Electric storage device

The present application claims priority under 35 U.S.C. § 119 to Japanese Patent Application No. 2015-113974, filed Jun. 4, 2015, entitled “Electric Storage Device.” The contents of this application are incorporated herein by reference in their entirety.

1. Field

The present disclosure relates to an electric storage device.

2. Description of the Related Art

In a general storage module (battery module), a plurality of storage cells (battery cells) are stacked. Since the storage module is mounted in an electric motor vehicle such as a hybrid vehicle or an EV, the output voltage is set high by stacking multiple storage cells.

A pair of end plates are disposed at opposite ends of the storage module in a stacking direction of the storage cells, and the pair of end plates are fastened, for example, by a pair of ladder frames disposed in the stacking direction along side surfaces of the storage cells. At this time, since the storage module is formed by stacking a plurality of storage cells, thickness tolerances of the storage cells accumulate, and this causes variations in the length of the storage module.

Accordingly, for example, Japanese Unexamined Patent Application Publication No. 2013-122820 discloses a battery module unit in which a pair of battery modules are arranged in series and combined. In each of the battery modules, a plurality of battery cells are stacked and clamped between a first end plate and a second end plate, and the first end plate and the second end plate are connected by connecting members.

Further, the connecting members are each fixed at one end to the second end plate, and fixed at the other end to the first end plate with a tolerance absorbing member being disposed therebetween, and the first end plates of the pair of battery modules are formed by a single common member.

This publication describes that, even if a difference in length in the stacking direction is caused between the battery modules by accumulation of the thickness tolerances of the battery cells, the difference can be absorbed by changing the positions of the second end plates.

According to a first aspect of the present invention, an electric storage device includes a storage module and a mounting plate. A plurality of storage cells are stacked in the storage module. The mounting plate is connected to the storage module by being connected to a fastening part provided in the storage module. The mounting plate has a displacement absorbing part that extends in a cell side surface direction intersecting a stacking direction of the storage cells and absorbs displacement in the stacking direction by being deformed by a load in the stacking direction. The displacement absorbing part is provided on an inner side of the fastening part in the stacking direction.

According to a second aspect of the present invention, an electric storage device includes a storage module and a mounting plate. The storage module includes a plurality of storage cells stacked in a stacking direction and has an end surface in the stacking direction. The storage module is mounted on the mounting plate. The mounting plate includes a fastening part and a displacement absorbing part. The storage module is connected to the mounting plate at the fastening part. The displacement absorbing part absorbs displacement of the storage module in the stacking direction. The fastening part is provided between the displacement absorbing part and the end surface of the storage module in the stacking direction.

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.

FIG. 1 is an explanatory perspective view of the principal part of a power unit in which an electric storage device according to a first embodiment of the present disclosure is incorporated.

FIG. 2 is an exploded explanatory perspective view of the electric storage device.

FIG. 3 is an explanatory cross-sectional view of the electric storage device, taken along line of FIG. 2 .

FIG. 4 is an explanatory perspective view of an added mounting plate that constitutes the electric storage device.

FIG. 5 is an explanatory cross-sectional view of the added mounting plate, taken along line V-V of FIG. 4 .

FIG. 6 is an exploded explanatory perspective view of the principal part of an electric storage device according to a second embodiment of the present disclosure.

FIG. 7 is an explanatory perspective view of the principal part of a power unit in which an electric storage device according to a third embodiment of the present disclosure is incorporated.

FIG. 8 is an explanatory side view of the principal part of the electric storage device.

FIG. 9 is an exploded explanatory perspective view of the principal part of an electric storage device according to a fourth embodiment of the present disclosure.

The embodiments will now be described with reference to the accompanying drawings, wherein like reference numerals designate corresponding or identical elements throughout the various drawings.

As illustrated in FIG. 1 , an electric storage device 10 according to a first embodiment of the present disclosure is incorporated in a power unit 12 . The power unit 12 is mounted in an electric motor vehicle (for example, a hybrid vehicle or an EV). A drive motor (not illustrated) of the electric motor vehicle is driven by electric power supplied from the power unit 12 .

The power unit 12 includes a fixing plate (attachment part) 14 provided in a vehicle body frame (not illustrated). On the fixing plate 14 , a plurality of storage modules 16 that constitute the electric storage device 10 are mounted with a mounting plate 18 being disposed therebetween. On arbitrary storage modules 16 , other storage modules 16 are stacked with a mounting plate 18 a attached to the fixing plate 14 being disposed therebetween.

A control unit 20 is mounted in a space on almost the center of the fixing plate 14 . The control unit 20 includes various devices such as an inverter device, a relay device, and a battery ECU.

As illustrated in FIG. 2 , in each storage module 16 , a plurality of storage cells 22 are stacked in the horizontal direction (direction of arrow A). The storage cells 22 are rectangular, and are stacked in the direction of arrow A while being arranged in a standing posture so as to alternate with separators (holders) 24 having the electrical insulation property. For example, the storage cells 22 are formed by lithium ion batteries and have a rectangular shape (or a square shape).

At opposite ends of the stack of the storage cells 22 in the stacking direction, rectangular (or square) end plates 28 a and 28 b are disposed with insulator plates 26 a and 26 b (or the separators 24 ) having the heat insulating function and the electric insulating function being disposed therebetween. The end plates 28 a and 28 b are connected by, for example, a pair of connection bands 30 a and 30 b arranged at opposite ends in the direction of arrow B and extending in the direction of arrow A. Thus, a plurality of storage cells 22 are held integrally.

The end plates 28 a and 28 b are substantially shaped like a flat plate. End portions of the connection bands 30 a and 30 b are fixed to end portions of the end plates 28 a and 28 b in the direction of arrow B by a plurality of screws 31 a and 31 b . Holes 32 a vertically penetrate the end portions of the end plate 28 a in the direction of arrow B, and holes 32 b vertically penetrate the end portions of the end plate 28 b in the direction of arrow B. Fixing screws 34 serving as a fastening part are inserted in the holes 32 a and 32 b.

For example, a busbar unit 35 is attached to an upper part of the storage module 16 . The busbar unit 35 electrically connects a positive electrode terminal of one of adjacent storage cells 22 and a negative electrode terminal of the other storage cell 22 . The plural storage cells 22 are electrically connected in series by the busbar unit 35 .

The mounting plate 18 is formed by a metal plate that is long in the stacking direction (direction of arrow A) of the storage cells 22 . A pair of screw holes 36 a are provided in one end portion of the mounting plate 18 in the direction of arrow A, and a pair of screw holes 36 b are provided in the other end portion of the mounting plate 18 in the direction of arrow A. The screw holes 36 a and 36 b are disposed coaxially with the holes 32 a and 32 b of the end plates 28 a and 28 b , respectively, and the fixing screws 34 are screwed therein.

Flange portions 38 a and 38 b serving as a fixing part project in the direction of arrow B intersecting the direction of arrow A from long sides of the mounting plate 18 in the direction of arrow B. A pair of flange portions 38 a are provided at an end close to the pair of screw holes 36 a , and a pair of flange portions 38 b are provided at an end close to the pair of screw holes 36 b.

The flange portions 38 a and 38 b have holes 40 a and 40 b , respectively, and screws 42 inserted in the holes 40 a and 40 b are screwed in screw holes 44 a and 44 b provided in the fixing plate 14 . The mounting plate 18 is fixed to the fixing plate 14 by inserting the screws 42 in the holes 40 a and 40 b and screwing the screws 42 in the screw holes 44 a and 44 b.

The mounting plate 18 has displacement absorbing parts 46 a and 46 b that extend in the direction of arrow B (a cell side surface direction intersecting the stacking direction of the storage cells 22 ) and absorb displacement in the stacking direction by being deformed by the load in the stacking direction.

As illustrated in FIGS. 2 and 3 , the displacement absorbing part 46 a is provided on an inner side of the screw holes 36 a (fastening part) in the stacking direction, more specifically, between the fixing screws 34 and the screws 42 (fixing part) in the stacking direction. The displacement absorbing part 46 a is a curved portion extending in the direction of arrow B (cell side surface direction), and has a wavy shape in a side view of the mounting plate 18 from the direction of arrow B.

As illustrated in FIG. 2 , the displacement absorbing part 46 b is provided on an inner side of the screw holes 36 b (fastening part) in the stacking direction, more specifically, between the fixing screws 34 and the screws 42 (fixing part) in the stacking direction. The displacement absorbing part 46 b is a curved portion extending in the direction of arrow B (cell side surface direction), and has a wavy shape in a side view of the mounting plate 18 from the direction of arrow B.

As illustrated in FIGS. 4 and 5 , the mounting plate 18 a is formed by a metal plate, and has a vertical surface 50 a extending in the vertical direction from a plate surface (horizontal surface) of the fixing plate 14 . A horizontal portion 50 b bent and extending in the horizontal direction is provided integrally with an upper end portion of the vertical surface 50 a . A pair of screw holes 36 a are provided in one end portion in the direction of arrow A of the horizontal portion 50 b that constitutes the mounting plate 18 a , and a pair of screw holes 36 b are provided in the other end portion of the horizontal portion 50 b.

Flange portions 38 a and 38 b serving as a fixing part project in the direction of arrow B from a lower end portion of the vertical surface 50 a that constitutes the mounting plate 18 a . The flange portions 38 a and 38 b have holes 40 a and 40 b , respectively, and screws 42 inserted in the holes 40 a and 40 b are screwed in screw holes 44 a and 44 b provided in the fixing plate 14 . The mounting plate 18 a is fixed to the fixing plate 14 .

As illustrated in FIG. 4 , the mounting plate 18 a has displacement absorbing parts 46 a and 46 b that extend in the direction of arrow B (cell surface side direction intersecting the stacking direction of the storage cells 22 ) and absorb displacement in the stacking direction by being deformed by the load in the stacking direction. The displacement absorbing part 46 a is provided between the screw holes 36 a and the flange portion 38 a (screw 42 ) in the stacking direction, and the displacement absorbing part 46 b is provided between the screw holes 36 b and the flange portion 38 b (screw 42 ) in the stacking direction.

The displacement absorbing parts 46 a and 46 b are wavy curved portions extending in the direction of arrow B (cell side surface direction) and the direction of arrow C (cell side surface direction), and are continuously provided over the vertical surface 50 a and the horizontal portion 50 b.

As illustrated in FIG. 5 , on a back side of the mounting plate 18 a , a cover plate 52 is disposed to cover three surfaces of the storage module 16 together with the mounting plate 18 a . Flange portions 53 provided in a lower end portion of the cover plate 52 are fixed to the fixing plate 14 by screws 54 , and an upper end portion of the cover plate 52 is fixed to flange portions 55 provided in an upper part of the mounting plate 18 a by screws 56 .

In the electric storage device 10 having this structure, as illustrated in FIG. 2 , the mounting plate 18 has the displacement absorbing parts 46 a and 46 b that absorb the displacement in the stacking direction by being deformed by the load in the stacking direction. For this reason, when the storage cells 22 expand and the storage module 16 bulges in the stacking direction of the storage cells 22 , the mounting plate 18 that holds and fixes the storage module 16 deforms so that the displacement absorbing parts 46 a and 46 b extend in the stacking direction.

Specifically, the displacement absorbing parts 46 a and 46 b are wavy curved portions. In contrast, the flange portions 38 a and 38 b (fixing part) are provided on the inner sides of the screw holes 36 a and 36 b (fastening part), respectively, in the stacking direction. The displacement absorbing parts 46 a and 46 b are disposed between the flange portion 38 a and the screw holes 36 a and between the flange portion 38 b and the screw holes 36 b , respectively, in the stacking direction. Therefore, when the storage module 16 entirely bulges in the stacking direction, as illustrated in FIG. 3 , a load (stress) of arrow F is applied to both end portions of the storage module 16 .

The fixing screws 34 to be screwed in the screw holes 36 a are inserted in the end plate 28 a of the storage module 16 . Thus, when the load is applied to the fixing screws 34 , the displacement absorbing part 46 a deforms so that the wavy shape becomes gentle, and this can absorb expansion of the storage cells 22 (see solid lines and two-dot chain lines in FIG. 3 ). For this reason, the screws 42 can be reliably prevented from loosening. In the end plate 28 b , the displacement absorbing part 46 b can deform and absorb expansion of the storage cells 22 , similarly to the end plate 28 a.

Therefore, even when the storage cells 22 expand and the dimension in the stacking direction changes, the change of the dimension can be easily and reliably absorbed by the displacement absorbing parts 46 a and 46 b . This provides the effect of ensuring a proper fixed state between the storage module 16 and the mounting plate 18 .

Further, as illustrated in FIGS. 4 and 5 , on an arbitrary storage module 16 , another storage module 16 is stacked with the mounting plate 18 a attached to the fixing plate 14 being disposed therebetween. The mounting plate 18 a has the displacement absorbing parts 46 a and 46 b , similarly to the mounting plate 18 , and can obtain effects similar to those of the mounting plate 18 .

FIG. 6 is an exploded explanatory perspective view of the principal part of an electric storage device 60 according to a second embodiment of the present disclosure. The same constituent elements as those of the electric storage device 10 of the first embodiment are denoted by the same reference numerals, and detailed descriptions thereof are skipped. In the following third embodiment, detailed descriptions are similarly skipped.

The electric storage device 60 includes a mounting plate 62 , and the mounting plate 62 has displacement absorbing parts 64 a and 64 b that extend in the direction of arrow B and absorb displacement in the stacking direction by being deformed by the load in the stacking direction. The displacement absorbing part 64 a is provided between screw holes 36 a and flange portions 38 a in the stacking direction, and the displacement absorbing part 64 b is provided between screw holes 36 b and flange portions 38 b in the stacking direction. The displacement absorbing parts 64 a and 64 b are curved portions extending in the direction of arrow B (cell side surface direction), and have a wavy shape in a side view of the mounting plate 62 from the direction of arrow B.

Each of the displacement absorbing parts 64 a and 64 b includes a projecting center portion 66 a projecting outward in the stacking direction at a center portion in the direction of arrow B and end portions 66 b and 66 c separating inward in the stacking direction from the projecting center portion 66 a toward opposite ends in the direction of arrow B.

In the second embodiment that adopts this structure, the displacement absorbing parts 64 a and 64 b each include the projecting center portion 66 a and the end portions 66 b and 66 c , and are set to have a wavy shape in plan view. For this reason, the rigidity of the entire mounting plate 62 can be further increased. Moreover, effects similar to those of the above-described first embodiment can be obtained, for example, deformation in the stacking direction can be properly caused.

FIG. 7 is an explanatory perspective view of the principal part of a power unit 72 in which an electric storage device 70 according to a third embodiment of the present disclosure is incorporated.

The power unit 72 includes a fixing plate (attachment part) 74 provided in a vehicle body frame (not illustrated). A plurality of storage modules 16 are mounted on the fixing plate 74 with a mounting plate 18 being disposed therebetween to constitute the electric storage device 70 . A mounting plate 76 is integrally connected on a plurality of, for example, four storage modules 16 , and various devices 78 a , 78 b , and 78 c are mounted on the mounting plate 76 . At least the device 78 a , 78 b , or 78 c includes, for example, a power distribution component.

The mounting plate 76 is formed by a metal plate that is long in the arrangement direction of a plurality of, for example, four storage modules 16 (direction of arrow B intersecting the stacking direction), and integrally covers the four storage modules 16 . The length of the short sides of the mounting plate 76 corresponds to the total length of storage cells 22 in the stacking direction. In one long side of the mounting plate 76 , four holes 82 a (fastening part) are provided so that holding pins 80 a standing on upper surfaces of end plates 28 a are to be inserted. In the other long side of the attachment plate 76 , four holes 82 b are provided so that holding pins 80 b standing on upper surfaces of end plates 28 b are to be inserted.

The mounting plate 76 has displacement absorbing parts 84 a and 84 b that extend in the direction of arrow B (cell side surface direction intersecting the stacking direction of the storage cells 22 ) and absorb displacement in the stacking direction by being deformed by the load in the stacking direction. The displacement absorbing parts 84 a and 84 b are provided on inner sides of the holes 82 a and 82 b (fastening part), respectively, in the stacking direction. The displacement absorbing parts 84 a and 84 b are curved portions extending in the direction of arrow B (cell side surface direction), and have a wavy shape in a side view of the mounting plate 76 from the direction of arrow B (see FIGS. 7 and 8 ).

In the third embodiment that adopts this structure, the mounting plate 76 has the displacement absorbing parts 84 a and 84 b that absorb the displacement in the stacking direction by being deformed by the load in the stacking direction. For this reason, when the storage cells 22 expand and the storage modules 16 bulge in the stacking direction of the storage cells 22 , the mounting plate 76 integrally provided on the storage modules 16 deforms so that the displacement absorbing parts 84 a and 84 b extend in the stacking direction.

Therefore, the devices 78 a , 78 b , and 78 c mounted on the mounting plate 76 are not displaced unnecessarily. Particularly in the power distribution component that is remarkably affected by the displacement, the displacement can be minimized. This allows the power distribution component to be protected well.

FIG. 9 is an exploded explanatory perspective view of an electric storage device 90 according to a fourth embodiment of the present disclosure. The same constituent elements as those of the electric storage device 70 of the third embodiment are denoted by the same reference numerals, and detailed descriptions thereof are skipped.

In the electric storage device 90 , a mounting plate 92 is connected onto a single (or a plurality of) storage module 16 , and various devices (not illustrated) are mounted on the mounting plate 92 . The mounting plate 92 is formed by a metal plate that is long in the stacking direction of storage cells 22 . In one short side portion of the mounting plate 92 , two holes 82 a (fastening part) are provided so that two holding pins 80 a standing on an upper surface of an end plate 28 a are to be inserted therein. In the other short side portion of the attachment plate 92 , two holes 82 b (fastening part) are provided so that two holding pins 80 b standing on an upper surface of an end plate 28 b are to be inserted therein.

The mounting plate 92 has displacement absorbing parts 94 a and 94 b that extend in the direction of arrow B (cell side surface direction intersecting the stacking direction of the storage cells 22 ) and absorb displacement in the stacking direction by being deformed by the load in the stacking direction. The displacement absorbing parts 94 a and 94 b are provided on inner sides of the holes 82 a and 82 b (fastening part), respectively, in the stacking direction. The displacement absorbing parts 94 a and 94 b are curved portions extending in the direction of arrow B (cell side surface direction), and have a wavy shape in a side view of the mounting plate 92 from the direction of arrow B.

Each of the displacement absorbing parts 94 a and 94 b includes a projecting center portion 96 a projecting outward in the stacking direction at a center portion in the direction of arrow B and end portions 96 b and 96 c separating inward in the stacking direction from the projecting center portion 96 a toward opposite ends in the direction of arrow B.

In the fourth embodiment that adopts this structure, each of the displacement absorbing parts 94 a and 94 b includes the projecting center portion 96 a and the end portions 96 b and 96 c , and is set to have a wavy shape in plan view. For this reason, the rigidity of the entire mounting plate 92 can be further increased, and effects similar to those of the above-described second embodiment can be obtained, for example, deformation can be properly caused in the stacking direction.

The fourth embodiment can be applied to the mounting plate 76 that constitutes the electric storage device 70 of the third embodiment.

An electric storage device according to an aspect of the present disclosure includes a storage module in which a plurality of storage cells are stacked, and a mounting plate connected to the storage module by being connected to a fastening part provided in the storage module.

Preferably, the mounting plate has a displacement absorbing part that extends in a cell side surface direction intersecting a stacking direction of the storage cells and absorbs displacement in the stacking direction by being deformed by a load in the stacking direction. The displacement absorbing part may be provided on an inner side of the fastening part in the stacking direction.

Preferably, the displacement absorbing part is a curved portion extending in the cell side surface direction, and has a wavy shape in a side view of the mounting plate from the cell side surface direction.

Preferably, the displacement absorbing part includes a projecting center portion projecting outward in the stacking direction at a center portion in the cell side surface direction and end portions separating inward in the stacking direction from the projecting center portion toward opposite sides in the cell side surface direction.

Preferably, the mounting plate includes a fixing part that holds the storage module and is fixed to an attachment part. At this time, preferably, the fixing part is provided on an inner side of the fastening part in the stacking direction, and the displacement absorbing part is disposed between the fixing part and the fastening part in the stacking direction.

According to the present disclosure, the mounting plate has the displacement absorbing part that absorbs the displacement in the stacking direction by being deformed by the load in the stacking direction. For this reason, when the storage cells expand in the stacking direction, the displacement absorbing part deforms to extend in the stacking direction. This can absorb the expansion of the storage cells. Therefore, it is possible to reliably prevent the fastening part from loosening.

Thus, even when the storage cells expand and the dimension in the stacking direction changes, the change of the dimension can be easily and reliably absorbed by the displacement absorbing part. This allows a proper fixed state between the storage module and the mounting plate.

Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.