Patent Application
20250087845
This nonprovisional application is based on Japanese Patent Application No. 2023-147005 filed on Sep. 11, 2023 with the Japan Patent Office, the entire contents of which are hereby incorporated by reference.
The present technology relates to a secondary battery and a method of manufacturing the secondary battery.
Japanese Patent No. 4537353 discloses a prismatic secondary battery in which an electrode group (25) is accommodated in a case (14) provided with openings (14a, 14b) at both ends thereof and electrode terminals (21, 23) are respectively attached to cap plates (33, 33′) that seal the openings (14a, 14b).
In the secondary battery described in Japanese Patent No. 4537353, there is room for attaining improved energy density and stable manufacturing of the secondary battery.
The present technology has been made to solve the above-described problem, and has an object to provide a method of manufacturing a secondary battery and the secondary battery so as to attain improved energy density and stable manufacturing thereof.
A secondary battery according to the present technology comprises a first electrode assembly, a second electrode assembly, and a case. Each of the first electrode assembly and the second electrode assembly includes a first electrode and a second electrode having a polarity different from a polarity of the first electrode. The case accommodates the first electrode assembly and the second electrode assembly. The case includes a case main body having a tubular shape, a first sealing plate, and a second sealing plate. The case main body is provided with a first opening located at an end portion of the case main body on a first side, and is provided with a second opening located at an end portion of the case main body on a second side opposite to the end portion on the first side. The first sealing plate seals the first opening. The second sealing plate seals the second opening. The first sealing plate is provided with a first electrode terminal electrically connected to the first electrode. The second sealing plate is provided with a second electrode terminal electrically connected to the second electrode. The first electrode assembly has a first electrode tab located at an end portion of the first electrode assembly on the first sealing plate side and a second electrode tab located at an end portion of the first electrode assembly on the second sealing plate side, the first electrode tab being electrically connected to the first electrode, the second electrode tab being electrically connected to the second electrode. The second electrode assembly has a third electrode tab located at an end portion of the second electrode assembly on the first sealing plate side, and a fourth electrode tab located at an end portion of the second electrode assembly on the second sealing plate side, the third electrode tab being electrically connected to the first electrode, the fourth electrode tab being electrically connected to the second electrode. The first electrode tab is joined to a first current collector. The second electrode tab is joined to a second current collector. The third electrode tab is joined to a third current collector. The fourth electrode tab is joined to a fourth current collector. The first current collector and the third current collector are constituted of separate components. The second current collector and the fourth current collector are constituted of separate components. Each of the first current collector and the third current collector is connected to a fifth current collector electrically connected to the first electrode terminal. Each of the second current collector and the fourth current collector is connected to a sixth current collector electrically connected to the second electrode terminal.
A secondary battery in a method of manufacturing the secondary battery according to the present technology comprises a first electrode assembly, a second electrode assembly, and a case. Each of the first electrode assembly and the second electrode assembly includes a first electrode and a second electrode having a polarity different from a polarity of the first electrode. The case accommodates the first electrode assembly and the second electrode assembly. The case includes a case main body having a tubular shape, a first sealing plate, and a second sealing plate. The case main body is provided with a first opening located at an end portion of the case main body on a first side, and is provided with a second opening located at an end portion of the case main body on a second side opposite to the end portion on the first side. The first sealing plate seals the first opening. The second sealing plate seals the second opening. The first sealing plate is provided with a first electrode terminal electrically connected to the first electrode. The second sealing plate is provided with a second electrode terminal electrically connected to the second electrode. The first electrode assembly has a first electrode tab located at an end portion of the first electrode assembly on the first sealing plate side and a second electrode tab located at an end portion of the first electrode assembly on the second sealing plate side, the first electrode tab being electrically connected to the first electrode, the second electrode tab being electrically connected to the second electrode. The second electrode assembly has a third electrode tab located at an end portion of the second electrode assembly on the first sealing plate side, and a fourth electrode tab located at an end portion of the second electrode assembly on the second sealing plate side, the third electrode tab being electrically connected to the first electrode, the fourth electrode tab being electrically connected to the second electrode. The first electrode tab is joined to a first current collector. The second electrode tab is joined to a second current collector. The third electrode tab is joined to a third current collector. The fourth electrode tab is joined to a fourth current collector. The first current collector and the third current collector are constituted of separate components. The second current collector and the fourth current collector are constituted of separate components. Each of the first current collector and the third current collector is connected to a fifth current collector electrically connected to the first electrode terminal. Each of the second current collector and the fourth current collector is connected to a sixth current collector electrically connected to the second electrode terminal. The method of manufacturing the secondary battery comprises: producing the first electrode assembly and the second electrode assembly; joining the first electrode tab to the first current collector after producing the first electrode assembly and the second electrode assembly; joining the second electrode tab to the second current collector after producing the first electrode assembly and the second electrode assembly; joining the third electrode tab to the third current collector after producing the first electrode assembly and the second electrode assembly; joining the fourth electrode tab to the fourth current collector after producing the first electrode assembly and the second electrode assembly; overlapping the first electrode assembly and the second electrode assembly with each other in a thickness direction of each of the first electrode assembly and the second electrode assembly; connecting the first current collector and the third current collector to the fifth current collector after overlapping the first electrode assembly and the second electrode assembly with each other; after connecting the first current collector and the third current collector to the fifth current collector, inserting the first electrode assembly and the second electrode assembly into the case main body via the first opening with each of the second electrode tab side and the fourth electrode tab side being inserted first; and after inserting the first electrode assembly and the second electrode assembly into the case main body, connecting, to the sixth current collector, the second current collector and the fourth current collector each protruding from the second opening.
Regarding the expression “overlapping the first electrode assembly and the second electrode assembly with each other”, the first electrode assembly and the second electrode assembly may be overlapped with each other directly, or another member may be disposed between the first electrode assembly and the second electrode assembly. Further, the first electrode assembly and the second electrode assembly may or may not be fixed by a tape or the like.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
Hereinafter, embodiments of the present technology will be described. It should be noted that the same or corresponding portions are denoted by the same reference characters, and may not be described repeatedly.
It should be noted that in the embodiments described below, when reference is made to number, amount, and the like, the scope of the present technology is not necessarily limited to the number, amount, and the like unless otherwise stated particularly. Further, in the embodiments described below, each component is not necessarily essential to the present technology unless otherwise stated particularly. Further, the present technology is not limited to one that necessarily exhibits all the functions and effects stated in the present embodiment.
It should be noted that in the present specification, the terms “comprise”, “include”, and “have” are open-end terms. That is, when a certain configuration is included, a configuration other than the foregoing configuration may or may not be included.
Also, in the present specification, when geometric terms and terms representing positional/directional relations are used, for example, when terms such as “parallel”, “orthogonal”, “obliquely at 45°”, “coaxial”, and “along” are used, these terms permit manufacturing errors or slight fluctuations. In the present specification, when terms representing relative positional relations such as “upper side” and “lower side” are used, each of these terms is used to indicate a relative positional relation in one state, and the relative positional relation may be reversed or turned at any angle in accordance with an installation direction of each mechanism (for example, the entire mechanism is reversed upside down).
In the present specification, the term “secondary battery” is not limited to a lithium ion battery, and may include other secondary batteries such as a nickel-metal hydride battery and a sodium-ion battery. In the present specification, the term “electrode” may collectively represents a positive electrode and a negative electrode. It should be noted that in each of the figures, the X direction is defined to represent a direction along a winding axis of an electrode assembly included in the secondary battery, the Y direction is defined to represent a short-side direction of the electrode assembly when viewed in the X direction, and the Z direction is defined to represent a long-side direction of the electrode assembly when viewed in the X direction. Further, in order to facilitate understanding of the invention, the size of each configuration in the figures may be illustrated to be changed from its actual size. In the specification of the present application, the X direction may be referred to as a “width direction” of the secondary battery or the case main body, the Y direction may be referred to as a “thickness direction” of the secondary battery or the case main body, and the Z direction may be referred to as a “height direction” of the secondary battery or the case main body.
Secondary battery 1 can be mounted on a battery electric vehicle (BEV), a plug-in hybrid electric vehicle (PHEV), a hybrid electric vehicle (HEV), or the like. It should be noted that the purpose of use of secondary battery 1 is not limited to the use on a vehicle.
As shown in
When forming a battery assembly including secondary battery 1, a plurality of secondary batteries 1 are stacked in the thickness direction of each of the plurality of secondary batteries 1. Secondary batteries 1 stacked may be restrained in the stacking direction (Y direction) by a restraint member to form a battery module, or the battery assembly may be directly supported by a side surface of a case of a battery pack without using the restraint member.
Case main body 110 is constituted of a member having a tubular shape, preferably, a prismatic tubular shape. Thus, secondary battery 1 having a prismatic shape is obtained. Case main body 110 is composed of a metal. Specifically, case main body 110 is composed of aluminum, an aluminum alloy, iron, an iron alloy, or the like.
As shown in
In the present embodiment, case main body 110 is formed to be longer in the width direction (X direction) of secondary battery 1 than in each of the thickness direction (Y direction) and the height direction (Z direction) of secondary battery 1. The size (width) of case main body 110 in the X direction is preferably about 30 cm or more. In this way, secondary battery 1 can be formed to have a relatively large size (high capacity). The size (height) of case main body 110 in the Z direction is preferably about 20 cm or less, more preferably about 15 cm or less, and further preferably about 10 cm or less. Thus, (low-height) secondary battery 1 having a relatively low height can be formed, thus resulting in improved ease of mounting on a vehicle, for example.
Case main body 110 includes a pair of first side surface portions 111 and a pair of second side surface portions 112. The pair of first side surface portions 111 constitute parts of the side surfaces of case 100. The pair of second side surface portions 112 constitute the bottom surface portion and upper surface portion of case 100. The pair of first side surface portions 111 and the pair of second side surface portions 112 are provided to intersect each other. The pair of first side surface portions 111 and the pair of second side surface portions 112 are connected at their respective end portions. Each of the pair of first side surface portions 111 desirably has an area larger than that of each of the pair of second side surface portions 112.
As shown in
The thickness of the plate-shaped member in gas-discharge valve 150 is thinner than the thickness of the plate-shaped member of case main body 110 other than gas-discharge valve 150. Thus, when the pressure in case 100 becomes equal to or more than a predetermined value, gas-discharge valve 150 is fractured prior to the other portions of case main body 110, thereby discharging the gas in case 100 to the outside.
As shown in
As shown in
A negative electrode terminal 301 (first electrode terminal) is provided on first sealing plate 120. The position of negative electrode terminal 301 can be appropriately changed.
As shown in
Second sealing plate 130 is provided with a positive electrode terminal 302 (second electrode terminal) and an injection hole 134. The positions of positive electrode terminal 302 and injection hole 134 can be appropriately changed.
Each of first sealing plate 120 and second sealing plate 130 is composed of a metal. Specifically, each of first sealing plate 120 and second sealing plate 130 is composed of aluminum, an aluminum alloy, iron, an iron alloy, or the like.
Negative electrode terminal 301 is electrically connected to a negative electrode (first electrode) of electrode assembly 200. Negative electrode terminal 301 is attached to first sealing plate 120, i.e., case 100.
Positive electrode terminal 302 is electrically connected to a positive electrode (second electrode) of electrode assembly 200. Positive electrode terminal 302 is attached to second sealing plate 130, i.e., case 100.
Negative electrode terminal 301 is composed of a conductive material (more specifically, a metal), and can be composed of copper, a copper alloy, or the like, for example. A portion or layer composed of aluminum or an aluminum alloy may be provided at a portion of an outer surface of negative electrode terminal 301.
Positive electrode terminal 302 is composed of a conductive material (more specifically, a metal), and can be composed of aluminum, an aluminum alloy, or the like, for example.
Injection hole 134 is sealed with a sealing member (not shown). As the sealing member, for example, a blind rivet or another metal member can be used.
Electrode assembly 200 is an electrode assembly having a flat shape and having a below-described positive electrode plate and a below-described negative electrode plate. Specifically, electrode assembly 200 is a wound type electrode assembly in which a strip-shaped positive electrode plate and a strip-shaped negative electrode plate are both wound with a strip-shaped separator (not shown) being interposed therebetween. It should be noted that in the present specification, the “electrode assembly” is not limited to the wound type electrode assembly, and may be a stacked type electrode assembly in which a plurality of positive electrode plates and a plurality of negative electrode plates are alternately stacked. The strip-shaped separator can be constituted of, for example, a microporous membrane composed of polyolefin. The electrode assembly may include a plurality of positive electrode plates and a plurality of negative electrode plates, respective positive electrode tabs provided in the positive electrode plates may be stacked to form a positive electrode tab group, and respective negative electrode tabs provided in the negative electrode plates may be stacked to form a negative electrode tab group. It should be noted that electrode assembly 200 may include a plurality of wound type electrode assemblies or may include a plurality of stacked type electrode assemblies.
As shown in
Specifically, one or a plurality of the wound type electrode assemblies and an electrolyte solution (electrolyte) (not shown) are accommodated inside a below-described insulating sheet 700 disposed in case 100. As the electrolyte solution (non-aqueous electrolyte solution), it is possible to use, for example, a solution obtained by dissolving LiPF6 at a concentration of 1.2 mol/L in a non-aqueous solvent obtained by mixing ethylene carbonate (EC), ethyl methyl carbonate (EMC), and diethyl carbonate (DEC) at a volume ratio (25° C.) of 30:30:40. It should be noted that instead of the electrolyte solution, a solid electrolyte may be used.
First electrode assembly 201 includes: a main body portion (portion in which a positive electrode plate and a negative electrode plate are stacked with a separator being interposed therebetween); a first tab 220 (negative electrode tab group); and a second electrode tab 250 (positive electrode tab group).
The main body portion is constituted of a below-described negative electrode plate 210 and a below-described positive electrode plate 240. First electrode tab 220 is located at an end portion of first electrode assembly 201 on the first side with respect to the main body portion in the first direction (X direction). The first side in the present embodiment is the first sealing plate 120 side. Second electrode tab 250 is located at an end portion of first electrode assembly 201 on the second side with respect to the main body portion in the first direction (X direction). The second side in the present embodiment is the second sealing plate 130 side.
Each of first electrode tab 220 and second electrode tab 250 is formed to protrude from a central portion of electrode assembly 200 toward first sealing plate 120 or second sealing plate 130.
Current collectors 400 include a negative electrode current collector 400A and a positive electrode current collector 400B. Each of negative electrode current collector 400A and positive electrode current collector 400B is constituted of a plate-shaped member. Electrode assembly 200 is electrically connected to negative electrode terminal 301 and positive electrode terminal 302 through current collectors 400.
Negative electrode current collector 400A is disposed on first sealing plate 120 with an insulating member composed of a resin being interposed therebetween. Negative electrode current collector 400A is electrically connected to first electrode tab 220 and negative electrode terminal 301. Negative electrode current collector 400A is composed of a conductive material (more specifically, a metal), and can be composed of copper, a copper alloy, or the like, for example. It should be noted that details of negative electrode current collector 400A will be described later.
Positive electrode current collector 400B is disposed on second sealing plate 130 with an insulating member composed of a resin being interposed therebetween. Positive electrode current collector 400B is electrically connected to second electrode tab 250 and positive electrode terminal 302. Positive electrode current collector 400B is composed of a conductive material (more specifically, a metal), and can be composed of aluminum, an aluminum alloy, or the like, for example. It should be noted that second electrode tab 250 may be electrically connected to second sealing plate 130 directly or via positive electrode current collector 400B. In this case, second sealing plate 130 may serve as positive electrode terminal 302. Moreover, details of positive electrode current collector 400B will be described later.
Negative electrode plate 210 is manufactured by processing negative electrode raw plate 210S. As shown in
Negative electrode active material layer 212 is formed on negative electrode core body 211 except for each of end portions of both surfaces of negative electrode core body 211 on one side. Negative electrode active material layer 212 is formed by applying a negative electrode active material layer slurry using a die coater.
The negative electrode active material layer slurry is produced by kneading graphite serving as a negative electrode active material, styrene-butadiene rubber (SBR) and carboxymethyl cellulose (CMC) each serving as a binder, and water serving as a dispersion medium such that the mass ratio of the graphite, the SBR, and the CMC is about 98:1:1.
Negative electrode core body 211 having the negative electrode active material layer slurry applied thereon is dried to remove the water included in the negative electrode active material layer slurry, thereby forming negative electrode active material layer 212. Further, by compressing negative electrode active material layer 212, negative electrode raw plate 210S including negative electrode core body 211 and negative electrode active material layer 212 is formed. Negative electrode raw plate 210S is cut into a predetermined shape, thereby forming negative electrode plate 210. Negative electrode raw plate 210S can be cut by laser processing with application of an energy ray, die processing, cutter processing, or the like.
As shown in
Positive electrode plate 240 serving as the second electrode has a polarity different from a polarity of negative electrode plate 210 serving as the first electrode. Positive electrode plate 240 is manufactured by processing positive electrode raw plate 240S. As shown in
Positive electrode active material layer 242 is formed on positive electrode core body 241 except for each of end portions of both surfaces of positive electrode core body 241 on one side. Positive electrode active material layer 242 is formed on positive electrode core body 241 by applying a positive electrode active material layer slurry using a die coater.
The positive electrode active material layer slurry is produced by kneading a lithium-nickel-cobalt-manganese composite oxide serving as a positive electrode active material, polyvinylidene difluoride (PVdF) serving as a binder, a carbon material serving as a conductive material, and N-methyl-2-pyrrolidone (NMP) serving as a dispersion medium such that the mass ratio of the lithium-nickel-cobalt-manganese composite oxide, the PVdF, and the carbon material is about 97.5:1:1.5.
Positive electrode protective layer 243 is formed in contact with positive electrode core body 241 at an end portion of positive electrode active material layer 242 on the one side in the width direction. Positive electrode protective layer 243 is formed on positive electrode core body 241 by applying a positive electrode protective layer slurry using a die coater. Positive electrode protective layer 243 has an electrical resistance larger than that of positive electrode active material layer 242.
The positive electrode protective layer slurry is produced by kneading alumina powder, a carbon material serving as a conductive material, PVdF serving as a binder, and NMP serving as a dispersion medium such that the mass ratio of the alumina powder, the carbon material, and the PVdF is about 83:3:14.
Positive electrode core body 241 having the positive electrode active material layer slurry and the positive electrode protective layer slurry applied thereon is dried to remove the NMP included in the positive electrode active material layer slurry and the positive electrode protective layer slurry, thereby forming positive electrode active material layer 242 and positive electrode protective layer 243. Further, by compressing positive electrode active material layer 242, positive electrode raw plate 240S including positive electrode core body 241, positive electrode active material layer 242, and positive electrode protective layer 243 is formed. Positive electrode raw plate 240S is cut into a predetermined shape, thereby forming positive electrode plate 240. Positive electrode raw plate 240S can be cut by laser processing with application of an energy ray, die processing, cutter processing, or the like.
As shown in
Positive electrode protective layer 243 is provided at the root of each of the plurality of positive electrode tabs 260. Positive electrode protective layer 243 may not necessarily be provided at the root of positive electrode tab 260.
In a typical example, the thickness of (one) negative electrode tab 230 is smaller than the thickness of (one) positive electrode tab 260. In this case, the thickness of first electrode tab 220 is smaller than the thickness of second electrode tab 250.
(Connection Structure between Electrode Assembly 200 and Current Collector 400)
Electrode assembly 200 is formed by overlapping first electrode assembly 201 and second electrode assembly 202 with each other. First electrode assembly 201 and second electrode assembly 202 are arranged side by side in the thickness direction (Y direction) of each of first electrode assembly 201 and second electrode assembly 202.
First electrode assembly 201 includes first electrode tab 220. First electrode tab 220 is electrically connected to the first electrode at its first end portion 205 on the first sealing plate 120 side in the X direction. Second electrode assembly 202 includes a third electrode tab 270. Third electrode tab 270 is electrically connected to the first electrode at its third end portion 207 on the first sealing plate 120 side in the X direction.
First electrode tab 220 has a curved portion 221 and a tip portion 222. Curved portion 221 is a portion at which first electrode tab 220 is curved on the side, on which the first electrode is connected, with respect to tip portion 222. Tip portion 222 is a portion located at an end portion of first electrode tab 220 on the side opposite to the side on which the first electrode is connected.
Third electrode tab 270 has a curved portion 271 and a tip portion 272. Curved portion 271 is a portion at which third electrode tab 270 is curved on the side, on which the first electrode is connected, with respect to tip portion 272. Tip portion 272 is a portion located at an end portion of third electrode tab 270 on the side opposite to the side on which the first electrode is connected.
First electrode tab 220 and third electrode tab 270 are curved in opposite directions such that tip portions 222, 272 are close to each other. It should be noted that tip portions 222, 272 are separated from each other in the present embodiment; however, it is not limited to this configuration, and tip portions 222, 272 may be in contact with each other.
Negative electrode current collector 400A electrically connects negative electrode terminal 301 to first electrode tab 220 and third electrode tab 270. Negative electrode current collector 400A in the present embodiment is connected to negative electrode terminal 301 between electrode assembly 200 and first sealing plate 120.
Negative electrode current collector 400A includes a first current collector 410, a third current collector 430, and a fifth current collector 450.
First current collector 410 is a plate-shaped member. First current collector 410 has a long-side direction in the Z direction and a short-side direction in the Y direction. Third current collector 430 is a plate-shaped member. Third current collector 430 has a long-side direction in the Z direction and a short-side direction in the Y direction. First current collector 410 and third current collector 430 are arranged side by side in parallel in the Y direction. In this way, first current collector 410 and third current collector 430 are constituted of separate components.
First electrode tab 220 is joined to first current collector 410 at a joining location 411 described later. Third electrode tab 270 is joined to third current collector 430 at a joining location 431 described later. Joining locations 411, 431 can be formed by, for example, ultrasonic welding, resistance welding, laser welding, swaging, or the like. In the present embodiment, first electrode tab 220 and first current collector 410 are joined by ultrasonic joining, and third electrode tab 270 and third current collector 430 are joined by ultrasonic joining, for example.
Fifth current collector 450 is electrically connected to each of first current collector 410 and third current collector 430 at a joining location located at a below-described end portion in the Z direction. Fifth current collector 450 is electrically connected to negative electrode terminal 301. The connection between fifth current collector 450 and negative electrode terminal 301 can be formed by swaging and/or welding, for example.
Negative electrode terminal 301 is provided to be exposed to the outside of first sealing plate 120 and reach fifth current collector 450 of negative electrode current collector 400A provided on the inner surface side of first sealing plate 120. Negative electrode terminal 301 is connected to a first plate portion 303.
First plate portion 303 is located on the outer side with respect to first sealing plate 120. First plate portion 303 is disposed along first sealing plate 120. First plate portion 303 has electric conductivity. First plate portion 303 is disposed to secure an area of connection with a bus bar or the like that electrically connects secondary battery 1 and another secondary battery adjacent thereto. The connection between negative electrode terminal 301 and first plate portion 303 can be formed by, for example, laser welding.
A first insulating member 510 is disposed between first plate portion 303 and first sealing plate 120. A second insulating member 520 is disposed between negative electrode terminal 301 and first sealing plate 120. A third insulating member 530 is disposed between fifth current collector 450 and first sealing plate 120.
It should be noted that negative electrode terminal 301 may be electrically connected to first sealing plate 120. Further, first sealing plate 120 may serve as negative electrode terminal 301.
A spacer 600 is disposed between first sealing plate 120 and electrode assembly 200. Spacer 600 is composed of a resin member having an insulating property. Spacer 600 includes a first component 610 and a second component 620. First component 610 and second component 620 are engaged with each other at engagement portions (not shown) at both ends in the Z direction.
Each of first component 610 and second component 620 protrudes in the Y direction at its end portion side on the electrode assembly 200 side in the X direction. Thus, spacer 600 functions as a guide to facilitate curving of curved portions 221, 271 when forming curved portions 221, 271.
Insulating sheet 700 (electrode assembly holder) composed of a resin is disposed between electrode assembly 200 and case main body 110. Insulating sheet 700 may be composed of, for example, a resin. More specifically, the material of insulating sheet 700 is, for example, polypropylene (PP), polyethylene terephthalate (PET), polyphenylene sulfide (PPS), polyimide (PI), or polyolefin (PO).
Second electrode tab 250 has a curved portion 251 and a tip portion 252. Curved portion 251 is a portion at which second electrode tab 250 is curved on the side, on which the second electrode is connected, with respect to tip portion 252. Tip portion 252 is a portion located at an end portion of second electrode tab 250 on the side opposite to the side on which the second electrode is connected.
Fourth electrode tab 280 has a curved portion 281 and a tip portion 282. Curved portion 281 is a portion at which fourth electrode tab 280 is curved on the side, on which the second electrode is connected, with respect to tip portion 282. Tip portion 282 is a portion located at an end portion of fourth electrode tab 280 on the side opposite to the side on which the second electrode is connected.
Second electrode tab 250 and fourth electrode tab 280 are curved in opposite directions such that tip portions 252, 282 are close to each other. It should be noted that tip portions 252, 282 are separated from each other in the present embodiment; however, it is not limited to this configuration, and tip portions 252, 282 may be in contact with each other.
Positive electrode current collector 400B electrically connects positive electrode terminal 302 to second electrode tab 250 and fourth electrode tab 280. Positive electrode current collector 400B in the present embodiment is connected to positive electrode terminal 302 between electrode assembly 200 and second sealing plate 130.
Positive electrode current collector 400B includes a second current collector 420, a fourth current collector 440, and a sixth current collector 460.
Second current collector 420 is a plate-shaped member. Second current collector 420 has a long-side direction in the Z direction and a short-side direction in the Y direction. Fourth current collector 440 is a plate-shaped member. Fourth current collector 440 has a long-side direction in the Z direction and a short-side direction in the Y direction. Second current collector 420 and fourth current collector 440 are arranged side by side in parallel in the Y direction. In this way, second current collector 420 and fourth current collector 440 are constituted of separate components.
Second electrode tab 250 is joined to second current collector 420 at a joining location 421 described later. Fourth electrode tab 280 is joined to fourth current collector 440 at a joining location 441 described later. Joining locations 421, 441 can be formed by, for example, ultrasonic welding, resistance welding, laser welding, swaging, or the like. In the present embodiment, second electrode tab 250 and second current collector 420 are joined by ultrasonic joining, and fourth electrode tab 280 and fourth current collector 440 are joined by ultrasonic joining, for example.
Sixth current collector 460 is electrically connected to each of second current collector 420 and fourth current collector 440 at a joining location located at a below-described end portion in the Z direction. Sixth current collector 460 is electrically connected to positive electrode terminal 302. The connection between sixth current collector 460 and positive electrode terminal 302 may be formed by swaging and/or welding, for example.
Positive electrode terminal 302 is provided to be exposed to the outside of second sealing plate 130 and reach sixth current collector 460 of positive electrode current collector 400B provided on the inner surface side of second sealing plate 130. Positive electrode terminal 302 is connected to a second plate portion 304.
Second plate portion 304 is located on the outer side with respect to second sealing plate 130. Second plate portion 304 is disposed along second sealing plate 130. Second plate portion 304 has electric conductivity. Second plate portion 304 is disposed to secure an area of connection with a bus bar or the like that electrically connects secondary battery 1 and another secondary battery adjacent thereto. The connection between positive electrode terminal 302 and second plate portion 304 may be formed by, for example, laser welding.
A first insulating member 510 is disposed between second plate portion 304 and second sealing plate 130. A second insulating member 520 is disposed between positive electrode terminal 302 and second sealing plate 130. A third insulating member 530 is disposed between sixth current collector 460 and second sealing plate 130.
It should be noted that positive electrode terminal 302 may be electrically connected to second sealing plate 130. Further, second sealing plate 130 may serve as positive electrode terminal 302.
A spacer 600 is disposed between second sealing plate 130 and electrode assembly 200. Spacer 600 is composed of a resin member having an insulating property. Spacer 600 includes a first component 610 and a second component 620. First component 610 and second component 620 are engaged with each other at engagement portions (not shown) at both ends in the Z direction.
Each of first component 610 and second component 620 protrudes in the Y direction at its end portion side on the electrode assembly 200 side in the X direction. Thus, spacer 600 functions as a guide to facilitate curving of curved portions 251, 281 when forming curved portions 251, 281.
Insulating sheet 700 (electrode assembly holder) composed of a resin is disposed between electrode assembly 200 and case main body 110.
Hereinafter, a method of manufacturing the secondary battery according to the present embodiment will be described.
As shown in
As shown in
In the height direction of each of first electrode assembly 201 and second electrode assembly 202, each of first current collector 410, second current collector 420, third current collector 430, and fourth current collector 440 is disposed on one side with respect to the center of a corresponding one of first electrode assembly 201 and second electrode assembly 202. Thus, each of the current collectors can be formed to be short, thereby reducing the size of the current collector.
It should be noted that each of first current collector 410, second current collector 420, third current collector 430, and fourth current collector 440 is not limited to this configuration. In the height direction of each of first electrode assembly 201 and second electrode assembly 202, each of first current collector 410, second current collector 420, third current collector 430, and fourth current collector 440 may be disposed at the center of a corresponding one of first electrode assembly 201 and second electrode assembly 202. In this case, in the height direction of each of first electrode assembly 201 and second electrode assembly 202, each of first electrode tab 220, second electrode tab 250, third electrode tab 270, and fourth electrode tab 280 is disposed at the center of a corresponding one of first electrode assembly 201 and second electrode assembly 202 so as to correspond to a corresponding one of first current collector 410, second current collector 420, third current collector 430, and fourth current collector 440.
The order of the steps of joining first current collector 410, second current collector 420, third current collector 430, and fourth current collector 440 to first electrode assembly 201 and second electrode assembly 202 is not limited to the one described above, and the order may be changed.
Regarding the expression “overlapping the first electrode assembly and the second electrode assembly with each other”, the first electrode assembly and the second electrode assembly may be overlapped with each other directly, or another member may be disposed between the first electrode assembly and the second electrode assembly. Further, the first electrode assembly and the second electrode assembly may or may not be fixed by a tape or the like.
First electrode tab 220, second electrode tab 250, third electrode tab 270, and fourth electrode tab 280 are bent in respective directions of arrows in
It should be noted that the step of overlapping first electrode assembly 201 and second electrode assembly 202 with each other is preferably performed before the steps of joining first current collector 410, second current collector 420, third current collector 430, and fourth current collector 440 to first electrode assembly 201 and second electrode assembly 202. The step of overlapping first electrode assembly 201 and second electrode assembly 202 with each other may be performed during each of the steps of joining first current collector 410, second current collector 420, third current collector 430, and fourth current collector 440.
It should be noted that insulating sheet 700 does not necessarily need to cover a whole of the surfaces of electrode assembly 200. Insulating sheet 700 preferably covers an area of about 50% or more, more preferably about 70% or more, of the outer surfaces of the electrode assembly. Insulating sheet 700 preferably covers a whole of at least four surfaces of the six surfaces of electrode assembly 200 having a substantially rectangular parallelepiped shape (flat shape) other than the two surfaces thereof on which first electrode tab 220 and second electrode tab 250 are formed respectively.
As shown in
It should be noted that step S8 can be performed before step S7. By performing step S8 before step S7, negative electrode terminal 301 and each of first electrode tab 220 and third electrode tab 270 can be more stably connected to each other when electrically connecting them. Further, a configuration with a smaller space between first sealing plate 120 and the main body portion of electrode assembly 200 can be readily attained.
First electrode tab 220 and third electrode tab 270 are bent such that tip portions 222, 272 face each other.
Each of negative electrode terminal 301 and fifth current collector 450 is attached to first sealing plate 120 with an insulating member being interposed therebetween. Fifth current collector 450 is brought into abutment with first current collector 410 and third current collector 430 in the X direction. Fifth current collector 450 is joined to first current collector 410 and third current collector 430 by laser welding from between first sealing plate 120 and insulating sheet 700. It should be noted that the connecting of first plate portion 303 to negative electrode terminal 301 may be performed at any timing.
The connecting of each of first current collector 410, third current collector 430, and fifth current collector 450 is performed through welding in the same manner as in the connecting of each of second current collector 420, fourth current collector 440, and sixth current collector 460 as described later.
Specifically, when viewed in the long-side direction (Y direction) of first sealing plate 120, a third overlapping region is defined in which first current collector 410 and fifth current collector 450 overlap with each other on the end portion side (upper end portion in the Z direction) in the long-side direction of first sealing plate 120. Further, when viewed in the long-side direction (Y direction) of first sealing plate 120, a fourth overlapping region is defined in which third current collector 430 and fifth current collector 450 overlap with each other on the end portion side (upper end portion in the Z direction) in the long-side direction of first sealing plate 120.
In the third overlapping region, first current collector 410 and fifth current collector 450 are connected to each other by welding. In the fourth overlapping region, third current collector 430 and fifth current collector 450 are connected to each other by welding.
First sealing plate 120 is brought into abutment with case main body 110. Thus, first electrode tab 220 and third electrode tab 270 are curved. As shown in
Thereafter, first sealing plate 120 is temporarily joined to case main body 110. By the temporary joining, first sealing plate 120 is partially joined to first opening 113 of case main body 110. Thus, first sealing plate 120 is positioned with respect to case main body 110.
When inserting electrode assembly 200 into case main body 110, electrode assembly 200 may be pulled from each of the second current collector 420 side and the fourth current collector 440 side, or may be pushed from each of the first current collector 410 side and the third current collector 430 side. When electrode assembly 200 is pressed from each of the first current collector 410 side and the third current collector 430 side, first electrode tab 220 and third electrode tab 270 can be curved at the same time.
Next, as shown in
Specifically, each of positive electrode terminal 302 and sixth current collector 460 is attached to second sealing plate 130 with an insulating member being interposed therebetween. Sixth current collector 460 is brought into abutment with second current collector 420 in the X direction. It should be noted that the connecting of second plate portion 304 to positive electrode terminal 302 may be performed at any timing.
As shown in
When viewed in the long-side direction (Y direction) of second sealing plate 130, a first overlapping region R11 is formed in which second current collector 420 and sixth current collector 460 overlap with each other on the end portion side of second sealing plate 130 in the long-side direction. First overlapping region R11 is formed by arranging folded portions F side by side in the Z direction.
Further, when viewed in the long-side direction (Y direction) of second sealing plate 130, a second overlapping region R12 is formed in which fourth current collector 440 and sixth current collector 460 overlap with each other on the end portion side of second sealing plate 130 in the long-side direction. Second overlapping region R12 is formed by arranging folded portions F side by side in the Z direction.
When connecting second current collector 420 and fourth current collector 440 to sixth current collector 460, high-energy ray 2 is applied to at least one of second current collector 420 and sixth current collector 460 from between second sealing plate 130 and the end portion of case main body 110 on the second opening 114 side so as to weld second current collector 420 and sixth current collector 460. Further, high-energy ray 2 is applied to at least one of fourth current collector 440 and sixth current collector 460 from between second sealing plate 130 and the end portion of case main body 110 on the second opening 114 side so as to weld fourth current collector 440 and sixth current collector 460.
In first overlapping region R11, second current collector 420 and sixth current collector 460 are connected to each other by welding. In the present embodiment, second current collector 420 and sixth current collector 460 are connected to each other by welding at a welding position P1 of first overlapping region R11.
In second overlapping region R12, fourth current collector 440 and sixth current collector 460 are connected to each other by welding. In the present embodiment, fourth current collector 440 and sixth current collector 460 are connected by welding at a welding position P2 of second overlapping region R12.
A method of welding second current collector 420 or fourth current collector 440 to sixth current collector 460 is, for example, piercing welding. Sixth current collector 460 may be provided with a thin portion, and the current collectors may be welded to each other at the thin portion, or sixth current collector 460 may be provided with a through hole, and the current collectors may be welded to each other at a position away from the through hole.
Second electrode tab 250 and fourth electrode tab 280 are bent such that tip portions 252, 282 face each other. Second sealing plate 130 is brought into abutment with case main body 110. Thus, second electrode tab 250 and fourth electrode tab 280 are curved. As shown in
Thereafter, second sealing plate 130 is temporarily welded to case main body 110. By the temporary joining, second sealing plate 130 is partially joined to second opening 114 of case main body 110. Thus, second sealing plate 130 is positioned with respect to case main body 110.
After the above-described steps, an inspection such as a leakage inspection is performed (step S12). After the leakage inspection, secondary battery 1 is dried to remove moisture in case 100. Then, the electrolyte solution is injected into case 100 through injection hole 134. When injecting the electrolyte solution, case 100 is inclined with second sealing plate 130 facing upward and first sealing plate 120 facing downward, thereby injecting the electrolyte solution into case 100 via injection hole 134 of second sealing plate 130. Thereafter, charging is performed to result in release of gas. For performing the charging to result in release of gas, injection hole 134 may be temporarily sealed. Thereafter, the injection hole is sealed, thereby completing secondary battery 1.
In each of secondary battery 1 and the method of manufacturing the same according to the first embodiment of the present technology, since first electrode assembly 201 is provided with first electrode tab 220 and second electrode tab 250 and second electrode assembly 202 is provided with third electrode tab 270 and fourth electrode tab 280, first electrode assembly 201 and second electrode assembly 202 can be configured to have separate electrode tabs. With this configuration, the electrode tabs can be shortened as compared with a case where one collective electrode tab is formed by first electrode assembly 201 and second electrode assembly 202 and the electrode tab is bent. As a result, the occupied volume of the electrode tabs can be reduced, thereby improving the energy density of secondary battery 1. Further, in the configuration in which the separate electrode tabs are respectively provided for first electrode assembly 201 and second electrode assembly 202, the electrode tabs are readily bent and the electrode tabs and the current collectors can be therefore readily joined as compared with the case where one collective electrode tab is formed by first electrode assembly 201 and second electrode assembly 202, with the result that the secondary battery can be stably manufactured. In particular, since secondary battery 1 can be stably manufactured, reliability of the connection portion between each of the electrode tabs and each of the current collectors can be increased.
In each of secondary battery 1 and the method of manufacturing the same according to the first embodiment of the present technology, by providing each of first overlapping region R11 in which second current collector 420 and sixth current collector 460 overlap with each other and second overlapping region R12 in which fourth current collector 440 and sixth current collector 460 overlap with each other, it is possible to secure a region in which the current collectors can be joined to each other, with the result that the current collectors can be stably connected to each other. When connecting the current collectors to each other by applying high-energy ray 2 from between second opening 114 and second sealing plate 130 of case main body 110, a range in which the current collectors can be welded can be readily secured for the application of high-energy ray 2 in the second direction (Z direction) intersecting the first direction in which first opening 113 and second opening 114 are arranged side by side.
In each of secondary battery 1 and the method of manufacturing the same according to the first embodiment of the present technology, by providing each of the third overlapping region in which first current collector 410 and fifth current collector 450 overlap with each other and the fourth overlapping region in which third current collector 430 and fifth current collector 450 overlap with each other, it is possible to secure a region in which the current collectors can be joined to each other, with the result that the current collectors can be stably connected to each other. When connecting the current collectors to each other by applying a high-energy ray from between first opening 113 and first sealing plate 120 of case main body 110, a range in which the current collectors can be welded can be readily secured for the application of the high-energy ray in the second direction (Z direction) intersecting the first direction in which first opening 113 and second opening 114 are arranged side by side.
In the method of manufacturing secondary battery 1 according to the first embodiment of the present technology, since second current collector 420 and sixth current collector 460 are welded by applying high-energy ray 2 to at least one of second current collector 420 and sixth current collector 460 from between second sealing plate 130 and the end portion of case main body 110 on the second opening 114 side and fourth current collector 440 and sixth current collector 460 are welded by applying high-energy ray 2 to at least one of fourth current collector 440 and sixth current collector 460 from between second sealing plate 130 and the end portion of case main body 110 on the second opening 114 side, the current collectors on the second opening 114 side can be stably connected to each other after electrode assembly 200 is inserted into case main body 110.
Hereinafter, a secondary battery according to a second embodiment will be described. Since the secondary battery according to the second embodiment is different from secondary battery 1 according to the first embodiment of the present technology in terms of the connection structure between the electrode assembly and the current collector, the same configurations as those of secondary battery 1 according to the first embodiment of the present technology will not be described repeatedly.
Thereafter, a first electrode assembly 201A and a second electrode assembly 202A are inserted into the case main body, and first sealing plate 120 is brought into abutment with the case main body. Thus, first electrode tab 220A and third electrode tab 270A are curved in the same direction such that tip portions 222A, 272A located at the end portions thereof on the side opposite to the side on which the first electrode is connected are oriented in the same direction. In order to facilitate curving of tip portions 222A, 272A in the same direction, a third component 630A of a spacer 600A is provided between first electrode tab 220A and third electrode tab 270A.
Since tip portions 222A, 272A of first electrode tab 220A and third electrode tab 270A are curved in the same direction in the Y direction and the tip portions of the second electrode tab and the fourth electrode tab are curved in the same direction in the Y direction, first electrode assembly 201A to which first current collector 410 and second current collector 420 are attached and second electrode assembly 202A to which third current collector 430 and fourth current collector 440 are attached can be prepared to have the same configuration. Thus, first electrode assembly 201A to which first current collector 410 and second current collector 420 are attached and second electrode assembly 202A to which third current collector 430 and fourth current collector 440 are attached can be formed as electrode assemblies of one type and therefore can be readily manufactured.
Hereinafter, secondary batteries according to third to seventh embodiments will be described. Since each of the secondary batteries according to the third to seventh embodiments is different from secondary battery 1 according to the first embodiment of the present technology in terms of the connection structure between the current collectors, the same configurations as those of secondary battery 1 according to the first embodiment of the present technology will not be described repeatedly and the same configurations among the third to seventh embodiments will not be described repeatedly.
As shown in
There is a clearance G1 at a flat plate portion of each of second current collector 420B, fourth current collector 440B, and sixth current collector 460B other than folded portion F. Thus, the current collectors are facilitated to be in contact with each other at folded portion F. Further, a reaction force due to bending of each electrode tab is applied toward the current collector. Thus, the current collectors can be brought into close contact with each other.
In each of the secondary battery and the method of manufacturing the same according to the third embodiment of the present technology, by providing each of a first overlapping region R31 in which second current collector 420B and sixth current collector 460B overlap with each other and a second overlapping region R32 in which fourth current collector 440B and sixth current collector 460B overlap with each other, it is possible to secure a region in which the current collectors can be joined to each other, with the result that the current collectors can be stably connected to each other. When connecting the current collectors to each other by applying high-energy ray 2 from between second opening 114 and second sealing plate 130 of case main body 110, a range in which the current collectors can be welded can be readily secured for the application of high-energy ray 2 in the direction intersecting the first direction in which first opening 113 and second opening 114 are arranged side by side.
As shown in
There is a clearance G2 at extension portion E of sixth current collector 460C. As a result, a distance between the current collector and the insulating member can be provided, with the result that heat generated when joining the current collectors to each other using the high-energy ray is less likely to be transmitted to the insulating member.
By bringing extension portions E of second current collector 420C and sixth current collector 460C into abutment with each other, a first abutment region R41 is formed to extend in the directions (Y and Z directions) intersecting the first direction (X direction) in which first opening 113 and second opening 114 are arranged side by side, first abutment region R41 being a region in which second current collector 420C and sixth current collector 460C are in abutment with each other in the first direction (X direction). First abutment region R41 includes an abutment plane between second current collector 420C and sixth current collector 460C. First abutment region R41 expands on a plane intersecting the first direction (X direction). First abutment region R41 extends in the Y direction and the Z direction. First abutment region R41 is preferably disposed along second sealing plate 130.
By bringing extension portions E of fourth current collector 440C and sixth current collector 460C into abutment with each other, a second abutment region R42 is formed to extend in the directions (Y and Z directions) intersecting the first direction (X direction), second abutment region R42 being a region in which fourth current collector 440C and sixth current collector 460C are in abutment with each other in the first direction (X direction).
At the end portion of first abutment region R41, second current collector 420C and sixth current collector 460C are connected by welding. At the end portion of second abutment region R42, fourth current collector 440C and sixth current collector 460C are connected by welding.
The connection between the current collectors on the first sealing plate 120 side of the secondary battery is configured in the same manner as the connection between the current collectors on the second sealing plate 130 side.
Specifically, a third abutment region is formed to extend in the direction intersecting the first direction, the third abutment region being a region in which the first current collector and the fifth current collector are in abutment with each other in the first direction (X direction). A fourth abutment region is formed to extend in the direction intersecting the first direction, the fourth abutment region being a region in which the third current collector and the fifth current collector are in abutment with each other in the first direction. The first current collector and the fifth current collector are connected to each other by welding at an end portion of the third abutment region. The third current collector and the fifth current collector are connected by welding at an end portion of the fourth abutment region.
In each of the secondary battery and the method of manufacturing the same according to the fourth embodiment of the present technology, by providing each of first abutment region R41 and second abutment region R42, it is possible to secure a region in which the current collectors can be joined to each other, with the result that the current collectors can be readily stably connected to each other. In particular, a joining location can be secured between the current collectors without highly precisely positioning the current collectors to be joined to each other.
In each of the secondary battery and the method of manufacturing the same according to the fourth embodiment of the present technology, by providing each of the third abutment region and the fourth abutment region, it is possible to secure a region in which the first current collector or the third current collector and the fifth current collector can be joined to each other, with the result that the current collectors can be readily stably connected to each other.
As shown in
As shown in
Each of second current collector 420E and fourth current collector 440E is provided with a fuse portion 422E. When the current collector generates an excessive amount of heat, the current collector is melted first at fuse portion 422E of the positive electrode current collector that is located as far as possible from the insulating member.
As shown in
In each of the secondary battery and the method of manufacturing the same according to each of the fifth to seventh embodiments of the present technology, by providing each of first abutment region R51, R61, R71 and second abutment region R52, R62, it is possible to secure a region in which the current collectors can be joined to each other, with the result that the current collectors can be readily stably connected to each other. In particular, a joining location between the current collectors can be secured without highly precisely positioning the current collectors to be joined to each other.
Each of first sealing plate 120 and second sealing plate 130 preferably has a pair of long end sides disposed in parallel to each other and short end sides disposed in parallel to each other and shorter than the pair of long end sides. In this case, a direction in which the pair of long end sides extends is the long-side direction thereof.
Although the embodiments of the present invention have been described and shown in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation. The scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2023-147005 | Sep 2023 | JP | national |
