Patent Publication Number: US-2022238946-A1

Title: Energy storage device

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application is a Continuation application of U.S. patent application Ser. No. 16/633,531, filed on Jan. 23, 2020, which is a U.S. National Stage entry of International Patent Application PCT/EP2018/070017 filed on Jul. 24, 2018, which is based on Japanese Patent Application No. 2017-148357 filed on Jul. 31, 2017, the entire contents of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to an energy storage device. 
     BACKGROUND ART 
     A chargeable and dischargeable energy storage device is used in various equipment such as a mobile phone and an automobile. A vehicle which uses electric energy as a power source such as an electric vehicle (EV) or a plug-in hybrid electric vehicle (PHEV) requires a large energy. Accordingly, a large-capacity energy storage module which includes a plurality of energy storage devices is mounted on such a vehicle. 
     The energy storage device includes an outer case, and an electrode assembly housed in the outer case and having a plurality of positive electrode plates and a plurality of negative electrode plates stacked by way of separators. Tabs are formed on the positive electrode plates and the negative electrode plates respectively. Two external terminals corresponding to the positive electrode plates and the negative electrode plates are mounted on the outer case respectively. 
     Patent document 1 discloses a lithium ion secondary battery having a prismatic case. Through holes are formed in a lid of the case. A rod like barrel portion is inserted into each through hole, a first flange portion is connected to one end portion of the barrel portion in the inside of the case, and a terminal plate (external terminal) is connected to the other end portion of the barrel portion. The tabs of the electrode assembly are connected to the first flange portion. 
     PRIOR ART DOCUMENTS 
     Patent Documents 
     Patent Document 1: JP-A-2016-91659 
     SUMMARY OF THE INVENTION 
     Problems to be Solved by the Invention 
     Recently, there has been a demand for an energy storage device capable of performing a quick charge and a quick discharge. When a quick charge or a quick discharge is performed, a relatively large electric current flows in a current path. There has been a demand for a high-performance energy storage device which exhibits a small resistance loss in the current path even when a large electric current flows in the current path. There has been also a demand for an energy storage device where a current path is not shut down by fusing even when a large electric current flows in the current path. 
     The present invention has been made in view of such circumstances, and it is an object of the present invention to provide an energy storage device capable of sufficiently lowering a resistance of a current path. 
     Means for Solving the Problems 
     An energy storage device according to the present invention includes: an outer case having a lid plate on which an external terminal is mounted; a plate having a tab and housed in the outer case; a conductive shaft portion penetrating the lid plate and having one end thereof connected to the external terminal; and a conductive plate portion housed in the outer case, and having a first surface to which the other end of the conductive shaft portion is connected and a second surface to which the tab is connected, wherein a size of the conductive plate portion and a size of the tab are respectively set larger than a size of the external terminal in a planar direction of the lid plate. 
     Advantages of the Invention 
     In the present invention, the size of the conductive plate portion and the size of the tab are respectively larger than the size of the external terminal in the planar direction of the lid plate. Accordingly, compared to a case where the size of the conductive plate portion and the size of the tab are respectively set smaller than the size of the external terminal in the planar direction, a contact area between the tab and the conductive plate portion is increased so that a resistance of a current path can be reduced. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view of an energy storage device. 
         FIG. 2  is a schematic front view of the energy storage device. 
         FIG. 3  is a schematic cross-sectional view of the energy storage device taken along line III-III in  FIG. 2 . 
         FIG. 4  is a partially enlarged cross-sectional view of a lid plate and an area in the vicinity of the lid plate taken along line IV-IV in  FIG. 2 . 
         FIG. 5  is a schematic view of an energy storage module having a plurality of energy storage devices. 
     
    
    
     MODE FOR CARRYING OUT THE INVENTION 
     Hereinafter, the present invention is described with reference to drawings which show an energy storage device according to an embodiment.  FIG. 1  is a schematic perspective view of the energy storage device, and  FIG. 2  is a schematic front view of the energy storage device. The energy storage device  1  may also be a lithium ion secondary battery. 
     The energy storage device  1  includes an outer case  2  having a rectangular parallelepiped shape. A stacked electrode assembly  3  described later is accommodated in the outer case  2  together with an electrolyte solution. In this embodiment, the outer case  2  is formed of a metal case. A material for forming the metal case may be aluminum, an aluminum alloy, or stainless steel, for example. The outer case  2  has: a rectangular-shaped bottom wall  7  and a rectangular-shaped ceiling wall  8  which are disposed opposite to each other and have substantially the same size; a rectangular-shaped lid plate  9  and a rectangular-shaped rear wall  10  which connect short sides of the bottom wall  7  and short sides of the ceiling wall  8  to each other respectively and have an area smaller than an area of the bottom wall  7  and the ceiling wall  8 ; and two rectangular-shaped side walls  11 ,  11  which connect long sides of the bottom wall  7  and long sides of the ceiling wall  8  to each other respectively and have an area larger than the area of the bottom wall  7  and the ceiling wall  8 . In this embodiment, the lid plate  9  extends perpendicular to the bottom wall  7  mounted on a mounting surface (not shown in the drawing) of the energy storage device  1 , and the lid plate  9  forms a part of the side surface of the energy storage device  1 . Alternatively, the lid plate may be disposed at a position of the ceiling wall  8  on a side opposite to the bottom wall  7  of the energy storage device  1 . 
     As shown in  FIG. 2 , a positive electrode external terminal  4  is mounted on one end portion of an outer surface of the lid plate  9  by way of an outer gasket  19 , and a negative electrode external terminal  5  is mounted on the other end portion of the outer surface of the lid plate  9  by way of an outer gasket  19 . The positive electrode external terminal  4  and the negative electrode external terminal  5  expose respective flat outer surfaces, and a conductive member such as a bus bar (not shown in the drawing) is welded to the positive electrode external terminal  4  and the negative electrode external terminal  5 . A rupture valve  6  is formed on the lid plate  9  between the positive electrode external terminal  4  and the negative electrode external terminal  5 . 
       FIG. 3  is a schematic cross-sectional view of the energy storage device  1  taken along a line III-III in  FIG. 2 . As shown in  FIG. 3 , the stacked electrode assembly  3  includes a plurality of positive electrode plates  12 , a plurality of negative electrode plates  13  and a plurality of separators  14 . The positive electrode plate  12 , the negative electrode plate  13  and the separator  14  respectively have a rectangular shape as viewed in a direction which penetrates side walls  11 ,  11  in  FIG. 3 . The plurality of positive electrode plates  12  and the plurality of negative electrode plates  13  are alternately stacked to each other with the separator  14  sandwiched between the positive electrode plate  12  and the negative electrode plate  13 . In  FIG. 3 , negative electrode tabs  16  (described later) extending from the respective negative electrode plates  13  are bundled on a distal end side of these negative electrode tabs  16 , and the negative electrode tabs  16  are joined to a conductive plate portion  18   a . To increase energy density of the energy storage device  1  (to reduce a space occupied by a current path between the negative electrode external terminal  5  and the negative electrode plates  13 ), the negative electrode tabs  16  are housed in the inside of the outer case  2  in a bent state. Although not shown in the drawing, positive electrode tabs  15  (described later) extending from the positive electrode plates  12  also have substantially the same configuration as the negative electrode tabs  16 . 
     The positive electrode plate  12  has: a foil-like or a sheet-like positive electrode substrate having conductivity; and a positive active material layer which is stacked on both surfaces of the positive electrode substrate. The negative electrode plate  13  has: a foil-like or a sheet-like negative electrode substrate having conductivity; and a negative active material layer stacked on both surfaces of the negative electrode substrate. 
     The separator  14  is made of a sheet-like or a film-like material which allows the infiltration of an electrolyte solution into the separator  14 . As a material for forming the separator  14 , a woven fabric, a non-woven fabric, or porous and sheet-like or film-like resin are named, for example. The separator  14  makes the positive electrode plate  12  and the negative electrode plate  13  separate from each other and, at the same time, retains an electrolyte solution between the positive electrode plate  12  and the negative electrode plate  13 . 
       FIG. 4  is a partially enlarged cross-sectional view of the lid plate  9  and an area in the vicinity of the lid plate  9  taken along line IV-IV in  FIG. 2 . Two through holes  9   a ,  9   b  are formed in the lid plate  9  in a paced apart manner from each other in a longitudinal direction of the lid plate  9 . The rupture valve  6  is disposed between two through holes  9   a ,  9   b . Alternatively, the rupture valve  6  may be disposed on the rear wall  10  (see  FIG. 3 ) disposed opposite to the lid plate  9 . 
     As shown in  FIG. 4 , an inner gasket  20  having electrically insulating property is disposed on an inner surface of the lid plate  9  at a position in the vicinity of the through hole  9   a . The inner gasket  20  has a rectangular plate-shaped gasket body having long sides parallel to a longitudinal direction of the lid plate  9 , and the gasket body extends along and in contact with an inner surface of the lid plate  9 . A through hole is formed in the gasket body of the inner gasket  20 , and a cylindrical boss  20   b  is formed on the gasket body so as to surround the through hole. On a surface of the gasket body of the inner gasket  20  which opposedly faces the stacked electrode assembly  3 , a recessed portion  20   a  extending in a longitudinal direction of the lid plate  9  is formed. The inner gasket  20  has a ring-shaped protruding portion to be compressed on both surfaces of the gasket body on an outer peripheral side of the boss  20   b  respectively. The protruding portion to be compressed is not limited to a ring shape, and a plurality of protruding portions to be compressed may be formed in a spaced apart manner in a peripheral direction of the inner gasket  20 . The protruding portion to be compressed may be formed only one-side surface (outer surface or inner surface) of the gasket body. Gas tightness of the outer case  2  can be ensured by collapsing the protruding portion to be compressed by pressing. 
     An outer gasket  19  having electrically insulating property is disposed in the vicinity of the through hole  9   a  on the outer surface of the lid plate  9 . The outer gasket  19  has substantially the same rectangular-plate shape as the inner gasket  20 , and a through hole  19   a  is formed in a center portion of the outer gasket  19 . A diameter of the through hole  19   a  is larger than an outer diameter of the boss  20   b  of the inner gasket  20 . A recessed portion  19   b  is formed on one surface of the outer gasket  19 . The other surface of the outer gasket  19  opposedly faces the outer surface of the lid plate  9 . The boss portion  20   b  of the inner gasket  20  is inserted into the through hole  9   a  formed in the lid plate  9  and the through hole  19   a  formed in the outer gasket  19 . A distal end surface of the boss  20   b  is approximately coplanar with a bottom surface of the recessed portion  19   b  of the outer gasket  19 . 
     The positive electrode external terminal  4  has a plate shape, and a through hole  4   a  is formed in the positive electrode external terminal  4  in the vicinity of a center of the positive electrode external terminal  4 . A diameter of the through hole  4   a  is approximately equal to an inner diameter of the boss  20   b . A counter bore  4   b  is formed in one surface of the positive electrode external terminal  4  around the through hole  4   a . The positive electrode external terminal  4  is disposed in the inside of the recessed portion  19   b  such that the other surface of the positive electrode external terminal  4  and a bottom surface of the recessed portion  19   b  of the outer gasket  19  opposedly face each other. The through hole  4   a  and the boss  20   b  are coaxially disposed, and the counter bore  4   b  is exposed to the outside. 
     The positive electrode external terminal  4  and the outer gasket  19  are disposed on the outer surface of the lid plate  9  and the inner gasket  20  and the positive electrode current collector  17  are disposed on the inner surface of the lid plate  9 . At the time of welding a bus bar or the like to the positive electrode external terminal  4 , heat generated by welding is liable to be easily transferred to the outer gasket  19 . The protruding portion to be compressed which is provided for ensuring gas tightness of the outer case  2  is disposed on the inner gasket  20  as described previously and hence, heat is minimally transferred to the protruding portion to be compressed whereby gas tightness of the outer case  2  by the protruding portion to be compressed can be maintained. 
     The positive electrode current collector  17  is mounted on the positive electrode external terminal  4 . The positive electrode current collector  17  includes: a rectangular-shaped positive electrode conductive plate portion  17   a  having long sides parallel to the longitudinal direction of the lid plate  9 ; and a cylindrical positive electrode conductive shaft portion  17   b  protruding from one surface of the positive electrode conductive plate portion  17   a . An outer diameter of the positive electrode conductive shaft portion  17   b  is set smaller than a diameter of the through hole  4   a  of the positive electrode external terminal  4  and an inner diameter of the boss  20   b  of the inner gasket  20 . In this embodiment, although the positive electrode conductive shaft portion  17   b  is hollow (hollow rivet), the positive electrode conductive shaft portion may be solid (solid rivet) as an alternative case. The other surface of the positive electrode conductive plate portion  17   a  is formed flat. Although it is preferable that the other surface of the positive electrode conductive plate portion  17   a  be a flat surface, the presence of a recess is allowed to some extent provided that joining property of the tabs is not lost. The positive electrode conductive plate portion  17   a  and the positive electrode conductive shaft portion  17   b  are integrally formed with each other. In this embodiment, the positive electrode conductive plate portion  17   a  and the positive electrode conductive shaft portion  17   b  are formed as an integral part made of the same material. 
     A size of the positive electrode conductive plate portion  17   a  is larger than a size of the positive electrode external terminal  4  in the longitudinal direction of the lid plate  9 , that is, in a planar direction of the lid plate  9 . As shown in  FIG. 4 , as viewed in cross section, one end  17   d  and the other end  17   e  of the positive electrode conductive plate portion  17   a  respectively protrude from one side end  4   c  and the other side end  4   d  of the positive electrode external terminal  4  in the planar direction of the lid plate  9 . 
     The positive electrode conductive shaft portion  17   b  is inserted into the boss  20   b  from the recessed portion  20   a  of the inner gasket  20 , and a distal end portion  17   c  of the positive electrode conductive shaft portion  17   b  is disposed outside the through hole  4   a  of the positive electrode external terminal  4  and is swaged (expanded by pressing). The swaged distal end portion  17   c  is disposed in the inside of the counter bore  4   b . The positive electrode conductive plate portion  17   a  is disposed in the inside of the recessed portion  20   a . By swaging the distal end portion  17   c , the positive electrode external terminal  4 , the outer gasket  19 , the lid plate  9 , and the inner gasket  20  are clamped between the distal end portion  17   c  and the positive electrode conductive plate portion  17   a.    
     As shown in  FIG. 4 , the plurality of positive electrode plates  12  respectively have the strip-shaped positive electrode tab  15 . A size of the positive electrode tab  15  is larger than a size of the positive electrode external terminal  4  in the longitudinal direction of the lid plate  9 , that is, in the planar direction of the lid plate  9 . The positive electrode tab  15  is connected to the other surface of the positive electrode conductive plate portion  17   a , that is, a surface of the positive electrode conductive plate portion  17   a  on a side opposite to a surface of the positive electrode conductive plate portion  17   a  from which the positive electrode conductive shaft portion  17   b  protrudes by ultrasonic welding, laser welding, or swaging, for example. The positive electrode tab  15  is connected to the positive electrode conductive plate portion  17   a  ranging from a portion of the positive electrode conductive plate portion  17   a  protruding from one side end  4   c  of the positive electrode external terminal  4  to a portion of the positive electrode conductive plate portion  17   a  protruding from the other side end  4   d  of the positive electrode external terminal  4 . The positive electrode tab  15  is connected to at least a portion of the other surface of the positive electrode conductive plate portion  17   a  which is opposite to the positive electrode conductive shaft portion  17   b.    
     In the vicinity of the through hole  9   b  of the lid plate  9 , the inner gasket  20 , the outer gasket  19 , the negative electrode external terminal  5 , and the negative electrode current collector  18  are disposed. These inner gasket  20 , the outer gasket  19 , the negative electrode external terminal  5 , and the negative electrode current collector  18  have substantially the same configurations as the previously-mentioned the inner gasket  20 , the outer gasket  19 , the positive electrode external terminal  4 , and the positive electrode current collector  17  disposed in the vicinity of the through hole  9   a  and hence, the detailed description of these parts is omitted when appropriate. 
     The negative electrode external terminal  5  includes a through hole  5   a  and a counter bore  5   b . The negative electrode current collector  18  includes: a negative electrode conductive plate portion  18   a ; and a negative electrode conductive shaft portion  18   b  protruding from one surface of the negative electrode conductive plate portion  18   a . A distal end portion  18   c  of the negative electrode conductive shaft portion  18   b  is swaged. A size of the negative electrode conductive plate portion  18   a  is larger than a size of the negative electrode external terminal  5  in the longitudinal direction of the lid plate  9 , that is, in the planar direction of the lid plate  9 . 
     The plurality of negative electrode plates  13  respectively have the strip-shaped negative electrode tab  16 . A size of the negative electrode tab  16  is larger than a size of the negative electrode external terminal  5  in the longitudinal direction of the lid plate  9 , that is, in the planar direction of the lid plate  9 . One end  18   d  and the other end  18   e  of the negative electrode conductive plate portion  18   a  respectively protrude from one side end  5   c  and the other side end  5   d  of the negative electrode external terminal  5  in the planar direction of the lid plate  9 . The negative electrode tab  16  is connected to the other surface of the negative electrode conductive plate portion  18   a  ranging from a portion of the negative electrode conductive plate portion  18   a  protruding from one side end  5   c  of the negative electrode external terminal  5  to a portion of the negative electrode conductive plate portion  18   a  protruding from the other side end  5   d  of the negative electrode external terminal  5  by ultrasonic welding, laser welding, or swaging, for example. 
     In the above-mentioned energy storage device  1 , the stacked electrode assembly formed by stacking the plurality of positive electrode plates  12  and the plurality of negative electrode plates  13  is used. However, alternatively, a winding electrode assembly formed by winding one positive electrode plate and one negative electrode plate with a separator interposed therebetween may be used. Although the positive electrode external terminal  4  and the negative electrode external terminal  5  are arranged on the lid plate  9 , the positive electrode external terminal  4  and the negative electrode external terminal  5  may be disposed on two surfaces of the outer case  2  respectively. 
     In the above-mentioned energy storage device  1 , respective sizes of the conductive plate portions  17   a ,  18   a  and tabs  15 ,  16  are larger than sizes of the external terminals  4 ,  5  in the planar direction of the lid plate  9 . Compared to a case where the respective sizes of the conductive plate portions  17   a ,  18   a  and tabs  15 ,  16  are smaller than the sizes of the external terminals  4 ,  5  in the planar direction of the lid plate  9 , contact areas between the tabs  15 ,  16  and the conductive plate portions  17   a ,  18   a  can be increased so that resistances of current paths can be reduced. Since width sizes of the tabs  15 ,  16  are large, even when a large electric current flows in the tabs  15 ,  16 , the tabs  15 ,  16  are minimally shut down by fusing. 
     The tabs  15 ,  16  are connected to at least portions of the conductive plate portions  17   a ,  18   a  which are disposed opposite to the conductive shaft portions  17   b ,  18   b . Accordingly, current paths from the tabs  15 ,  16  to the external terminals  4 ,  5  become the shortest and hence, resistance values of the current paths can be lowered. 
     One ends  17   d ,  18   d  and the other ends  17   e ,  18   e  of the conductive plate portions  17   a ,  18   a  protrude from one side ends  4   c ,  5   c  and the other side ends  4   d ,  5   d  of the external terminals  4 ,  5  respectively in the planar direction of the lid plate  9 , and the tabs  15 ,  16  are connected to the conductive plate portions  17   a ,  18   a  ranging from portions of the conductive plate portions  17   a ,  18   a  protruding from one side ends  4   c ,  5   c  of the external terminals  4 ,  5  to portions of the conductive plate portions  17   a ,  18   a  protruding from the other side ends  4   d ,  5   d  of the external terminals  4 ,  5 . Accordingly, sufficiently large contact areas can be ensured between the tabs  15 ,  16  and the conductive plate portions  17   a ,  18   a  and hence, resistance values of current paths can be lowered. 
     The conductive plate portion  17   a  and the conductive shaft portion  17   b  are integrally formed with each other, and the conductive plate portion  18   a  and the conductive shaft portion  18   b  are integrally formed with each other. Accordingly, compared to a case where the conductive plate portion  17   a  and the conductive shaft portion  17   b  are formed as separate parts and the conductive plate portion  18   a  and the conductive shaft portion  18   b  are formed as separate parts, the resistance values of the current paths can be lowered, and strengths of the current collectors  17 ,  18  can be increased. 
     One ends of the conductive shaft portions  17   b ,  18   b  are inserted into the through holes  4   a ,  5   a  of the external terminals  4 ,  5  and are swaged to the external terminals  4 ,  5 . For example, the conductive shaft portions  17   b ,  18   b  can be mounted on the external terminals  4 ,  5  simply in a short time by spin swaging. By disposing the swaged portions outside the lid plate  9 , the swaged portions do not exist inside the lid plate  9 . Accordingly, surfaces of the conductive plate portions  17   a ,  18   a  which opposedly face the stacked electrode assembly  3  can be formed into flat surfaces having no unevenness and hence, the tabs  15 ,  16  can be joined to the flat surfaces easily and with certainty. 
     An energy storage module can be manufactured by using a plurality of energy storage devices  1 .  FIG. 5  is a schematic view of an energy storage module  26  having the plurality of energy storage devices  1 . The energy storage module  26  includes: a holder  24  formed of a box, end plates and the like; and the plurality of energy storage devices  1  held by the holder  24 . The plurality of energy storage devices  1  are arranged such that walls (lid plates) on which the external terminals are disposed are directed in the same direction. In this embodiment, the lid plates of the plurality of energy storage devices  1  are raised from a mounting surface, and the external terminals mounted on these lid plates are directed toward a side of the energy storage module. With respect to the plurality of energy storage devices  1 , the energy storage devices disposed adjacently to each other are arranged such that a vertical arrangement relationship between the positive electrode external terminal  4  and the negative electrode external terminal  5  is reversed. By connecting the positive electrode external terminal  4  of the energy storage device  1  and the negative electrode external terminal  5  of the energy storage device  1  disposed adjacently to the former energy storage device  1  by the bus bar  25 , the plurality of energy storage devices  1  can be connected in series. The plurality of energy storage devices  1  may be connected to each other in parallel by connecting the same electrodes. 
     The conductive plate portions  17   a ,  18   a  of the energy storage device  1  are disposed just below the conductive shaft portions  17   b ,  18   b . Accordingly, compared to a case where the conductive plate portions  17   a ,  18   a  are not disposed just below the conductive shaft portions  17   b ,  18   b , sizes of the current collectors  17 ,  18  in the longitudinal direction of the lid plate  9  can be reduced. Accordingly, a height size of the energy storage module  26  can be also reduced and hence, the present invention is applicable to a case where an energy storage module is arranged in a space having a limited height. 
     The embodiment disclosed in this specification is provided for an exemplifying purpose in all aspects and is not limitative. The technical features described in the embodiment can be combined with each other, and the scope of the present invention is intended to include all modifications which fall within Claims and scopes equivalent to Claims. 
     The sizes of the tabs  15 ,  16  may be set equal to or slightly smaller than the sizes of the external terminals  4 ,  5  provided that resistances of current paths can be sufficiently suppressed. By joining the tabs  15 ,  16  to portions of the conductive plate portions  17   a ,  18   a  which are disposed opposite to the conductive shaft portions  17   b ,  18   b  and portions disposed on both sides of such portions on the surfaces of the conductive plate portions  17   a ,  18   a  which opposedly face the stacked electrode assembly  3 , contact areas between the tabs  15 ,  16  and the conductive plate portions  17   a ,  18   a  can be ensured. 
     Although the description has been made with respect to the case where the energy storage device  1  is the lithium ion secondary battery, the energy storage device  1  is not limited to a lithium ion secondary battery. The energy storage device  1  may be one of other secondary batteries such as a nickel hydrogen battery. Further, the energy storage device  1  may be a primary battery or an electrochemical cell such as a capacitor. 
     DESCRIPTION OF REFERENCE SIGNS 
     
         
         
           
               1 : energy storage device 
               2 : outer case 
               4 : positive electrode external terminal 
               5 : negative electrode external terminal 
               9 : lid plate 
               12 : positive electrode plate 
               13 : negative electrode plate 
               17 : positive electrode current collector 
               17   a : positive electrode conductive plate portion 
               17   b : positive electrode conductive shaft portion 
               18 : negative electrode current collector 
               18   a : negative electrode conductive plate portion 
               18   b : negative electrode conductive shaft portion 
               26 : energy storage module