foreign matter, such as burrs generated by joining, enters the cells 160 can be avoided.
In addition, with the bipolar battery 100 according to the first embodiment, the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material include the joining surfaces 132a and 112a extending along the direction perpendicular to the stacking direction, and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material include the joining surfaces 112a and 122a extending along the direction perpendicular to the stacking direction, the joining surfaces being joined at the welded portions 140.
As a result, the joining surfaces 132a and 112a, 112a and 112a, and 112a and 122a of the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material are joined at the welded portions 140, so that it is possible to reliably prevent the electrolytic solution leakage out of the cells 160.
In addition, with the bipolar battery 100 according to the first embodiment, the resin component of the light transmissive resin material serving as the base material is the thermoplastic resin, and the resin component of the light absorbing resin material serving as the base material is the thermoplastic resin and contains the light absorbing agent. As a result, the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material, the resin component of the light transmissive resin material serving as the base material being the thermoplastic resin, and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material, the resin component of the light absorbing resin material serving as the base material being the thermoplastic resin and containing the light absorbing agent, are welded and joined together. Thus, it is possible to reliably prevent the electrolytic solution leakage out of the cells 160 by means of the simple seal structure.
In addition, with the bipolar battery 100 according to the first embodiment, the light transmissive resin material uses as the base material the thermoplastic resin exhibiting the transmittance between 50% and 95% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive. The light absorbing resin material contains the light absorbing agent in the thermoplastic resin as the base material to exhibit the absorbance between 5% and 60% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive. As a result, the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material using as the base material the thermoplastic resin exhibiting the transmittance between 50% and 95% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive, and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material containing the light absorbing agent in the thermoplastic resin as the base material to exhibit the absorbance between 5% and 60% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive, are welded and joined together. Thus, it is possible to reliably prevent the electrolytic solution leakage out of the cells 160 by means of a simple seal structure.
In addition, with the bipolar battery 100 according to the first embodiment, the thermoplastic resin contains at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin. As a result, the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material using as the base material the thermoplastic resin containing at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material containing the light absorbing agent in the thermoplastic resin containing at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin are welded and joined together. Thus, it is possible to reliably prevent the electrolytic solution leakage out of the cells 160 by means of the simple seal structure.
In addition, the method of manufacturing the bipolar battery 100 according to the first embodiment of the present invention includes the frame unit arranging step of arranging the plurality of frame units (the plurality of internal frame units 110, the first end frame unit 120, and the second end frame unit 130) to cause the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material to be alternately arranged in the stacking direction of the cell members 150. The method also includes the joining step of joining together at the welded portions 140 the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material adjacent in the stacking direction of the cell members 150. The welded portions 140 are formed by emitting the laser beams to pass through the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material to the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material, and by causing the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material and the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material to be melted and solidified.
As a result, it is possible to reliably prevent electrolytic solution leakage out of the cells 160 by means of a simple seal method using laser welding and a simple seal structure.
In addition, by joining the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material adjacent in the stacking direction of the cell members 150 at the welded portions 140 by laser welding, increased airtightness is achieved compared to joining using an adhesive method, and an electrolytic solution sealing performance can be further improved. Moreover, by joining the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material at the welded portions 140, burrs are less likely to be generated at a joining place, and a possibility that foreign matter, such as burrs generated by joining, enters the cells can be avoided.
In addition, with the method of manufacturing the bipolar battery 100 according to the first embodiment, in the joining step, the joining surfaces 132a and 112a of the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material, the joining surfaces 132a and 112a extending along the direction perpendicular to the stacking direction, and the joining surfaces 112a and 122a of the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material, the joining surfaces 112a and 122a extending along the direction perpendicular to the stacking direction, are joined at the welded portions 140.
As a result, the joining surfaces 132a and 112a, 112a and 112a, and 112a and 122a of the second end frame unit 130 and the internal frame unit 110 made of the light transmissive resin material and the internal frame unit 110 and the first end frame unit 120 made of the light absorbing resin material are joined at the welded portions 140 by laser welding, so that it is possible to reliably prevent the electrolytic solution leakage out of the cells 160.
A bipolar battery and a method of manufacturing the same according to a second embodiment of the present invention will be described with reference to
A bipolar battery 200 according to the second embodiment of the present invention illustrated in
The plurality of cell members 250 are arranged to be stacked at intervals in a stacking direction (e.g., the vertical direction in
The first internal frame unit 210, the plurality of second internal frame units 220, the first end frame unit 230, and the second end frame unit 240 respectively form a plurality of cells 280 (also called spaces) respectively incorporating the plurality of cell members 250.
The first internal frame unit 210 includes a substrate 211 (also called a bipolar plate) having a rectangular planar shape, and a rim 212 having a quadrangular shape provided on an outer periphery of the substrate 211. The substrate 211 is arranged between the cell members 250 adjacent in the stacking direction (the vertical direction in
In the present embodiment, the second internal frame units 220 are respectively arranged on one side (the lower side in
Each of the second internal frame units 220 includes a substrate 221 (also called a bipolar plate) having a rectangular planar shape, and a rim 222 having a quadrangular shape provided on an outer periphery of the substrate 221. The substrate 221 is arranged between the cell members 250 adjacent in the stacking direction (the vertical direction in
The rim 222 of the second internal frame unit 220 arranged on the one side of the first internal frame unit 210 is arranged inside the rim 212 protruding from the surface on the one side of the substrate 211 of the first internal frame unit 210. In addition, the rim 222 of the second internal frame unit 220 arranged on the other side of the first internal frame unit 210 is arranged inside the rim 212 protruding from the surface on the other side of the substrate 211 of the first internal frame unit 210.
The rim 212 protruding from the surface on the one side of the substrate 211 of the first internal frame unit 210 and the rim 222 of the second internal frame unit 220 arranged on the one side of the first internal frame unit 210 are arranged to be in contact with each other on their side surfaces. The surface of the rim 212 protruding from the surface on the one side of the substrate 211 of the first internal frame unit 210 facing the rim 222 of the second internal frame unit 220 serves as a joining surface 212a. The surface of the rim 222 of the second internal frame unit 220 arranged on the one side of the first internal frame unit 210 facing the rim 212 of the first internal frame unit 210 serves as a joining surface 222a. The joining surfaces 212a and 222a extend along the stacking direction of the cell members 250.
In addition, the rim 212 protruding from the surface on the other side of the substrate 211 of the first internal frame unit 210 and the rim 222 of the second internal frame unit 220 arranged on the other side of the first internal frame unit 210 are arranged to be in contact with each other on their side surfaces. The surface of the rim 212 protruding from the surface on the other side of the substrate 211 of the first internal frame unit 210 facing the rim 222 of the second internal frame unit 220 serves as the joining surface 212a. The surface of the rim 222 of the second internal frame unit 220 arranged on the other side of the first internal frame unit 210 facing the rim 212 of the first internal frame unit 210 serves as the joining surface 222a. The joining surfaces 212a and 222a extend along the stacking direction of the cell members 250.
In addition, the first end frame unit 230 includes a first end plate 231 having a rectangular planar shape and a rim 232 having a quadrangular shape provided on an outer periphery of the first end plate 231. The first end frame unit 230 surrounds the negative electrode 262 of the cell member 250 and a side surface of the second internal frame unit 220 positioned adjacent thereto, on one end side (the lower end side in
The first end plate 231 has substantially the same thickness as the substrate 221. The rim 232 has a thickness larger than the thickness of the first end plate 231, and the first end plate 231 is integrated with the inside of the rim 232. The first end plate 231 is positioned at one end (e.g., the lower end) of the rim 232 in a thickness direction (the vertical direction in
The first end plate 231 of the first end frame unit 230 is arranged in parallel with the substrate 221 of the second internal frame unit 220 positioned adjacent thereto, and the rim 232 is arranged to be in contact with the side surface of the rim 222 of the second internal frame unit 220. A surface of the rim 232 of the first end frame unit 230 facing the rim 222 of the second internal frame unit 220 serves as a joining surface 232a. In addition, the surface of the rim 222 of the second internal frame unit 220 facing the rim 232 of the first end frame unit 230 serves as the joining surface 222a. The joining surfaces 232a and 222a extend along the stacking direction of the cell members 250.
In addition, the second end frame unit 240 includes a second end plate 241 having a rectangular planar shape and a rim 242 having a quadrangular shape provided on an outer periphery of the second end plate 241. The second end frame unit 240 surrounds the positive electrode 261 of the cell member 250 and a side surface of the second internal frame unit 220 positioned adjacent thereto, on the other end side (the upper end side in
The second end plate 241 has substantially the same thickness as the substrate 221. The rim 242 has a thickness larger than the thickness of the second end plate 241, and the second end plate 241 is integrated with the inside of the rim 242. The second end plate 241 is positioned at the other end (e.g., the upper end) of the rim 242 in a thickness direction (the vertical direction in
The second end plate 241 of the second end frame unit 240 is arranged in parallel with the substrate 221 of the second internal frame unit 220 positioned adjacent thereto, and the rim 242 is arranged to be in contact with the side surface of the rim 222 of the second internal frame unit 220. A surface of the rim 242 of the second end frame unit 240 facing the rim 222 of the second internal frame unit 220 serves as a joining surface 242a. In addition, the surface of the rim 222 of the second internal frame unit 220 facing the rim 242 of the second end frame unit 240 serves as the joining surface 222a. The joining surfaces 242a and 222a extend along the stacking direction of the cell members 250.
The positive-electrode lead layer 201 is disposed on one surface (the lower surface in
An electrolyte layer 205 made of a glass fiber mat or the like impregnated with an electrolytic solution such as sulfuric acid is disposed between the positive active material layer 203 and the negative active material layer 204 facing each other.
The positive-electrode lead layer 201 is also disposed on one surface (the lower surface in
The electrolyte layer 205 made of a glass fiber mat or the like impregnated with an electrolytic solution such as sulfuric acid is disposed between the positive active material layer 203 and the negative active material layer 204 facing each other.
The negative-electrode lead layer 202 is also disposed on the other surface of the first end plate 231 of the first end frame unit 230. The negative active material layer 204 is disposed on the negative-electrode lead layer 202 of the first end plate 231. The electrolyte layer 205 made of a glass fiber mat or the like impregnated with an electrolytic solution such as sulfuric acid is disposed between the negative active material layer 204 on the first end plate 231 and the facing positive active material layer 203 of the substrate 221.
The positive-electrode lead layer 201 is also disposed on one surface (the lower surface in
The negative-electrode lead layer 202 on the first end plate 231 of the first end frame unit 230 is provided with a negative electrode terminal 207 that is electrically connected with the outside of the first end plate 231. The positive-electrode lead layer 201 on the second end plate 241 of the second end frame unit 240 is provided with a positive electrode terminal 206 that is electrically connected with the outside of the second end plate 241.
That is, the bipolar battery 200 according to the second embodiment includes the plurality of cell members 250, each including the positive electrode 261 having the positive active material layer 203, the negative electrode 262 having the negative active material layer 204, and the electrolyte layer 205 interposed between the positive electrode 261 and the negative electrode 262. The plurality of cell members 250 is arranged to be stacked at intervals. The plurality of frame units (the first internal frame unit 210, the plurality of second internal frame units 220, the first end frame unit 230, and the second end frame unit 240) respectively forming the plurality of cells 280 respectively incorporate the plurality of cell members 250.
The cell members 250 adjacent in the stacking direction are electrically connected in series. Therefore, the substrates 211 and 221 interposed between the cell members 250 adjacent in the stacking direction include means of electrically connecting the positive-electrode lead layer 201 and the negative-electrode lead layer 202.
In the bipolar battery 200 according to the second embodiment, the plurality of frame units (the first internal frame unit 210, the plurality of second internal frame units 220, the first end frame unit 230, and the second end frame unit 240) include the second end frame unit 240, first internal frame unit 210, and first end frame unit 230 made of a light transmissive resin material and the plurality of second internal frame units 220 and 220 made of a light absorbing resin material being alternately arranged in the stacking direction of the cell members 250.
Specifically, the first end frame unit 230 at one end (the lower end in
Here, a resin component of the light transmissive resin material serving as a base material is a thermoplastic resin, and the thermoplastic resin that exhibits a transmittance between 50% and 95% inclusive with respect to light having a wavelength (approximately between 380 nm and 2000 nm inclusive) selected from a range of visible light (approximately between 380 nm and 780 nm inclusive) and near-infrared light (approximately between 780 nm and 2000 nm inclusive) may be used as the base material.
In addition, a resin component of the light absorbing resin material serving as a base material is a thermoplastic resin and contains a light absorbing agent. The thermoplastic resin serving as the base material may contain the light absorbing agent to exhibit an absorbance between 5% and 60% inclusive with respect to light having a wavelength (approximately between 380 nm and 2000 nm inclusive) selected from a range of visible light (approximately between 380 nm and 780 nm inclusive) and near-infrared light (approximately between 780 nm and 2000 nm inclusive).
Examples of the thermoplastic resin applicable as the light transmissive resin material and the light absorbing resin material include ABS resin, PC, PS, PMMA, COP, PE, PP, PVC, PBT, POM, and PPS. PP and ABS resin are particularly preferable.
Although the light transmissive resin material and the light absorbing resin material may use different thermoplastic resins as their base materials, it is preferable to use the same thermoplastic resin because there is no difference in melting point and thermal expansion coefficient, and joining reliability is increased.
As the light absorbing agent, for example, conventionally known dyes, pigments, and the like can be used, and examples thereof include a cyanine compound, a phthalocyanine compound, a dithiol metal complex, a naphthoquinone compound, a diimmonium compound, an azo compound, a naphthalocyanine compound, a nickel dithiolene complex, a squarylium dye, a quinone-based compound, quinacridone, dioxane, benzimidazolone, carbon black, titanium oxide, a ferrite compound such as nickel-iron ferrite, manganese-zinc ferrite, nickel-zinc ferrite, or copper-zinc ferrite, nickel, iron particles, gold particles, and copper particles. One of these components can be used singly, or two or more of them can be used in combination.
In particular, in a case where light (e.g., a laser beam) in a visible light region (approximately between 380 nm and 780 nm inclusive) is used, for example, a phthalocyanine compound, quinacridone, dioxane, benzimidazolone, titanium oxide, gold particles, copper particles, or the like is preferably applied as the light absorbing agent. In a case where light in a near-infrared region (approximately between 780 nm and 2000 nm inclusive) is used, for example, a phthalocyanine compound, nickel, iron particles, manganese-zinc ferrite, nickel-zinc ferrite, copper-zinc ferrite, titanium oxide, or the like, or some combination thereof, is preferably applied as the light absorbing agent.
As the light absorbing agent, any shape such as a spherical form, a powdery form, or a granular form can be used as well as a particulate form. An average particle size of the light absorbing agent is preferably within a range of approximately 0.01 μm to 2 μm. For measurement of the average particle size, for example, a primary particle size of the light absorbing agent in an observation sample may be measured at a predetermined magnification (for example, 100,000 times) using a transmission electron microscope, and an average value thereof may be used. In a case where the shape of the light absorbing agent is not spherical, a major axis and a minor axis may be measured, and a value calculated by (the sum of the major axis and the minor axis)/2 may be used as the average particle size.
In the bipolar battery 200 according to the second embodiment, the second end frame unit 240, first internal frame unit 210, and first end frame unit 230 made of the light transmissive resin material and the second internal frame units 220 and 220 made of the light absorbing resin material adjacent in the stacking direction of the cell members 250 are joined at welded portions 270.
Specifically, in order from top to bottom in
In addition, the joining surface 222a provided on the rim 222 of the second internal frame unit 220 (a frame unit made of the light absorbing resin material), the joining surface 222a extending along the stacking direction, and the joining surface 212a provided on the rim 212 of the first internal frame unit 210 (a frame unit made of the light transmissive resin material) adjacent to the second internal frame unit 220 (a frame unit made of the light absorbing resin material) in the stacking direction are joined at the welded portion 270. The welded portion 270 is formed over an entire periphery of the rims 222 and 212. The joining surface 212a extends along the stacking direction.
Furthermore, the joining surface 212a provided on the rim 212 of the first internal frame unit 210 (a frame unit made of the light transmissive resin material), the joining surface 212a extending along the stacking direction, and the joining surface 222a provided on the rim 222 of the second internal frame unit 220 (a frame unit made of the light absorbing resin material) adjacent to the first internal frame unit 210 (a frame unit made of the light transmissive resin material) in the stacking direction are joined at the welded portion 270. The welded portion 270 is formed over an entire periphery of the rim 212 and rim 222. The joining surface 222a extends along the stacking direction.
Furthermore, the joining surface 222a provided on the rim 222 of the second internal frame unit 220 (a frame unit made of the light absorbing resin material), the joining surface 222a extending along the stacking direction, and the joining surface 232a provided on the rim 232 of the first end frame unit 230 (a frame unit made of the light transmissive resin material) adjacent to the second internal frame unit 220 (a frame unit made of the light absorbing resin material) in the stacking direction are joined at the welded portion 270. The welded portion 270 is formed over an entire periphery of the rims 222 and 232. The joining surface 232a extends along the stacking direction.
Here, the respective welded portions 270 are formed by melting and solidifying the second internal frame units 220 made of the light absorbing resin material and the second end frame unit 240, first internal frame unit 210, and first end frame unit 230 made of the light transmissive resin material.
When the bipolar battery 200 is manufactured, particularly when the frame units made of the light absorbing resin material and the frame units made of the light transmissive resin material are joined at the welded portions 270, first, as illustrated in
Specifically, the first end frame unit 230 (a frame unit made of the light transmissive resin material), the second internal frame unit 220 (a frame unit made of the light absorbing resin material), the first internal frame unit 210 (a frame unit made of the light transmissive resin material), the second internal frame unit 220 (a frame unit made of the light absorbing resin material), and the second end frame unit 240 (a frame unit made of the light transmissive resin material) are arranged in this order from the lower side to the upper side in
Next, the frame units made of the light absorbing resin material and the frame units made of the light transmissive resin material are joined together by generating the welded portions 270 by laser welding. That is, as illustrated in
Specifically, as illustrated in
Note that it is preferable that a region irradiated with the laser beam C in the stacking direction is substantially an entire region of a width W2 of each of the joining surfaces 232a and 222a.
Moreover, the laser beam C preferably has a wavelength selected from the range between 380 nm and 2000 nm inclusive (furthermore, between 380 nm and 1200 nm inclusive, and particularly between 380 nm and 500 nm inclusive, and between 1000 nm and 1200 nm inclusive).
In addition, as illustrated in
Note that it is preferable that a region irradiated with the laser beam D in the stacking direction is substantially an entire region of the width W2 of each of the joining surfaces 222a and 212a similarly to the laser beam C.
Moreover, the laser beam D also preferably has a wavelength selected from the range between 380 nm and 2000 nm inclusive (furthermore, between 380 nm and 1200 nm inclusive, and particularly between 380 nm and 500 nm inclusive, and between 1000 nm and 1200 nm inclusive).
In addition, as illustrated in
Note that it is preferable that a region irradiated with the laser beam E in the stacking direction is substantially an entire region of the width W2 of each of the joining surfaces 222a and 212a similarly to the laser beam C.
Moreover, the laser beam E also preferably has a wavelength selected from the range between 380 nm and 2000 nm inclusive (furthermore, between 380 nm and 1200 nm inclusive, and particularly between 380 nm and 500 nm inclusive, and between 1000 nm and 1200 nm inclusive).
In addition, although not illustrated in the drawings, a laser beam is emitted to pass through the second end frame unit 240 (a frame unit made of the light transmissive resin material) to the joining surface 222a on the other side provided on the rim 222 of the other second internal frame unit 220 (a frame unit made of the light absorbing resin material). The joining surface 222a extends along the stacking direction. As a result, the vicinity of the joining surface 222a on the other side of the other second internal frame unit 220 (a frame unit made of the light absorbing resin material) and the vicinity of the joining surface 242a of the second end frame unit 240 (a frame unit made of the light transmissive resin material) are melted by generated heat and cooled and solidified to generate the welded portion 270 (see
Note that it is preferable that a region irradiated with the laser beam in the stacking direction is substantially an entire region of the width W2 of each of the joining surfaces 242a and 222a.
Moreover, the laser beam also preferably has a wavelength selected from the range between 380 nm and 2000 nm inclusive (furthermore, between 380 nm and 1200 nm inclusive, and particularly between 380 nm and 500 nm inclusive, and between 1000 nm and 1200 nm inclusive).
As described above, with the bipolar battery 200 according to the second embodiment, the plurality of frame units (the first internal frame unit 210, the plurality of second internal frame units 220, the first end frame unit 230, and the second end frame unit 240) include the second end frame unit 240, first internal frame unit 210, and first end frame unit 230 made of the light transmissive resin material and the second internal frame units 220 made of the light absorbing resin material being alternately arranged in the stacking direction of the cell members 250.
The second end frame unit 240, first internal frame unit 210, and first end frame unit 230 made of the light transmissive resin material and the second internal frame units 220 made of the light absorbing resin material adjacent in the stacking direction of the cell members 250 are joined at the welded portions 270.
As a result, it is possible to reliably prevent electrolytic solution leakage out of the cells 280 by means of a simple seal structure.
In addition, because the frame units 240, 210, and 230 made of the light transmissive resin material and the frame units 220 and 220 made of the light absorbing resin material adjacent in the stacking direction of the cell members 250 are joined at the welded portions 270, increased airtightness is achieved compared to joining using an adhesive method, and electrolytic solution sealing performance can be further improved. Moreover, because the frame units 240, 210, and 230 made of the light transmissive resin material and the frame units 220 and 220 made of the light absorbing resin material are joined at the welded portions 270, burrs are less likely to be generated at a joining place, and a possibility that foreign matter, such as burrs generated by joining, enters the cells 280 can be minimized or avoided.
In addition, with the bipolar battery 200 according to the second embodiment, the frame units 240, 210, and 230 made of the light transmissive resin material include the joining surfaces 242a, 212a, and 232a extending along the stacking direction, and the frame units 220 and 220 made of the light absorbing resin material include the joining surfaces 222a and 222a extending along the stacking direction, the joining surfaces being joined at the welded portions 270.
As a result, the width W2 of each of the joining surfaces 242a, 212a, 232a, and 222a extending along the stacking direction can be made larger than the width W1 of each of the joining surfaces 112a, 122a, and 132a extending along the direction perpendicular to the stacking direction in the first embodiment. Thus, a creepage distance of the electrolytic solution leakage out of the cells 280 can be made larger than that in a case of the first embodiment, and the electrolytic solution sealing performance can be further improved. If the width W1 of each of the joining surfaces 112a, 122a, and 132a extending along the direction perpendicular to the stacking direction is made larger than the width W2 of each of the joining surfaces 242a, 212a, 232a, and 222a extending along the stacking direction, the bipolar battery increases in size in the direction perpendicular to the stacking direction, which is not suitable for miniaturization.
In addition, with the bipolar battery 200 according to the second embodiment, the resin component of the light transmissive resin material serving as the base material is the thermoplastic resin, and the resin component of the light absorbing resin material serving as the base material is the thermoplastic resin and contains the light absorbing agent. As a result, the frame units 240, 210, and 230 made of the light transmissive resin material, the resin component of the light transmissive resin material serving as the base material being the thermoplastic resin, and the frame units 220 and 220 made of the light absorbing resin material, the resin component of the light absorbing resin material serving as the base material being the thermoplastic resin and containing the light absorbing agent, are welded and joined together. Thus, it is possible to reliably prevent the electrolytic solution leakage out of the cells 280 by means of the simple seal structure.
In addition, with the bipolar battery 200 according to the second embodiment, the light transmissive resin material uses as the base material the thermoplastic resin exhibiting the transmittance between 50% and 95% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive. The light absorbing resin material contains the light absorbing agent in the thermoplastic resin as the base material to exhibit the absorbance between 5% and 60% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive. As a result, the frame units 240, 210, and 230 made of the light transmissive resin material using as the base material the thermoplastic resin exhibiting the transmittance between 50% and 95% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive, and the frame units 220 and 220 made of the light absorbing resin material containing the light absorbing agent in the thermoplastic resin as the base material to exhibit the absorbance between 5% and 60% inclusive with respect to the light having the wavelength selected from the range between 380 nm and 2000 nm inclusive, are welded and joined together. Thus, it is possible to reliably prevent the electrolytic solution leakage out of the cells 280 by means of the simple seal structure.
In addition, with the bipolar battery 200 according to the second embodiment, the thermoplastic resin contains at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin. As a result, the frame units 240, 210, and 230 made of the light transmissive resin material using as the base material the thermoplastic resin containing at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin, and the frame units 220 and 220 made of the light absorbing resin material containing the light absorbing agent in the thermoplastic resin containing at least one of the acrylonitrile-butadiene-styrene resin or the polypropylene resin are welded and joined together. Thus, it is possible to reliably prevent the electrolytic solution leakage out of the cells 280 by means of the simple seal structure.
In addition, the method of manufacturing the bipolar battery 200 according to the second embodiment of the present invention includes the frame unit arranging step of arranging the plurality of frame units (the first internal frame unit 210, the plurality of second internal frame units 220, the first end frame unit 230, and the second end frame unit 240) to cause the frame units 240, 210, and 230 made of the light transmissive resin material and the frame units 220 and 220 made of the light absorbing resin material to be alternately arranged in the stacking direction of the cell members 250. The method also includes the joining step of joining together at the welded portions 270 the frame units 240, 210, and 230 made of the light transmissive resin material and the frame units 220 and 220 made of the light absorbing resin material adjacent in the stacking direction of the cell members 250, the welded portions 270 being formed by emitting the laser beams to pass through the frame units 240, 210, and 230 made of the light transmissive resin material to the frame units 220 and 220 made of the light absorbing resin material. This causes the frame units 220 and 220 made of the light absorbing resin material and the frame units 240, 210, and 230 made of the light transmissive resin material to be melted and solidified.
As a result, it is possible to reliably prevent electrolytic solution leakage out of the cells 280 by means of a simple seal method using laser welding and a simple seal structure.
In addition, by joining the frame units 240, 210, and 230 made of the light transmissive resin material and the frame units 220 and 220 made of the light absorbing resin material adjacent in the stacking direction of the cell members 250 at the welded portions 270 by laser welding, increased airtightness is achieved compared to joining using an adhesive method, and electrolytic solution sealing performance can be further improved. Moreover, by joining the frame units 240, 210, and 230 made of the light transmissive resin material and the frame units 220 and 220 made of the light absorbing resin material at the welded portions 270, burrs are less likely to be generated at a joining place, and a possibility that foreign matter, such as burrs generated by joining, enters the cells can be minimized or avoided.
In addition, with the method of manufacturing the bipolar battery 200 according to the second embodiment, in the joining step, the joining surfaces 242a, 212a, and 232a of the frame units 240, 210, and 230 made of the light transmissive resin and extend along the stacking direction and the joining surfaces 222a and 222a of the frame units 220 and 220 made of the light absorbing resin material and along the stacking direction are joined at the welded portions 270.
As a result, the width W2 of each of the joining surfaces 242a, 212a, 232a, and 222a extending along the stacking direction can be made larger than the width W1 of each of the joining surfaces 112a, 122a, and 132a extending along the direction perpendicular to the stacking direction in the first embodiment. Thus, a creepage distance of the electrolytic solution leakage out of the cells 280 can be made larger than that in a case of the first embodiment, and the electrolytic solution sealing performance can be further improved.
Although the embodiments of the present invention have been described above, the present invention is not limited thereto, and various modifications and improvements can be made therein.
For example, in the bipolar battery 100 according to the first embodiment, the two internal frame units 110 are provided. However, the number may be one or may be three or more.
In addition, in the bipolar battery 200 according to the second embodiment, the single first internal frame unit 210 is provided. However, the first internal frame unit does not have to be provided, or the number may be two or more.
In addition, in the bipolar battery 200 according to the second embodiment, the two second internal frame units 220 are provided. However, the number may be one or may be three or more. The number of second internal frame units 220 only needs to be larger than the number of first internal frame units 210 by one.
In addition, the electrical connection means provided in the substrates 111, 211, and 221 in the bipolar storage batteries 100 and 200 according to the first and second embodiments is not limited to a specific method. For example, opposite surfaces of the substrate may be electrically connected by causing the entire substrate to contain conductive particles or conductive fibers. A conductive member that enables an electrical connection may also be incorporated in the substrate.
Moreover, in the method of manufacturing the bipolar battery 100 according to the first embodiment, the laser beams are emitted to pass through the frame units 130 and 110 made of the light transmissive resin material to the frame units 110 and 120 made of the light absorbing resin material. However, light other than the laser beam may be emitted to pass through the frame units 130 and 110 made of the light transmissive resin material to the frame units 110 and 120 made of the light absorbing resin material. The same applies to the method of manufacturing the bipolar battery 200 according to the second embodiment.
In addition, the bipolar battery 100 according to the first embodiment is the bipolar lead-acid battery in which the positive electrode 151 has the positive-electrode lead layer 101, and the negative electrode 152 has the negative-electrode lead layer 102. However, the bipolar battery may use a metal other than lead for the positive electrode 151 and the negative electrode 152. The same applies to the bipolar battery 200 according to the second embodiment.
Because the bipolar battery and the method of manufacturing the same according to the present invention can reliably prevent the electrolytic solution leakage out of the cell by means of the simple seal structure, both high energy density and long-term reliability can be achieved, and the bipolar battery and the method of manufacturing the same can be extremely advantageously used in various industries.
The following is a list of reference signs used in this specification and in the drawings.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-212733 | Dec 2020 | JP | national |
This application is a continuation of PCT Application No. PCT/JP2021/043236, filed Nov. 25, 2021, the disclosure of which is incorporated herein in its entirety by reference.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2021/043236 | Nov 2021 | US |
| Child | 18338994 | US |
