Battery and battery pack

According to one embodiment, a battery includes a flat-shaped electrode group, a package member and a terminal section. The package member includes a stainless steel-made first package having a flange at an opening and a stainless steel-made second package. The electrode group is stored in a space formed by welding the flange of the first package to the second package. The terminal section includes a through-hole that is open to the first package, a ring-shaped rising portion that extends from a periphery of the through-hole toward an inside of the package member, a ring-shaped member that is arranged on an outer surface of the rising portion, an insulation gasket, and an external terminal. The external terminal is fixed to the first package by caulking.

FIELD

The embodiment of the present invention relates to a battery and a battery pack.

BACKGROUND

A battery, such as a primary battery and a secondary battery, generally includes an electrode group having a positive electrode and a negative electrode, and a package member for storing the electrode group.

A metal can and a laminated film-made container have been commercially used as a package member. A metal can is formed by deep-drawing processing of a metal plate of aluminum, etc. To form a can by deep-drawing processing, a metal plate needs to have a certain thickness; however, this is an obstacle to reducing a thickness of a package, and leads to a loss in volume and capacity. For example, if a package can having a plate the plate thickness in total to the thickness of the battery is 7.7%. Since a package has high rigidity but less flexibility, a gap is often generated between the inner wall of a package can and an electrode group. As a consequence, a gap between a positive electrode and a negative electrode in the electrode group may lead to degradation of a charge-and-discharge cycle. Furthermore, a package with high rigidity is inclined to have defects, such as cracking, when an excess force is applied to the vicinity of a welded portion.

However, because a portion of a laminated film-made container that is sealed by heat sealing may melt at a high temperature, its reliability is insufficient.

Also, the manufacturing costs for both a package can and a laminated film-made container are high.

Under such circumstances, it has been requested to provide a package with an improvement in thickness reduction and flexibility, and with excellent reliability at low manufacturing costs.

DETAILED DESCRIPTION

A problem to be solved by the invention is to provide a battery and a battery pack that can achieve thickness reduction and improved flexibility, includes a package member that excels at reliability, and can reduce manufacturing costs.

According to one embodiment, a battery includes a flat-shaped electrode group, a package member and a terminal section. The electrode group includes a positive electrode, a positive electrode current collector tab electrically connected to the positive electrode, a negative electrode, and a negative electrode current collector tab electrically connected to the negative electrode. The positive electrode current collector tab is wound into a flat shape and located at a first edge surface. The negative electrode current collector tab is wound into a flat shape and located at a second edge surface. The package member includes a stainless steel-made first package having a flange at an opening and a stainless steel-made second package. The electrode group is stored in a space formed by welding the flange of the first package to the second package. The terminal section includes a through-hole that is open to the first package, a ring-shaped rising portion that extends from a periphery of the through-hole toward an inside of the package member, a ring-shaped member that is arranged on an outer surface of the rising portion, an insulation gasket that has a cylindrical portion to be inserted into the rising portion. The terminal section further includes an external terminal. The external terminal includes a head portion and a shank portion extending from the head portion. The external terminal is fixed to the first package by caulking with the head portion projecting to an outside of the first package and the shank portion being inserted into a cylindrical portion of the insulation gasket. The external terminal is electrically connected to the positive electrode or the negative electrode.

Embodiments will be described below with reference to the drawings. The same structures will be referenced by the same numbers and symbols throughout the embodiments, and overlapping descriptions will be omitted. Each drawing is a schematic drawing to aid understanding of the embodiments and the descriptions thereof. Shapes, dimensions, and ratios presented therein may be different from those of the actual apparatus; however, they may be appropriately changed as a design choice in consideration of the following descriptions and publicly-known techniques.

First Embodiment

A battery according to the first embodiment will be explained with reference toFIG. 1toFIG. 12.

The battery100shown inFIG. 1is a nonaqueous electrolyte battery. The battery100includes a package member1, an electrode group2, a positive electrode terminal3, a negative electrode terminal4, and a nonaqueous electrolyte (not shown).

As shown inFIGS. 1 and 2, the package member1includes a first package5and a second package6. The first package5is a bottomed square cylindrical container made of stainless steel, and has a flange5bat its opening5a. As shown inFIGS. 1, 2, and 5A, a reentrant portion toward the inner side is provided near the center of the corner connecting the short-side side wall and the bottom of the first package5, and the bottom of the reentrant portion, constitutes an inclined surface5d. The first package5has a depth equal to or shorter than the size of the opening5a(a maximum length of the area constituting the opening). More preferably, the first package5has a depth equal to or shorter than the short side of the area constituting the opening (as shown inFIG. 2for example). The first package5is manufactured by shallow-drawing processing of a stainless-steel plate, for example. On the other hand, the second package6is a rectangular plate made of stainless steel. An electrode group2is stored in a space formed by welding the flange5bof the first package5to the four sides of the second package6. For welding, resistance seam welding is used, for example. Compared to laser welding, resistance seam welding can realize high air-tightness and heat resistance at a low cost.

The electrode group2has a flat shape as shown inFIG. 4, and includes a positive electrode7, a negative electrode8, and a separator9provided between the positive electrode7and the negative electrode8. The positive electrode7includes a band-shaped positive electrode current collector made of, for example, a foil, a positive electrode current collector tab7aconsisting of one edge portion parallel to the long side of the positive electrode current collector, and a positive electrode material layer7b(a layer containing a positive electrode active material) formed on the positive electrode current except for at least positive electrode current collector tab7a. A negative electrode8includes a band-shaped negative electrode made of, for example, a foil, a negative electrode current collector tab8aconsisting of one edge portion parallel to the long side of the negative electrode current collector, and a negative electrode material layer8b(a layer containing a negative electrode active material) formed in the negative electrode current collector except for at least negative electrode current collector tab8a. The electrode group2is produced by winding the positive electrode7, the separator9, and the negative electrode8into a flat shape, in such a manner that the positive electrode material layer7bof the positive electrode7and the negative electrode material layer8bof the negative electrode8face each other with the separator9being interposed therebetween, and the positive electrode current collector tab7aprojects further to one side of the winding axis than the negative electrode8and the separator9project, and the negative electrode current collector tab8aprojects further to the other side than the positive electrode7and the separator9. Thus, in the electrode group2, the positive electrode current collector tab7athat is spirally wound into a flat shape is located at a first edge surface perpendicular to the winding axis. The negative electrode current current collector tab8athat is spirally wound into a flat shape is located at a second edge surface perpendicular to the winding axis. The insulating sheet10covers a portion in the outermost surface of the electrode group2, except for the positive electrode current current collector tab7aand the negative electrode current current collector tab8a. The electrode group2contains a nonaqueous electrolyte (not shown).

The backup positive electrode lead11(the third positive electrode lead) is a conductive plate folded into a U shape to bring the vicinity of the center of the layers of the positive electrode current collector tab7ainto tight contact with each other, except for the curved portion at both ends of the positive electrode current collector tab7a. The electrode group side positive electrode lead12(the second positive electrode lead) is a conductive plate having an area larger than the backup positive electrode lead11. As shown inFIG. 5A, the electrode group side positive electrode lead12is connected to a surface of the backup positive electrode lead11. The surface of the backup positive electrode lead11faces the opening side of the first package5. The positive electrode current collector tab7a, the backup positive electrode lead11, and the electrode group side positive electrode lead12are integrated by welding, thereby electrically connecting the positive electrode7to the electrode group side positive electrode lead12via the positive electrode current collector tab7aand the backup positive electrode lead11. The welding is, for example, ultrasonic welding.

The backup negative electrode lead13(the third positive electrode lead) is a conductive plate folded into a U shape to bring the vicinity of the center of the layers of the negative electrode current collector tab8ainto tight contact with each other with a portion except for the curved portion at both ends of the negative electrode current collector tab8a. The electrode group side negative electrode lead14(the second negative electrode lead) is a conductive plate having an area larger than the backup negative electrode lead13. The electrode group side negative electrode lead14is connected to a surface of the backup negative electrode lead13. The surface of the backup negative electrode lead13faces the opening side of the first package5. The negative electrode current current collector tab8a, the backup negative electrode lead13, and the electrode group side negative electrode lead14are integrated by welding, thereby electrically connecting the negative electrode8to the electrode group side negative electrode lead14via the negative electrode current collector tab8aand the backup negative electrode lead13. The welding is, for example, ultrasonic welding.

As shown inFIGS. 2, 5A, 5B, and 7, the positive electrode terminal3includes a through-hole15(a first through-hole) that is open to the inclined surface5dof the first package5, a burring portion16(a first burring portion), a positive electrode external terminal17, a ring-shaped member18(a first ring-shaped member), an insulation gasket19(a first insulating gasket), and a positive electrode terminal insulating member20(a third positive electrode insulating member).

The burring portion16(a ring-shaped rising portion) extends from the periphery of the through-hole15toward the inside of the package member1as shown inFIGS. 5A and 7, and is formed by burring processing.

The positive electrode external terminal17includes a head portion21having a shape of a truncated rectangular prism, and a shank portion22having a cylindrical shape, as shown inFIG. 6. The head portion21has two lateral surfaces21aand21b(first and second inclined surfaces) and a top surface21cwhich has a rectangular shape and connects the two lateral surfaces21aand21b. The shank portion22in a cylindrical shape extends from a plane that is parallel to the top surface21cof the head portion21. The positive electrode external terminal17is made of a conductive material, such as aluminum or an aluminum alloy.

The ring-shaped member18consists of a circular ring made of a material harder than the gasket, for example. Examples of a material harder than the gasket include stainless steel, plated steel (e.g., plated with Ni or NiCr, etc.), ceramics, and a resin harder than a gasket, (e.g., polyphenylene sulfide (PPS), and polybutylene terephthalate (PBT)). The ring-shaped member18is arranged on the outer circumference surface of the burring portion16and is in contact with the burring portion16, as shown inFIGS. 5A and 7.

If the ring-shaped member18is made of an insulating material, such as a resin or ceramics, it may be integrated with the terminal insulation reinforcement member24.

As shown inFIG. 7, the insulation gasket19has a cylindrical body (cylindrical portion) having a flange19aat one opening edge of the insulation gasket19. As shown inFIGS. 5A and 7, the cylindrical portion of the insulation gasket19is inserted into the through-hole15and the burring portion16, and the flange19ais arranged at the outer periphery of the through-hole15on the outer surface of the first package5. The insulation gasket19is made of a resin, such as a fluororesin, a fluororubber, a polyphenylenesulfide resin (a PPS resin), a polyetheretherketone resin (a PEEK resin), a polypropylene resin (a PP resin), or a polybutylene terephthalate resin (a PBT resin).

The positive electrode terminal insulating member20(the third positive electrode insulating member) is a bottomed square cylindrical body and has a through-hole20aon its bottom, as shown inFIG. 5B. The positive electrode terminal insulating member20is arranged on the outer surface of the first package5. The flange19aof the insulation gasket19is inserted into the through-hole20aof the positive electrode terminal insulating member20, as shown inFIG. 7.

The positive electrode terminal3may further include a positive electrode terminal lead23(a first positive electrode lead). The positive electrode terminal lead23is a conductive plate having a through-hole23a.

If the positive electrode terminal3includes the positive electrode terminal lead23, the positive electrode terminal3may further include the positive electrode terminal insulation reinforcement member24(a first positive electrode insulating member). As shown inFIG. 2, the positive electrode terminal insulation reinforcement member24has a main body24ahaving a structure of a longitudinally half-divided bottomed rectangular cylinder, a circle groove24bformed in the main body24a, and a through-hole24cthat is open in the center of the circle groove24b. The positive electrode terminal insulation reinforcement member24covers a corner portion where the main body24acontinues from the short-side side wall of the first package5to the bottom surface and a corner portion where the main body24acontinues from the short-side side surface of the first package5to the long-side side wall. The first package5, particularly the corner and the vicinity thereof where the short-side side wall, the long-side side wall, and the bottom cross each other, is thereby reinforced. The ring-shaped member18, which is arranged on the outer circumference surface of the burring portion16, is arranged in the circle groove24b. The through-hole24ccommunicates with the opening of the burring portion16and the through-hole15of the first package5. The positive electrode terminal lead23is arranged on the positive electrode terminal insulation reinforcement member24. The through-hole23aof the positive electrode terminal lead23communicates with the through-hole24cof the positive electrode terminal insulation reinforcement member24, the opening of the burring portion16, and the through-hole15of the first package5.

After the shank portion22is inserted into the insulation gasket19, the through-hole20aof the positive electrode terminal insulating member20, the through-hole15of the first package5, the burring portion16, the ring-shaped member18, the through-hole24cof the positive electrode terminal insulation reinforcement member24, and the through-hole23aof the positive electrode terminal lead23, plastic deformation occurs in the shank portion22of the positive electrode external terminal17by caulking. As a result, these members are integrated, and the positive electrode external terminal17is electrically connected to the positive electrode terminal lead23. Thus, the positive electrode external terminal17also serves as a rivet. The boundary of the edge surface of the shank portion22of the positive electrode external terminal17and the through-hole23aof the positive electrode terminal lead23is welded by a laser, etc., to achieve a firmer connection and improvement of electric conductivity.

As shown inFIG. 2, the negative electrode terminal4includes a through-hole30(a second through-hole) that is open to the inclined surface5dof the first package5, a burring portion31(a second burring portion), a negative electrode external terminal32, a ring-shaped member33(a second ring-shaped member), an insulation gasket34(a second insulating gasket), and a negative electrode terminal insulating member35(a third negative electrode insulating member). These members have structures similar to those explained in relation to the positive electrode terminal3.

The burring portion31(a ring-shaped rising portion) extends from the periphery of the through-hole30toward the inside of the package member1, and is formed by burring processing.

The negative electrode external terminal32includes a head portion32ahaving a shape of a truncated rectangular prism as shown inFIG. 11C, and a shank portion having a cylindrical shape. The head portion32ahas two lateral surfaces32band32c(first and second inclined surfaces) and a top surface32dwhich has a rectangular shape and connects the two lateral surfaces32band32c. The shank portion in a cylindrical shape extends from a plane that is parallel to the top surface of the head portion32a. The negative electrode external terminal32is made of a conductive material, such as aluminum or an aluminum alloy.

The ring-shaped member33consists of a circular ring made of a material harder than the gasket, for example. Examples of a material harder than the gasket include stainless steel, plated steel (e.g., plated with Ni or NiCr, etc.), ceramics, and a resin harder than a gasket, (e.g., polyphenylene sulfide (PPS), and polybutylene terephthalate (PBT)). The ring-shaped member33is arranged on the outer circumference surface of the burring portion31.

If the ring-shaped member33is made of an insulating material, such as a resin or ceramics, it may be integrated with the terminal insulation reinforcement member37.

The insulation gasket34has a cylindrical body having a flange at one opening edge of the insulation gasket34. The cylindrical portion of the insulation gasket34is inserted into the through-hole30and the burring portion31, and the flange is arranged in the outer periphery of the through-hole30on the outer surface of the first package5. Examples of the material of the insulation gasket34are similar to those explained for the positive electrode terminal3.

The negative electrode terminal insulating member35(the third negative electrode insulating member) is a bottomed square cylindrical body and has a through-hole35aon its bottom, as shown inFIG. 2. The negative electrode terminal insulating member35is arranged on the outer surface of the first package5. The flange of the insulation gasket34is inserted into the through-hole35aof the negative electrode terminal insulating member35.

The negative electrode terminal4may further include a negative electrode terminal lead36(a first negative electrode lead). The negative electrode terminal lead36is a conductive plate having a through-hole36a.

If the negative electrode terminal4includes the negative electrode terminal lead36, the negative electrode terminal4may further include the negative electrode terminal insulation reinforcement member37(a first negative electrode insulating member). As shown inFIG. 2, the negative electrode terminal insulation reinforcement member37has a main body37ahaving a structure of a longitudinally half-divided bottomed rectangular cylinder, a circle groove37bformed in the main body37a, and a through-hole37cthat is open in the center of the circle groove37b. The negative electrode terminal insulation reinforcement member37covers a corner portion where the main body37acontinues from the short-side side wall of the first package5to the bottom surface and a corner portion where the main body37acontinues from the short-side side wall of the first package5to the long-side side wall. The first package5, particularly the corner and the vicinity thereof where the short-side side wall, the long-side side wall, and the bottom cross each other, is thereby reinforced. The ring-shaped member33, which is arranged on the outer circumference surface of the burring portion31, is arranged in the circle groove37b. The through-hole37ccommunicates with the opening of the burring portion31and the through-hole30of the first package5. The negative electrode terminal lead36is arranged on the negative electrode terminal insulation reinforcement member37. The through-hole36aof the negative electrode terminal lead36communicates with the through-hole37cof the negative electrode terminal insulation reinforcement member37, the opening of the burring portion31, and the through-hole30of the first package5.

After the shank portion is inserted into the insulation gasket34, the through-hole35aof the negative electrode terminal insulating member35, the through-hole30of the first package5, the burring portion31, the ring-shaped member33, the through-hole37cof the negative electrode terminal insulation reinforcement member37, and the through-hole36aof the negative electrode terminal lead36, plastic deformation occurs in the shank portion of the negative electrode external terminal32by caulking. As a result, as shown inFIG. 8, these members are integrated, and the negative electrode external terminal32is electrically connected to the negative electrode terminal lead36. Thus, the negative electrode terminal36also serves as a rivet. The boundary of the edge surface of the shank portion of the negative electrode external terminal32and the through-hole36aof the negative electrode terminal lead36is welded by a laser, etc., to achieve a firmer connection and improvement of electric conductivity.

As shown inFIG. 2, each of a pair of the second insulation reinforcement members38has a structure of a longitudinally half-divided bottomed rectangular cylinder. One second insulation reinforcement member38covers almost half the positive electrode current collector tab7afrom the center of the winding to the second package6side. The other second insulation reinforcement member38covers almost half the negative electrode current collector tab8afrom the center of the winding to the second package6side. The second package6, particularly the vicinity of the short sides, is thereby reinforced.

The first to third positive electrode leads and the first to third negative electrode leads may be made of aluminum or an aluminum alloy, for example. To reduce contact resistance, a material of the lead is preferably the same as the material of the positive electrode current collector or the negative electrode current collector that may be in electrical contact with the lead.

The first to third positive electrode insulating members, the first to third negative electrode insulating members, and the insulation reinforcement member are made of a thermoplastic resin, such as a tetrafluoroethylene perfluoroalkyl vinylether copolymer (PFA), polypropylene (PP), polyethylene (PE), nylon, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE), polyphenylene sulfide (PPS), or polyetheretherketone (PEEK).

The electrode group2is stored in the first package5in such a manner that the first edge surface7afaces the positive electrode terminal3and the second edge surface8afaces the negative electrode terminal4. For this reason, the plane that intersects the first edge surface7aand the second edge surface8aof the electrode group2faces the bottom surface5cin the first package5, and the curved surface that intersects the first edge surface7aand the second edge surface8afaces the long-side side surface in the first package5.

In the corner portion that connects the short-side side wall of the first package5with the bottom, there are a gap between the corner and the first edge surface7aof the electrode group2and a gap between the corner and the second edge surface8aof the electrode group2. A reentrant portion projecting inside of the corner portion which connects the short-side side wall of the first package5with the bottom is provided, and the bottom surface of the reentrant portion is made as an inclined surface5d, so that the dead space in the first package5is decreased, thereby increasing volume energy density of the battery. By arranging the positive electrode terminal3and the negative electrode terminal4in each inclined surface5d, it is possible to increase an area where the terminal section is arranged, compared to arranging the positive electrode terminal3and the negative electrode terminal4in the short-side side surface that does not have an inclined surface. Thus, it becomes possible to increase the diameter of the shank portion22of the positive electrode external terminal17and the shank portion of the negative electrode external terminal32, thereby supplying a large current at low resistance (a high-rate current).

As a result of storing the electrode group2in the first package5, the positive electrode current collector tab7ais covered by a bottomed rectangular cylindrical cover, which is formed by bringing the lower edge of the second insulation reinforcement member38into contact with the upper edge of the first positive electrode insulating member24. The negative electrode current collector tab8ais covered by a bottomed rectangular cylindrical cover, which is formed by bringing the lower edge of the second insulation reinforcement member38into contact with the upper edge of the first positive electrode insulating member37.

The second package6functions as a lid of the first package5. The electrode group2is sealed inside the package member1by welding the flange5bof the first package5to the four sides of the second package6.

The above-described nonaqueous electrolyte battery shown inFIGS. 1 to 8includes a package member wherein the electrode group is stored in a space formed by welding the stainless steel-made first package having a flange at its opening to a stainless steel-made second package. Since the first package and the second package are made of stainless steel, it is possible to maintain high strength when the plate thickness of the first and second packages is reduced. As a result, since flexibility of the package members can be improved, it becomes easier to bind the electrode group by vacuum sealing or by adding a load from the outside of the package members. Thus, as a distance between electrodes in the electrode group becomes stable, allowing resistance to be decreased, a battery pack having resistance to vibration and to impact can be thereby easily realized. If the first and second packages have high flexibility, it becomes easy to shorten a distance from the inner surface of the first and second packages to the electrode group, thereby improving thermal radiation efficiency of the battery.

The stainless steel-made first and second packages are easy to be welded, and can be sealed by resistance seam welding, which can be carried out at a low cost. Thus, a package member with hermetic sealing higher than that of a laminated film-made container can be realized at a low cost. Thermal resistance properties of the package member can also be improved. For example, the melting point of SUS304 is 1400° C., whereas that of aluminum is 650° C.

Plastic deformation in the shank portion of the external terminal is caused by fixing the shank portion at the through-hole by caulking. As a result, force is applied to the insulation gasket in a diameter direction; however, since the rising portion is reinforced by the ring-shaped member arranged at the outer periphery of the rising portion, compressional stress is caused in the insulation gasket, and the external terminal can be connected to the first package at high strength. Since the rising portion can be reinforced by the ring-shaped member even if the plate thickness of the first package, in other words, the plate thickness of the rising portion, is decreased, it is possible to connect the external terminal to the first package with high strength, regardless of a plate thickness of the first package. Furthermore, since the rising portion extends from the periphery portion of the through-hole toward the inside of the package member, the action of the outer pressure can prevent liquid leakage when an inner pressure in the package member is increased due to a gas, etc. High reliability can thus be realized when the plate thickness of the first and second packages are decreased.

Therefore, according to the battery of the first embodiment, since high strength and reliability can be achieved even when the plate thickness of the first and second packages are reduced; it is possible to provide a battery with excellent flexibility and thermal radiation property and high strength and reliability.

If the first package has a depth equal to or longer than a maximum length of the opening, the opening area of the first package becomes larger. Since the second package is welded to the four sides of the first package, the larger the opening area becomes, the longer the length of a side to be welded becomes; thus, it is easy to inject an electrolyte from a gap in one side after the other three sides are welded first. Furthermore, the package member can be temporarily sealed by a portion having less welding strength, thereby negating a need of parts for temporary sealing, such as a rubber stopper. Furthermore, the flat shape of the package member improves thermal radiation of the battery.

Since the first package includes a reentrant portion having an inclined surface, thereby arranging a terminal section in the inclined surface, the dead space in the first package can be decreased, and an external terminal with a large diameter for its shank portion becomes usable; thus, a large current at low resistance (a high-rate current) can be supplied.

The inclined portion is not limited to an element that is provided near the center of the short side of the package member; it may stretch over the entire short side of the package member.

The terminal section desirably further includes a first lead which is electrically connected to an external terminal to electrically connect the first lead to the positive electrode tab or the negative electrode current collector tab. Positioning becomes easier using the first lead, compared to a case where the positive electrode tab or the negative electrode current collector tab is directly connected to the external terminal. Productivity can be thus improved. The first lead is connected to the external terminal by caulking, thereby reducing resistance between the first lead and the external terminal.

An insulating member that reinforces the first package is arranged between the first lead and the inner surface of the first package, thereby insulating the first lead from the first package while reinforcing the first package. Such an insulation member is effective for reducing the thickness of the package member.

It is further desirable to include a second lead that is electrically connected to the positive electrode tab or the negative electrode current collector tab, and to electrically connect the second lead to the first lead. Positioning when welding is performed becomes thereby easier. Since a sufficient area for connecting can be provided even when the position of the first lead with respect to the positive electrode tab or the negative electrode current collector tab is displaced, a battery with low resistance can be realized.

The first edge surface of the external terminal has a square-shaped top surface, and first and second inclined surfaces continuing to two opposite sides of the top surface; thus, the welding direction can be changed by selecting one of the three surfaces as a welding surface.

The plate thickness of each of the first and second packages preferably falls under the range from 0.02 mm to 0.3 mm. The range can balance conflicting properties, i.e., mechanical strength and flexibility. The more preferable range of the plate thickness is the range from 0.05 mm to 0.15 mm.

It is desirable that a difference (thickness) between the outer diameter and the inner diameter of the ring-shaped member of either or each of the positive electrode terminal and the negative electrode terminal is the same or larger than the plate thickness of the first package. Thus, the external terminal can be connected to the first package with high strength, regardless of the plate thickness of the first package. More specifically, the thinnest plate thickness may be 0.1 mm or thicker.

Furthermore, the outer shape of the ring-shaped member is not necessarily similar to the cross-sectional shape of the burring; rather, it may be a polyhedral shape, such as a rectangle or a hexagon, and may have a composite shape consisting of a single or multiple curved lines and a single or multiple straight lines.

A flat plate, like the one illustrated inFIGS. 5A and 5B, may be used for the second package; however, a package having a flange at its opening may be used instead of a flat plate. Examples of such a structure include a package having a structure similar to that of the first package.

The backup positive electrode lead11(the third positive electrode lead) and the backup negative electrode lead13(the third negative electrode lead) are not limited to a U-shaped conductive plate, and a conductive flat plate may be used. A structure not using one of the backup positive electrode lead11and the backup negative electrode lead13, or both of them, is also possible.

The package member may further include a safety valve for releasing a pressure inside the battery when the inner pressure rises higher than a predetermined value.

The battery according to the first embodiment may be a primary battery or a secondary battery. An example of the battery according to the first embodiment may be a lithium ion secondary battery.

Next, the positive electrode, the negative electrode, the separator, and the nonaqueous electrolyte of the battery according to the first embodiment will be described below.

A positive electrode may include, for example, a positive electrode current collector, a positive electrode material layer held by the positive electrode current collector, and a positive electrode current collector tab. The positive electrode material layer may include, for example, a positive electrode active material, a conductive agent, and a binder.

The binder is combined to bind the active material and the current collector. Examples of the binder include polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVdF), and fluororubber.

The conductive agent is combined, if necessary, in order to enhance the current collecting performance, and to reduce the contact resistance between the active material and the current collector. Examples of the conductive agent include carbonaceous materials, such as acetylene black, carbon black, and/or graphite.

In the positive electrode material layer, the positive electrode active material and the binder are preferably mixed respectively in proportions of: 80 mass % to 98 mass %; and 2 mass % to 20 mass %.

The amount of the binder is adjusted to 2 mass % or more, thereby providing sufficient electrode strength. The amount of the binder is adjusted to 20 mass % or less, thereby decreasing the amount of the binder contained as an insulating material in the electrode and decreasing internal resistance.

In a case of adding the conductive agent, the positive electrode active material, the binder, and the conductive agent are preferably mixed respectively in proportions of: 77 mass % to 95 mass %; 2 mass % to 20 mass %; and 3 mass % to 15 mass %. The amount of the conductive agent is adjusted to 3 mass % or more, thereby achieving the above-described effect. The amount of the conductive agent is adjusted 15 mass % or less, thereby reducing the decomposition of the nonaqueous electrolyte on the surface of the conductive agent under high-temperature storage.

An aluminum foil, or an aluminum alloy foil including at least one element selected from a group of Mg, Ti, Zn, Ni, Cr, Mn, Fe, Cu, and Si is preferably used for the positive electrode current collector.

The positive electrode current collector is preferably integrated with the positive electrode tab. Or, the positive electrode current collector may be different from the positive electrode current collector tab.

A negative electrode may include, for example, a negative electrode current collector, a negative electrode material layer held by the negative electrode current collector, and a negative electrode current collector tab. The negative electrode material layer may include, for example, a negative electrode active material, a conductive agent, and a binder.

As a negative electrode active material, a metal oxide, a metal nitride, an alloy, or a carbon which can allow lithium ions to be intercalated in and released from, for example, can be used. A material which capable of allowing lithium ions to be intercalated and released at the potential of 0.4 V (vs Li/Li+) or more is preferably used as a negative electrode active material.

The conductive agent is mixed in order to enhance the current collecting performance, and to reduce the contact resistance between the negative electrode active material and the current collector. Examples of the conductive agent include carbonaceous materials, such as acetylene black, carbon black, and/or graphite.

The binder is mixed to fill a gap among dispersed negative electrode active materials and to bind the active material and the current collector. Examples of the binder include polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVdF), and fluororubber, and styrene-butadiene rubber.

The active material, the conductive agent, and the binder in the negative electrode material layer are preferably mixed respectively in proportions of: 68 mass % to 96 mass %; 2 mass % to 30 mass %; and 2 mass % to 30 mass %. The amount of the conductive agent is adjusted to 2 mass % or more, thereby improving the current collecting performance of the negative electrode layer. The amount of the binder is adjusted to 2 mass % or more, thereby achieving sufficient binding between the negative electrode material layer and the current collector, and expecting excellent cycle characteristics. On the other hand, it is preferable to adjust each of the conductive agent and the binder to 28 mass % or less to achieve larger capacity.

As a current collector, a material that is electrochemically stable in an intercalating potential and a releasing potential of lithium in the negative electrode active material is used. Copper, nickel, stainless steel, or aluminum, or an aluminum alloy foil including at least one element selected from a group of Mg, Ti, Zn, Mn, Fe, Cu, and Si is preferably used for the current collector. The thickness of the current collector preferably falls within the range from 5 to 20 μm. The current collector having such a thickness can balance strength and light weight for the negative electrode.

The negative electrode current collector is preferably integrated with the negative electrode current collector tab. Or, the negative electrode current collector may be different from the negative electrode current collector tab.

The negative electrode is prepared, for example, by suspending a negative electrode active material, a conductive agent, and a binder in an appropriate solvent to prepare slurry, applying the slurry to the current collector, drying the slurry to obtain a negative electrode material layer, and performing a press. The negative electrode may be formed by arranging on the current collector a negative electrode material layer, which is obtained by forming the negative electrode active material, the binder, and the conductive agent into a pellet shape.

A separator may be made of, for example, a porous film including polyethylene, polypropylene, cellulose, or polyvinylidene fluoride (PVdF), or a nonwoven cloth made of a synthesis resin. Particularly, a porous film made of polyethylene or polypropylene melts at a certain temperature to break a current, thereby improving safety.

As an electrolytic solution, an nonaqueous electrolyte solution can be used, for example.

A nonaqueous electrolyte may be, for example, a liquid nonaqueous electrolyte prepared by dissolving an electrolyte in an organic solvent, or a gel nonaqueous electrolyte which is a composite of a liquid electrolyte and a polymer material.

The liquid nonaqueous electrolyte is prepared by, for example, dissolving an electrolyte in a concentration from 0.5 mol/L to 2.5 mol/L in an organic solvent.

Examples of the electrolyte dissolved in the organic solvent include lithium salts, for example, lithium perchlorate (LiClO4), lithium hexafluorophosphate (LiPF6), lithium tetrafluoroborate (LiBF4), lithium hexafluoroarsenate (LiAsF6), lithium trifluoromethanesulfonate (LiCF3SO3), and lithium bis(trifluoromethylsulphonyl)imide [LiN(CF3SO2)2], etc., and any mixtures thereof. An electrolyte is preferably resistant to oxidizing even under a high potential, and LiPF6is most preferable.

Examples of an organic solvent include: cyclic carbonate, such as propylene carbonate (PC), ethylene carbonate (EC), or vinylene carbonate; chain carbonate, such as diethyl carbonate (DEC), dimethyl carbonate (DMC), or methyl ethyl carbonate (MEC); cyclic ether, such as tetrahydrofuran (THF), 2-methyltetrahydrofuran (2MeTHF), and dioxolane (DOX); cyclic ether, such as dimethoxyethane (DME), and diethoxyethane (DEE); γ-butyrolactone (GEL), acetonitryl (AN), and sulfolane (SL). These organic solvents may be used individually or mixed.

Examples of polymer materials include polyvinylidene fluoride (PVdF), polyacrylonitrile (PAN), and polyethylene oxide (PEO).

Or, as a nonaqueous electrolyte, a room temperature molten salt (ionic melts) containing lithium ions, a polymer solid electrolyte, an inorganic solid electrolyte, etc., may be used.

Of organic salts including organic cations and anions, a room temperature molten salt (ionic melts) is a compound that may exist as a liquid under a room temperature (15 to 25° C.). Examples of a room temperature molten salt include a room temperature molten salt that exists as a liquid by itself, a room temperature molten salt that converts into a liquid if mixed with an electrolyte, and a room temperature molten salt that converts into a liquid when dissolved in an organic solvent. Generally, the melting point of a room temperature molten salt that is used for a nonaqueous electrolyte battery is 25° C. or lower. Organic cations generally have a quaternary ammonium skeleton.

A method of manufacturing a battery of the first embodiment will be described below.

An electrode group2with an insulating sheet10as illustrated inFIG. 3is formed. A first package5, in which a positive electrode terminal3and a negative electrode terminal4are stationarily fixed as illustrated inFIG. 8, is formed. At least one guide hole used for positioning is made in each of the first package5and a second package6. An example is shown inFIGS. 9A and 9B.FIG. 9Ashows an example where the guide holes39are made in the four corners of the second package6.FIG. 9Bshows an example where the guide holes39are made in the four corners of the first package5.

The electrode group2is stored in a first package5, an electrode group side positive electrode lead12is welded to a positive electrode terminal lead23, and an electrode side negative electrode lead14is welded to a negative electrode terminal lead36. For the welding, laser welding is used, for example.

Subsequently, the positive electrode current collector tab7aand the negative electrode current collector tab8aof the electrode group2are covered by a pair of second insulation reinforcement members38. Then, the second package6is arranged on the first package5. Since the guide holes39are open at the four corners of each of the first package5and the second package6, it is easy to determine a position of the second package6with respect to the first package5.

Subsequently, the three sides of each of the first package5and the second package6(for example, one long side and two short sides) are welded, as shown inFIG. 10A. For welding, resistance seam welding is used, for example. The welded portion is indicated by reference number40. The welded portion40is desirably located further inside than the outer periphery of the first package5and the second package6.

After injecting an electrolyte from the opening at the unwelded side, this side is welded by, for example, resistance seam welding, as shown inFIG. 10B. The welded portion41is desirably located at the outer periphery of the first package5and the second package6.

Next, after performing aging and initial charging/discharging, a part42is cut off from the welded portion41as shown inFIG. 10C, so that a gas inside the package member is ejected. Thereafter, as shown inFIG. 10D, the portion further inside than the welded portion41is welded by, for example, resistance seam welding. This welding is desirably performed under a vacuum atmosphere.

After that, the guide holes39may be removed as needed by cutting off the vicinity of the outer periphery of the first package5and the second package6. The guide holes39may remain.

It is thus possible to manufacture a battery of the first embodiment by the above-described method at high productivity.

The battery of the first embodiment may include a plural of electrode groups in one package member. In this case, a package having a flange at its opening, similar to the first package, is desirably used as the second package.

If a plural of electrode groups are stored in one package member, the electrode groups may be connected in series or in parallel.FIGS. 11A to 11Cshow examples of the plural of electrode groups connected in parallel. As illustrated inFIG. 11A, the first electrode group50is laminated on the second electrode group51so that the negative electrode current collector tab8aof the first electrode group50is electrically connected to the negative electrode current collector tab8aof the second electrode group51by the fourth negative electrode lead52, and the positive electrode tab7aof the first electrode group50is electrically connected to the positive electrode tab7aof the second electrode group51by the fourth positive electrode lead (not shown). Subsequently, as shown inFIG. 11B, the negative electrode current collector tabs8aof the first and second electrode groups50and51are bent inward, as needed. The positive electrode current collector tabs7aare bent in a similar manner. Thereafter, as shown inFIG. 11C, the first and second electrode groups50and51are stored inside the first package5in which the positive electrode terminal3and the negative electrode terminal4are stationarily fixed. Subsequently, as shown inFIG. 12A, the fourth negative electrode lead52is welded to the negative electrode terminal lead36. The fourth positive electrode lead is welded to the positive electrode terminal lead23. After the above-described process, manufacturing of the battery shown inFIG. 12Bis completed. The fourth positive electrode lead and the fourth negative electrode lead can be made of a material similar to those listed for the first to third positive electrode leads and negative electrode leads.

The above-described battery of the first embodiment includes a package member in which an electrode group is stored in a space formed by welding a stainless steel-made first package having a flange at its opening to a stainless steel-made second package. The battery includes a terminal section that includes a through-hole that is open to the first package, a ring-shaped rising portion that extends from the periphery portion of the through-hole toward the inside of the package member, a ring-shaped member that is arranged on the outer surface of the rising portion, an insulation gasket that has a cylindrical portion to be inserted into the rising portion, and an external terminal that is fixed to the first package by caulking, with its head portion projecting to the outside of the first package and its axial portion being inserted into the cylindrical portion of the insulation gasket. Therefore, it is possible to provide a battery with excellent flexibility and thermal radiation properties, and high strength and reliability.

The terminal section may be applied to both of or either one of the positive electrode terminal section and the negative electrode terminal section.

Second Embodiment

The battery pack according to the second embodiment includes at least one battery of the first embodiment. An example of a battery module including the battery according to the first embodiment is shown inFIGS. 13 and 14.

As shown inFIG. 13, the battery pack101includes a battery module102including the battery100of the first embodiment as a single battery. A conductive coupling member62having a shape of a triangular prism is arranged between the top surface32bof the negative electrode external terminal32of the first single battery60, which serves as the battery100, and the top surface of the negative electrode external terminal32bof the second single battery61. A conductive coupling member62having a shape of triangular prism is arranged between the top surface21bof the positive electrode external terminal17of the first single battery60and the top surface21bof the positive electrode external terminal17of the second single battery61. The conductive coupling member62is electrically connected to each of the two top surfaces by welding. As the welding, for example, laser welding, arc welding, or resistance welding may be used. Thus, a battery module unit63in which the first single battery60and the second single battery61are connected in parallel is obtained. The battery module102is obtained by connecting the battery module units63in series by bus-bars64.

The battery pack101shown inFIG. 14includes a battery module102including the battery100of the first embodiment as a single battery. The first single battery60and the second single battery61serve as the battery100, and constitute a battery module unit65. The second single battery61is connected to the first single battery60in series by the conductive coupling member62. The battery module102is obtained by connecting the battery module units65by bus-bars64. A method of electrically connecting the first single battery60and the second single battery61using the conductive coupling member62is the same as the method described with reference toFIG. 13.

In the battery module shown inFIGS. 13 and 14, the

neighboring first single battery60and second single battery61are laminated with their main surfaces of the package members1facing each other. In the battery module units63shown inFIG. 13, for example, the main surface of the first package5of the first single battery60faces the main surface of the first package5of the second single battery61. In the neighboring battery module unit63, the main surface of the second package6of the second single battery61of one battery module unit63faces the main surface of the second package6of the second single battery61of the other battery module unit63. The batteries are thus laminated with their main surfaces of the package members facing each other, thereby increasing volume energy density of the battery module.

It is desirable to provide an insulating space between the single battery60and the single battery61, between the single batteries60, or between the single batteries61, as shown inFIGS. 13 and 14, and a gap of 0.03 mm or wider may be provided, or an insulating member (for example, a resin, such as polypropylene, polyphenylene sulfide, or epoxy, or fine ceramics, such as alumina or zirconium dioxide) may be provided between the cells.

Since each of the positive electrode external terminal17and the negative electrode external terminal32has a head portion having a shape of a truncated rectangular prism, the external terminal of the single battery can be connected to one of the two portions (for example, first and second inclined surfaces) of the head portion, that is, the first inclined surface, and a bus-bar can be connected to the other portion, that is, the second inclined surface. In other words, a two-direction connection is realized in one head portion. As a result, a path electrically connecting the batteries can be shortened, thereby supplying a large current at low resistance to a battery pack.

Since the battery pack according to the second embodiment includes at least one battery of the first embodiment, it is possible to provide a battery pack that can achieve a reduction in thickness and improved flexibility, reliability, and can reduce manufacturing costs.

The battery pack is used as a power supply of electronic devices and vehicles (railway vehicles, cars, motor bicycles, light vehicles, trolley buses, etc.), for example.

As described above, the battery module may include a plural of batteries that are electrically connected in series, in parallel, or both in series and in parallel. A battery pack may include a circuit, such as a battery control unit (BMU), etc., in addition to a battery module, and a circuit illustrated in a structure (e.g., a vehicle) to which the battery module is installed may be used as a battery control unit. The battery control unit has a function of monitoring either one of or both of a voltage and a current of a single battery and a battery module to prevent over-charge and over-discharge.

A battery according to at least one above-described embodiment includes a package member in which an electrode group is stored in a space formed by welding a first package that is made of stainless steel and has a flange at its opening to a second package that is made of stainless steel. The battery includes a terminal section that includes a ring-shaped rising portion that extends from the periphery portion of a through-hole that is open to the first package toward the inside of the package member, a ring-shaped member that is arranged on the outer surface of the rising portion, and an external terminal. Therefore, it is possible to provide a battery with excellent flexibility and thermal radiation property, and high strength and reliability.