Source: http://www.google.com/patents/US6451474?dq=6,970,917
Timestamp: 2014-09-23 19:30:28
Document Index: 730489256

Matched Legal Cases: ['arts 19', 'arts 19', 'arts 214', 'arts 215', 'arts 214', 'arts 215', 'arts 214', 'arts 214', 'art 215', 'arts 214', 'art 215', 'arts 214', 'arts 215', 'art 216', 'art 217', 'arts 215', 'art 217', 'arts 215', 'art 216', 'art 215', 'art 215', 'art 217', 'art 215', 'art 217', 'arts 214', 'art 216']

Patent US6451474 - Resiliently deformable battery pack - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign in<nobr>Advanced Patent Search</nobr>PatentsA battery pack that reduces thickness and lightens weight as required for battery power sources of portable electronic equipment. A battery pack is constituted by accommodating a battery and battery protection device between a top case and bottom case forming a pack case. Since the battery is formed...http://www.google.com/patents/US6451474?utm_source=gb-gplus-sharePatent US6451474 - Resiliently deformable battery packAdvanced Patent SearchPublication numberUS6451474 B1Publication typeGrantApplication numberUS 09/530,556Publication dateSep 17, 2002Filing dateSep 13, 1999Priority dateSep 11, 1998Fee statusPaidAlso published asDE69940252D1, EP1033766A1, EP1033766A4, EP1033766B1, EP1995819A2, EP1995819A3, EP1995819B1, WO2000016416A1Publication number09530556, 530556, US 6451474 B1, US 6451474B1, US-B1-6451474, US6451474 B1, US6451474B1InventorsKatsumi Kozu, Shigeru Kajiwara, Shoji Konishi, Takashi Takemura, Junji Fujiwara, Ryoichi Kaiwa, Tetsuo HirabayashiOriginal AssigneeMatsushita Electric Industrial Co., Ltd.Export CitationBiBTeX, EndNote, RefManPatent Citations (11), Referenced by (39), Classifications (33), Legal Events (5) External Links: USPTO, USPTO Assignment, EspacenetResiliently deformable battery packUS 6451474 B1Abstract A battery pack that reduces thickness and lightens weight as required for battery power sources of portable electronic equipment. A battery pack is constituted by accommodating a battery and battery protection device between a top case and bottom case forming a pack case. Since the battery is formed accommodated within an external casing wherein positive and negative electrode plates are formed by laminated sheet, reduced thickness and reduced weight of battery pack can be achieved. Also, since the face of bottom case opposite the battery is formed as a resiliently deformable face which is formed of small thickness, when expansion takes place such that the thickness of the battery as a whole increases, resiliently deformable face deforms maintaining a planar condition by resilient deformation, so that there is no possibility of an adverse effect on the equipment due to drum-shaped swelling being produced in battery pack, by such swelling.
BACKGROUND OF THE INVENTION The present invention relates to a battery pack constituted using secondary batteries which are formed accommodating electricity generating elements within a soft external case, in order to achieve reduction in size, weight and thickness that is required for battery power sources of portable information equipment such as mobile telephones or mobile computers.
SUMMARY OF THE INVENTION According to a first aspect of the present invention, a battery pack wherein a secondary battery formed in flat plate shape by accommodating electricity generating elements within an external casing formed of soft material is accommodated in a pack case is characterized in that a face on one side of said pack case, facing a flat plate face of said secondary battery, is formed as a resiliently deformable face that deforms resiliently corresponding to changes in thickness of the secondary battery, while the face on the other side is formed as a rigid face consisting of a rigid element.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view illustrating the construction of a battery pack according to a first embodiment;
FIG. 11 is given in explanation of deformation of a resiliently deformable face, FIG. 11A being a cross-sectional view in the normal condition and FIG. 11B being a cross sectional view seen in the direction of the arrows along the line A�A of FIG. 10A when the battery has expanded;
FIG. 20 is a cross-sectional view seen in the direction of the arrows along the line X�X of FIG. 19B;
FIG. 21 is a cross-sectional view seen in the direction of the arrows along the line Y�Y of FIG. 19B;
FIG. 25A is a plan view of an external casing and FIG. 25B is a cross sectional view seen in the direction of the arrows along the line E�E of FIG. 25A;
FIG. 28A is a cross sectional view seen in the direction of the arrows along the line C�C of FIG. 27, and FIG. 28B is a cross-sectional view seen in the direction of the arrows along the line B�B of FIG. 27;
FIG. 29A is a cross-sectional view seen in the direction of the arrows along the line G�G of FIG. 27, and
FIG. 29B is a cross-sectional view seen in the direction of the arrows along the line F�F of FIG. 27; and
BEST MODE FOR CARRYING OUT THE INVENTION Hereinbelow, preferred embodiments of the present invention will be described with reference to the accompanying drawings, these being provided for understanding of the present invention. An example is illustrated in which the battery pack of this embodiment constitutes a battery power source of a mobile telephone.
Also, battery protection device 8 comprises an SU 4 in which a protection circuit is constituted on circuit board 14 for protecting battery 3 from over-discharge or over-charging by controlling the charging/discharging current, and a PTC element 5 for protecting battery 3 from excessive discharge current due to for example short-circuiting, and is supplied in an assembled condition as shown in FIG. 1. As shown in FIG. 3, this battery protection device 8 is mounted with the plate surface direction of circuit board 14 and PTC element 5 parallel with the flat plate surface of battery 3 at the edge position where external input/output terminals 6 a�6 c of bottom case 2 b are mounted. AS shown in FIG. 4, the battery pack is completed by mounting this battery protection device 8 on bottom case 2 b, then accommodating battery 3 within bottom case 2 b, and bonding the top case 2 a and bottom case 2 b after connecting the positive electrode lead 12 and negative electrode lead 13 extending from battery 3 with battery protection device 8.
The procedure for arranging battery 3, battery protection device 8 and external input/output terminals 6 a�6 c within bottom case 2 b is performed as described below.
As shown in FIG. 1, in the 90� direction from the side face of bottom case 2 b to the back face side thereof, terminal mounting parts 19 a, 19 b, 19 c are formed as respective recesses; in the bottom face of each recess, as shown in FIG. 5, there are formed slit-shaped terminal insertion holes 22 in two, upper and lower, locations. As shown in FIG. 1, external input/output terminals 6 a, 6 b, and 6 c formed in U-shape are press-inserted from both respective tips into these terminal insertion holes 22. One of the tips of external input/output terminal 6 a constituting the positive electrode terminal is formed particularly long, so that, when it is mounted in bottom case 2 b, the insertion tip is positioned above a bonding hole 23 formed in bottom case 2 b, and the insertion tip projects from bonding hole 23. The end of positive electrode connection lead 30 shown in FIG. 1 is overlaid on the insertion tip on this connection hole 23, and these two are bonded by spot welding. FIG. 6 is a cross-sectional view showing how external input/output terminal 6 a is mounted and how positive electrode connection lead 30 is bonded. The end of positive electrode connection lead 30 is placed on top of the insertion tip of external input/output terminal 6 a, so that, as indicated by the upper and lower arrows, one side of the welded electrode is inserted from connection hole 23 and contacts the insertion tip of external input/output terminal 6 a, while the other side thereof contacts positive electrode connecting lead 30 and is spot-welded, these two being thereby bonded.
Each of the external input/output terminals 6 a�6 c is pressure-inserted from upper and lower terminal insertion holes 22, 22 so as to be thereby fitted into bottom case 2 b, and is bonded to each of the constituent elements arranged within bottom case 2 b, so that a reliable mounting construction is produced. Also, as shown in FIG. 6, they are mounted in a condition adhering to the bottom face of terminal mounting parts 19 a�19 c. Therefore, when battery pack 1 is mounted on the mobile telephone, even though it is subjected to pressure from a connecting probe 44 that makes pressure contact in order to effect electrical connection, a reliable connection condition is obtained, so that an electrical connection is achieved with little connection resistance.
When battery protection device 8 is located in position on bottom case 2 b, as shown in FIG. 8, circuit board 14 that constitutes SU 4 is arranged below each of the external input/output terminals 6 a, 6 b, 6 c that are mounted on bottom case 2 b, so that the respective input/output terminals 6 a, 6 b, 6 c are in a contacting condition with soldering lands 31 a, 31 b, 31 c that are formed on circuit board 14. At the same time as terminal connection is effected by soldering of respective external input/output terminals 6 a, 6 b, 6 c to these soldering lands 31 a, 31 b, 31 c, the external input/output terminals 6 a�6 c and battery protection device 8 are fixed in position on bottom case 2 b. After soldering has been completed, the soldered surface of circuit board or 14 is over-coated with insulating material so as to ensure electrical insulation and to prevent liquid short-circuiting or corrosion from occurring in the event of leakage of electrolyte from battery 3.
As shown in FIG. 9A, positive electrode lead 12 and positive electrode connection lead 30 are bonded, then, as shown in FIG. 9B, they are bent over onto lead connection side 11 b of battery 3. Identical bending is also effected in respect of the location of bonding of negative electrode lead 13 and negative electrode connection lead 33. Since lead connection side 11 b is present between this folded-over portion and battery protection device 8, there is no possibility of abnormalities being produced by contact of positive electrode lead 12 and negative electrode lead 13 with battery protection device 8. Also, insulation is more reliably ensured thanks to the application of over-coating to the soldered surface of circuit board 14 after soldering of external input/output terminals 6 a�6 c as described above.
Thus, since positive electrode lead 12 and negative electrode lead 13 exit from the same side of battery 3 and battery protection device 8 is arranged at the side of this lead connection side 11 b, there is no possibility of the leads for connection between battery 3 and battery protection device 8 having to adopt a circuitous route. External input/output terminals 6 a�6 c and battery protection device 8 are fixed in prescribed positions of bottom case 2 b, so the connection between the various structural elements accommodated in pack case 2 is made rigid and reliable, making it possible to provide a battery pack 1 which has rigidity in addition to the small thickness that is required for use with mobile equipment.
FIG. 11 shows a cross section along the direction of the arrows of line A�A of FIG. 10A; in this construction, resiliently deformable face 15 is formed of small thickness of 0.22 mm, and a peripheral portion 16 of prescribed height is formed at the periphery of this resiliently deformable face 15. The projecting height of peripheral portion 16 is formed such that a step H is produced between the peak of this circumferential portion 16 and the surface of thin stainless steel sheet 7 that is stuck onto resiliently deformable face 15. In the present construction, step H is set at 0.4 mm.
As shown in FIG. 16 and FIG. 17, upper fitting-in recesses 61 a, 61 b and lower fitting-in recesses 62 a, 62 b are formed at both the upper and lower edges of bottom case 102 b, so that when top case 102 a is made to overlap this bottom case 102 b, upper fitting-in projections 63 a, 63 b and lower fitting-in projections 64 a, 64 b formed on top case 102 a respectively fit into the aforementioned upper fitting-in recesses 61 a, 61 b and lower fitting-in recesses 62 a, 62 b, so that top case 102 a is fitted into and connected with the bottom case 102 b. FIG. 21 shows a cross sectional view along the direction of the arrows on the line Y�Y in FIG. 19B, and shows the fitted-in condition of the aforesaid upper fitting-in recess 61 a and upper fitting-in projection 63 a, as well as the fitted-in condition of the aforesaid lower fitting-in recess 61 b and lower fitting-in projection 62 b. By means of this fitting-in construction, a fitted-in condition of top case 102 a in a prescribed position of bottom case 102 b is obtained prior to the ultrasonic welding. In this condition, ultrasonic bonding at welding locations 66 at the periphery can be achieved by applying ultrasonic waves between top case 102 a and bottom case 102 b. As shown in FIG. 20, the welding location 66 where bottom case 102 b and top case 102 a are brought into contact in the thickness direction of pack case 102 is arranged close to the outside of side wall faces 73 a, 73 b formed on bottom case 102 b. These welding locations 66 are formed so as to encircle the periphery of pack case 102, being arranged in line as shown in FIG. 17 and FIG. 18. When top case 102 a is overlaid on bottom case 102 b by fitting together of the aforesaid upper fitting-in recesses 61 a, 61 b and lower fitting-in recesses 62 a, 62 b, top case 102 a contacts the welding locations 66 on bottom case 102 b. By clamping the top case 102 a and bottom case 102 b which are thus overlaid between a receiving jig and the horn of the ultrasonic welder from the contact direction, top case 102 a and bottom case 102 b adhere at the aforesaid welding locations 66. By applying ultrasonic vibration from the horn, fusion takes place at the adhering welding locations 66, thus bonding the top case 102 a and bottom case 102 b, to produce a unified pack case 102. In this way, the deformation strength of the side wall faces 73 a, 73 b is strengthened by the bonding of top case 102 a immediately on the outer side thereof, and the strength in respect of deforming pressure resulting from impacts etc. is improved, enabling the battery 3 which is accommodated to be protected and damage thereto due to impacts to be prevented. Also, as shown in FIG. 21, the deformation strength of upper wall faces 75 a, 75 b and lower wall face 74 is increased by the upper fitting-in projections 63 a, 63 b and lower fitting-in projections 64 a, 64 b that respectively fit into upper fittingin recesses 61 a, 61 b and lower fitting-in recesses 62 a, 62 b that are formed to the rear of these.
In the condition in which top case 202 a is bonded with bottom case 202 b accommodating battery 203 and battery protection device 204 illustrated in FIG. 27, the cross-section seen along the arrows of line C�C, which is the position of formation of the aforesaid position-restricting parts 214 c and 214 d, is shown in FIG. 28A, while the cross-section seen along the arrows of line B�B, which is the position of formation of the aforesaid position-restricting parts 215 a and 215 b, is shown in FIG. 28B. As shown in FIG. 28A, at the position where the position-restricting parts 214 c and 214 d are formed, the position of accommodation of battery 203 in the width direction is restricted by the proximity of the side faces of battery 203 (folded portions at sealed sides P2, P3). In contrast, as shown in FIG. 28B, at the position of space-forming parts 215 a and 215 b where the position-restricting parts 214 a, 214 b, 214 c, and 214 d are not formed, spaces are formed with respect to the side faces of battery 203.
Also, in the condition in which top case 202 a is bonded to bottom case 202 b accommodating battery 203 and battery protection device 204, the cross-section indicated by the arrows of line G�G which is the position of formation of the aforesaid position-restricting parts 214 b, 214 f is shown in FIG. 29A, while the cross-section indicated by the arrows of line F�F which is the position of formation of the aforesaid position-restricting part 215 c is shown in FIG. 29B. As shown in FIG. 29 A, at the position where the position-restricting parts 214 b and 214 f are formed, the position of accommodation of battery 203 in the width direction is restricted by the proximity of the side faces of battery 203. In contrast, as shown in FIG. 29B, at the position of space-forming part 215 c, a space is formed with respect to the side faces of battery 203.
Apart from the formation of position-restricting parts 214 a�214 f and space-forming parts 215 a�215 c with respect to the side faces of this battery 203, in respect of the planar faces of battery 203, there is formed an abutment part (position-restricting location 216) that applies tensioning force to battery 203 by abutting battery 203, and a gap part (space-forming location) 217 that forms a space with respect to battery 203. Specifically, as shown in FIG. 28, an abutment part 216 which is of increased thickness so as to abut the planar face of battery 203 is formed at the center of top case 202 a, while gap part 217 is formed of the reduced thickness so as to provide a gap G between it and battery 203 on both sides thereof.
Generation of gas may occur if a secondary battery is left in an over-charged or fully charged condition. When a external casing 211 is constituted of a laminated sheet, as in the case of battery 203, since the external casing is of soft material, generation of gas immediately causes swelling of external casing 211, and this swelling of external casing 211 produces changes in the external shape of battery pack 201. In order to deal with the generation of gas produced by such misuse of the battery, the aforesaid space-forming parts 215 a�215 c and gap part 217 are provided, so as to allow the swelling of external casing 211 produced by the generation of gas to escape into the space within pack case 202. Since external casing 211 is of soft material, the swelling can escape into portions where there are spaces, other than the portions of battery 203 that are abutted by position-restraining parts 215 a�215 c or abutment part 216, thereby preventing deformation of battery pack 201, even if there should be some generation of gas.
FIG. 30 shows a cross section of the position of formation of space-forming part 215 b. As shown in FIG. 30A, in the normal condition, in which there is no generation of gas, spaces are formed between the side face of battery 203 and space-forming part 215 b and between the flat plate face of battery 203 and gap part 217. If gas is generated within external casing 211 due to abnormal use of battery 203 as described above, as shown in FIG. 30B, external casing 211 made of soft material expands, but this expansion can be accommodated in the space formed by space forming part 215 b and gap part 217. Since external casing 211 is of soft material, the expansion can escape into the portions where there are spaces i.e. other than those which are abutted by position-restraining parts 214 a�214 f or abutment part 216 on external casing 211, so that deformation of battery pack 201 can be prevented even if generation of gas should occur.
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