JP7707715B2 - Module and manufacturing method thereof - Google Patents

Description

The present disclosure relates to a module including an element such as an electricity storage device, and a method for manufacturing the same.

A module is a component that contains elements such as an energy storage device inside a housing, and is provided with a housing. In vehicles such as automobiles, high levels of waterproofing and dustproofing are required to protect the elements from the intrusion of water from the outside air.

Regarding the sealing structure of the housing, it is known that a sealing material is applied to the seal groove of the housing and a lens is attached to this sealing material to make the housing chamber waterproof (for example, Patent Document 1).

Regarding the joining of the housing lid and the housing body, it is known to insert an O-ring between the housing lid and the housing body, and to attach the housing lid and the housing body using a tool provided on the housing lid side (for example, Patent Document 2).

Japanese Utility Model Application Publication No. 11-288608 Special Publication No. 2011-527524

The common structure for connecting the housing and cover is a sealing structure using an O-ring. When an O-ring is used, for example, a fixing structure is adopted in which the O-ring is fixed to the housing or cover, and the housing and cover are firmly fixed together using fixing screws to combine the two.

When using such a fixing structure, fixing parts are required to attach the fixing screws, and these fixing parts are located in several places. Furthermore, in addition to the housing and cover, fixing screws are also required, and there is the issue of the need for fixing work.

With regard to the above problem, the inventors have discovered that it is possible to eliminate O-rings and fixing screws, simplify the fixing process, and improve the waterproof and dustproof properties of the module.

Therefore, based on the above problems and findings, an object of the present disclosure is to realize a sealing structure that is lightweight and has improved waterproof and dustproof properties.

In order to achieve the above-mentioned object, according to one aspect of the module of the present disclosure, the module includes a housing, a cover covering the housing, a first adhesive accommodating section surrounded by first and second standing wall sections formed on an opening edge section of the housing and the cover installed on tops of the first and second standing wall sections , a second adhesive accommodating section provided on the outer edge of the housing and on the outer periphery of the first adhesive accommodating section and formed by the second standing wall section and a curved edge section of the cover , and an adhesive accommodated in the first adhesive accommodating section and the second adhesive accommodating section to join the housing and the cover.

In this module, the cover may further include a skirt portion formed with a curved edge and surrounding the adhesive in the second adhesive storage portion , the skirt portion having an opening area larger than the surface portion of the housing .

In this module, the cover may further be secured to the housing by a locking portion provided on the cover.

In this module, the adhesive contained in the first adhesive containing section and the second adhesive containing section is
The amount of adhesive contained in the first adhesive containing section may be set to be greater than the amount of adhesive contained in the second adhesive containing section.
In this module, the relationship between the amount of adhesive filled in the first adhesive storage section and the adhesive storage capacity of the first adhesive storage section may be "amount of adhesive filled = adhesive storage capacity" or "amount of adhesive filled ≒ adhesive storage capacity."

In order to achieve the above-mentioned object, according to one aspect of a manufacturing method for a module disclosed herein, the method includes the steps of: storing an amount of adhesive in a first adhesive storage section formed between a first vertical wall portion and a second vertical wall portion provided on an opening edge portion of a housing, the amount of adhesive exceeding the capacity of the adhesive storage section ; covering the housing with a cover to form a second adhesive storage section at an outer edge of the housing with the second vertical wall portion and a curved edge portion of the cover, causing the adhesive to flow from the first adhesive storage section into the second adhesive storage section at the outer edge of the housing, and joining the housing and the cover with the adhesive in the first adhesive storage section and the second adhesive storage section; and crimping an engagement portion provided on the cover to engage the cover to the housing.

According to the module of the present disclosure, any of the following effects can be obtained.
(1) The housing and the cover can be firmly fixed together by the common adhesive contained in the first and second adhesive containers, without the need for screws or fixing parts therefor.
(2) The adhesive contained in the second adhesive container is surrounded by the cover, so that the adhesive between the housing and the cover can be reinforced.

According to the module manufacturing method of the present disclosure, any one of the following effects can be obtained.
(1) In the process of covering a housing with adhesive contained in a first adhesive storage section, the housing and cover can be bonded with a common adhesive by a one-touch operation of moving a portion of the adhesive from the first adhesive storage section to the second adhesive storage section.
(2) Post-processing such as removing the adhesive after bonding can be simplified.

1A is a plan view showing an electric storage module with a part of a cover cut away according to one embodiment, and FIG. 1B is a side view showing the module cut along the line IB-IB in FIG. 1A is an enlarged cross-sectional view of a cut section taken along the line IIA-IIA in FIG. 1A, and FIG. 1B is an enlarged cross-sectional view of a portion IIB in FIG. 1B. 1A shows a manufacturing process for an electricity storage module, in which FIG. 1A is a diagram showing a pre-attachment process for the cover, FIG. 1B is a diagram showing a cover attachment process, and FIG. 1C is a diagram showing a crimping process for the locking portion. 1A is a cross-sectional view showing a locking structure of a locking portion according to a modified example, and FIG. 1B is a cross-sectional view showing a part of a housing according to the modified example.

<Electricity storage module 2>
Fig. 1A shows a partially cut-out plan view of a power storage module 2 according to an embodiment, and Fig. 1B shows a side view of the power storage module 2 cut along IB-IB in Fig. 1A. The configurations shown in Figs. 1A and 1B are merely examples, and the present disclosure is not limited to such configurations.

The energy storage module 2 is an example of a module of the present disclosure, and is a circuit device including an energy storage element. The energy storage module 2 includes a housing 4 and a cover 6. The housing 4 is, for example, a rectangular cylindrical container made of insulating resin, and includes an opening 8.

The cover 6 is a lid member that is placed on the housing 4 to close the opening 8, and is made of a moldable material, such as a steel plate. The cover 6 has a similar shape to the housing surface on the opening 8 side, but is larger than it, and is equipped with a reinforcing portion 10 and a skirt portion 12. The reinforcing portion 10 is a protruding portion that protrudes from the plate-like base material that forms the cover 6 over a narrow range beyond the opening 8 of the housing 4. The skirt portion 12 is a curved portion formed by curving the edge of the cover 6 in one direction, and the opening area of the skirt portion 12 is set wider than the surface of the housing 4 that includes the opening 8.

First and second vertical walls 14, 16 are formed on the edge of the opening 8 of the housing 4. The space surrounded by these vertical walls 14, 16 and the cover 6 constitutes the first adhesive storage section 18-1. The space surrounded by the vertical wall 16 and the skirt section 12 side of the cover 6 constitutes the second adhesive storage section 18-2.

Each adhesive storage section 18-1, 18-2 contains adhesive 20, and the housing 4 and cover 6 are bonded together by this adhesive 20.

The end of the skirt portion 12 of the cover 6 is provided with a locking portion 22, as shown in FIG. 1B, and this locking portion 22 is bent toward the rear side of the adhesive storage portion 18-1 of the housing 4 and is locked to a part of the housing 4.

Before the housing 4 is sealed with the cover 6, the storage space 24 contains elements such as a storage element 26 and circuit components such as a substrate 28, as shown in FIG. 1B.

<Adhesion Structure Between Housing 4 and Cover 6>
A in Fig. 2 shows a cross section taken along line IIA-IIA in Fig. 1. The housing 4 has a vertical wall 14 formed thereon, and a vertical wall 16 formed on a flange 30 protruding in the circumferential direction. The vertical walls 14, 16 are set to the same height, and a cover 6 is installed on the tops of the vertical walls 14, 16. As described above, the space surrounded by the vertical walls 14, 16 and the cover 6 constitutes the adhesive container 18-1, and the adhesive 20 contained in the space of the adhesive container 18-1 is solidified. The space surrounded by the vertical wall 16, the cover 6 and its skirt portion 12 constitutes the adhesive container 18-2, and the adhesive 20 contained in the space of the adhesive container 18-2 is solidified.

Therefore, the cover 6 placed on the vertical walls 14, 16 of the housing 4 is firmly adhered by the adhesive 20 on the adhesive storage section 18-1 side and the adhesive 20 on the adhesive storage section 18-2 side, and the storage space 24 of the housing 4 is sealed by the housing 4, the cover 6, and the adhesive 20. The adhesive 20 may be placed in the narrow area formed by the inside of the vertical wall 14 of the housing 4 and the cover 6.

<Adhesion and locking structure between housing 4 and cover 6>
Fig. 2B shows an enlarged view of part IIB of Fig. 1B. As already described in the above, in part IIB, the cover 6 placed on the vertical wall parts 14, 16 of the housing 4 is firmly bonded by the adhesive 20 on the adhesive accommodating part 18-1 side and the adhesive 20 on the adhesive accommodating part 18-2 side, and the storage space 24 of the housing 4 is sealed by the housing 4, the cover 6, and the adhesive 20. The adhesive 20 may be provided in a narrow space formed by the inside of the vertical wall part 14 of the housing 4 and the cover 6.

Furthermore, a locking portion 22 is formed integrally with the skirt portion 12 of the cover 6. This locking portion 22 surrounds the rear side of the flange portion 30 side of the housing 4, i.e., the adhesive storage portion 18-2, and is bent toward the rear side of the adhesive storage portion 18-1 and is locked to the flange portion 30.

Therefore, the housing 4 and cover 6 are firmly fixed together by the adhesive 20 on the adhesive storage sections 18-1 and 18-2, as well as by the locking section 22 on the cover 6 locking it to the housing 4.

<Molding material for housing 4>
An insulating synthetic resin material is used for the housing 4. For example, the synthetic resin material may be a resin having insulating properties and good moldability, such as PBT (polybutylene terephthalate) resin or TPS (styrene-based thermoplastic elastomer) resin.

<Molding material for cover 6>
A formable and highly rigid plated steel sheet or the like is used for the cover 6. The cover 6 may be coated with an insulating coating.

<Materials for Adhesive 20>
Before hardening, the adhesive 20 must have enough shape retention to remain in the adhesive storage section 18-1 due to surface tension when filled into the adhesive storage section 18-1, and must also have enough fluidity to allow a portion of it to be pushed out into the adhesive storage section 18-2 by the cover 6.

Therefore, the adhesive 20 can be a two-component adhesive that contains a base material and a hardener that can be hardened at room temperature, and silicone-based or urethane-based adhesives are suitable.

<Manufacturing process of power storage module 2>
3 shows a manufacturing process for the energy storage module 2, which includes a pre-attachment process for the cover 6 (A in FIG. 3), an attachment process for the cover 6 (B in FIG. 3), and a crimping process for the locking portion 22 (C in FIG. 3). The manufacturing process for the energy storage module 2 is an example of a manufacturing method for a module according to the present disclosure.

<Pre-installation process of cover 6>
3A, the device components including the substrate 28 on which the power storage element 26 is mounted are stored in the housing 4. After storing the device components, the housing 4 is maintained horizontally, and the adhesive 20 is supplied to the adhesive storage section 18-1 by a supplying means such as a dispenser (not shown). The appropriate amount of the adhesive 20 is, for example, such that the top of the adhesive 20 is higher than the standing wall sections 14, 16 due to the surface tension of the adhesive 20.

Before the adhesive 20 hardens, the cover 6 is aligned with the surface of the housing 4 on the opening 8 side, which is held horizontally, and the cover 6 is lowered onto the housing 4 as shown by the open arrow. As the cover 6 is lowered, air flows out from above the housing 4, and the adhesive 20 on the adhesive storage section 18-1 flows toward the adhesive storage section 18-2 side in response to this air.

<Step of attaching cover 6>
As shown in B of FIG. 3, when the cover 6 is pressed onto the housing 4 before the adhesive 20 hardens, the adhesive 20 is confined within the capacity of the space in the adhesive storage section 18-1, and the excess adhesive 20 that cannot be contained in the adhesive storage section 18-1 flows along the inner surface of the cover 6, over the vertical wall section 16, and into the adhesive storage section 18-2.

In FIG. 3B, the portion indicated by the two-dot dashed line is the excess of adhesive 20, which flows out and fills the adhesive storage section 18-2.

<Step of tightening the locking portion 22>
As shown in FIG. 3C , before the adhesive 20 hardens, the cover 6 is kept in close contact with the housing 4, and the locking portion 22 on the skirt portion 12 is crimped to the housing 4 side and locked to the flange portion 30 to maintain the same.

If the adhesive 20 is cured in this state, the cover 6 can be firmly fixed to the housing 4 by the locking portion 22 as the adhesive 20 hardens, achieving a strong sealing structure.

<Total Supply Amount of Adhesive 20 and Storage Amount Ratio of Adhesive Storage Units 18-1, 18-2>
The total supply amount of adhesive 20 is Mm, and the capacity of adhesive storage section 18-1 is M1. The total supply amount Mm is an amount that exceeds the capacity M1 of adhesive storage section 18-1. The capacity M1 corresponds to the volume of adhesive storage section 18-1. If the capacity of adhesive storage section 18-2 is M2, the capacity M2 is filled by the surplus amount obtained by subtracting the capacity M1 of adhesive storage section 18-1 from the total supply amount Mm. Therefore, the total supply amount Mm of adhesive 20 can be expressed by formula (1).
Mm=M1+M2...(1)

The ratio M2/M1 of the storage capacities M1 and M2 can be expressed by equation (2).
M2/M1=(Mm-M1)/M1=(Mm/M1)-1...(2)

Here, assuming that the total supply amount Mm of the adhesive 20 includes an increase of 20% in the accommodated amount M1, and substituting Mm = 1.2 x M1 into equation (2), it can be expressed by equation (3).
M2/M1=(1.2×M1/M1)-1=1.2-1=0.2...(3)

In other words, 20% of the adhesive 20, which is the increase from the capacity M1, becomes the capacity M2 of the adhesive storage section 18-2. This is just one example, and the increase from the capacity M1 may be less than 20% or may exceed 20%. In short, the appropriate amount of increase may be, for example, an amount that can be maintained in the adhesive storage section 18-1 before sealing.

Assuming that the total supply amount Mm including the amount M1 stored in the adhesive storage unit 18-1 can be maintained in the adhesive storage unit 18-1, the magnitude relationship between the amounts M1 and M2 can be expressed by equation (4).
M1>M2...(4)

<Relationship between adhesive storage section 18-2 and storage amount M2 of adhesive 20>
The adhesive containing section 18-2 is composed of the vertical wall section 16 and the skirt section 12 of the cover 6. As shown in Fig. 2A, the total volume V of the adhesive containing section 18-2 is proportional to the interval W between the vertical wall section 16 and the skirt section 12, the height H of the skirt section 12, and the circumferential length L of the adhesive containing section 18-2, and if the circumferential length L is assumed to be constant, it is proportional to the interval W and the height H. In other words, if the interval W is narrowed, the adhesive 20 will bridge between the vertical wall section 16 and the inner wall surface of the skirt section 12 and will flow in the height direction of the vertical wall section 16 and the skirt section 12.

Therefore, to keep the adhesive 20 within the range of the height H of the skirt portion 12, the distance W between the vertical wall portion 16 and the skirt portion 12, the height H of the skirt portion 12, or both, can be optimized in relation to the amount of adhesive 20 that can be accommodated M2.

<Effects of the embodiment>
According to this embodiment, any one of the following effects can be obtained.
<Electricity storage module 2>
(1) The housing 4 and the cover 6 are firmly fixed together by the vertical walls 14, 16 formed on the housing 4, the cover 6, and the adhesive 20, and the housing 4 is sealed with the cover 6, thereby realizing a sealing structure that has improved waterproof and dustproof properties.

(2) The adhesive 20 is applied to the adhesive storage section 18-1 on the vertical wall sections 14 and 16 side of the housing 4, and the adhesive 20 is applied to the adhesive storage section 18-2 on the vertical wall section 16 and the skirt section 12 side of the cover 6. This allows the housing 4 and the cover 6 to be firmly fixed together by the adhesive 20 in the adhesive storage sections 18-1 and 18-2, increasing the fixing strength and making the energy storage module 2 more robust.

(3) By adjusting either the distance W between the vertical wall portion 16 and the skirt portion 12 of the cover 6, or the height H of the skirt portion 12, or by adjusting the amount M2 of the adhesive 20 contained therein, the adhesive 20 can be optimized for the adhesive containing portion 18-2, preventing exposure from the skirt portion 12 and improving the appearance of the energy storage module 2.

(4) Even if the cover 6 is made of an opaque material such as a steel plate, the presence or absence of adhesive 20 in the gap between the skirt portion 12 and the vertical wall portion 16 of the cover 6 and its surface condition can be visually confirmed, and the adhesion state of the adhesive 20 in the adhesive storage portion 18-1 can be predicted from the state confirmation, so that the sealing state between the housing 4 and the cover 6 can be easily confirmed and the reliability of the sealing state can be ensured.

(5) Even if the housing 4 is made of insulating resin or the like and the cover 6 is made of steel plate or the like, the two can be fixed together with a common adhesive 20.

(6) The housing 4 and the cover 6 can be firmly fixed together at least with the adhesive 20 in each of the adhesive receptacles 18-1 and 18-2. This allows the volume of the fixing portion to be smaller than conventional mechanical fixing mechanisms using fixing screws or the like, making the energy storage module 2 lighter and more compact, and improving the workability of fixing.

<Method of Manufacturing Energy Storage Module 2>
(7) According to this method of manufacturing the energy storage module 2, an amount of adhesive 20 that exceeds the volume of the adhesive accommodating section 18-1 (i.e., the adhesive capacity of the adhesive accommodating section 18-1) is injected into the space of the adhesive accommodating section 18-1 formed in the opening 8 of the housing 4, and then the cover 6 is attached to the housing 4, whereby the adhesive 20 is pushed out of the adhesive accommodating section 18-1 and accommodated in the adhesive accommodating section 18-2, thereby combining and joining the housing 4 and the cover 6.

(8) The amount of adhesive 20 contained in the adhesive storage section 18-2 can be regulated by the amount of adhesive 20 that can be maintained in the adhesive storage section 18-1, eliminating the need to measure the amount contained, and eliminating the need for a sealing operation.

(9) It is easy to check whether the adhesive 20 is contained in the adhesive containing section 18-2 by checking whether the adhesive 20 is contained within the space between the skirt section 12 and the vertical wall section 16. This allows for control of the adhesive 20 and uniform sealing quality of the energy storage module 2.

<Relationship between the amount of adhesive 20 contained and the amount of filling>
The relationship between the amount of adhesive 20 filled in the adhesive storage section 18-1 and the adhesive storage capacity of the adhesive storage section 18-1 is set to "amount of adhesive filled = adhesive storage capacity" or "amount of adhesive filled ≒ adhesive storage capacity."

<Other embodiments>
The present disclosure includes the following other embodiments.
<Latching structure of the latching portion 22>
As shown in FIG. 4A, the end of the engagement portion 22 may be provided with a hook portion 32, which may be inserted into a recess 34 formed in the flange portion 30 for hooking.

This configuration allows the cover 6 to be more firmly attached to the housing 4, increasing the fixing strength between the housing 4 and the cover 6.

<Relationship between flange portion 30 and locking portion 22>
As shown in FIG. 4B, the flange portion 30 may have a protruding portion 36 below the adhesive containing portion 18-2, and the engaging portion 22 may be bent along the outer surface of the protruding portion 36.

This configuration allows the locking portion 22 to be bent along the protruding portion 36, making it easier to process the locking portion 22 and making the molded shape uniform.

<Adhesive 20 Between the Inside of the Standing Wall 14 of the Housing 4 and the Cover 6>
In the above embodiment, adhesive 20 is applied in the narrow area formed by the inside of the vertical wall portion 14 of the housing 4 and the cover 6, but this adhesive 20 may be applied around the entire periphery, or may be applied only to a part of it, or may not be applied at all.

As described above, a most preferred embodiment of the module and its manufacture has been described. The present disclosure is not limited to the above description. Various modifications and changes are possible for those skilled in the art based on the gist of the invention described in the claims or disclosed in the description for carrying out the invention. It goes without saying that such modifications and changes are included in the scope of the present invention.

According to the module or manufacturing method thereof disclosed herein, it is possible to reduce the weight of modules such as an energy storage module and improve their waterproof and dustproof properties, thereby preventing the intrusion of foreign matter such as water, dust, and mud into the energy storage device module, for example, when the module is used in an automobile.

REFERENCE SIGNS LIST 2 Energy storage module 4 Housing 6 Cover 8 Opening 10 Reinforcement portion 12 Skirt portion 14, 16 Standing wall portion 18-1, 18-2 Adhesive storage portion 20 Adhesive 22 Locking portion 24 Storage space 26 Energy storage element 28 Substrate 30 Flange portion 32 Hook-and-loop portion 34 Recess 36 Projection portion

Claims (6)

A housing and
A cover that covers the housing;
a first adhesive containing portion surrounded by a first standing wall portion and a second standing wall portion formed on an opening edge portion of the housing and the cover installed on tops of the first standing wall portion and the second standing wall portion;
a second adhesive containing portion provided on an outer edge of the housing and on an outer peripheral side of the first adhesive containing portion, the second vertical wall portion and a curved edge portion of the cover ;
an adhesive contained in the first adhesive containing portion and the second adhesive containing portion and configured to bond the housing and the cover;
A module comprising: The cover further includes a skirt portion that is formed by curving an edge and surrounds the adhesive in the second adhesive receiving portion ,
The module according to claim 1 , wherein the skirt portion has an open area larger than that of the face portion of the housing . The module according to claim 1, further comprising a locking portion provided on the cover that locks the cover to the housing. The adhesive contained in the first adhesive containing section and the second adhesive containing section is
The module according to claim 1 or 2, wherein the amount of adhesive contained in the first adhesive containing section is set to be greater than the amount of adhesive contained in the second adhesive containing section. The module according to claim 1 or claim 2, wherein the relationship between the amount of adhesive filled in the first adhesive storage section and the amount of adhesive contained in the first adhesive storage section is "amount of adhesive filled = amount of adhesive contained" or "amount of adhesive filled ≒ amount of adhesive contained". a step of storing an amount of adhesive in a first adhesive storage portion formed between a first standing wall portion and a second standing wall portion provided on an opening edge portion of the housing, the amount of adhesive exceeding the storage capacity of the adhesive storage portion;
a step of covering the housing with a cover , forming a second adhesive accommodating portion at an outer edge of the housing by the second standing wall portion and a curved edge portion of the cover, causing the adhesive to flow from the first adhesive accommodating portion into the second adhesive accommodating portion at the outer edge of the housing, and bonding the housing and the cover with the adhesive of the first adhesive accommodating portion and the second adhesive accommodating portion;
a step of fastening a locking portion of the cover to lock the cover to the housing;
A method for manufacturing a module comprising: