# US 8,465,861 B2 · Battery pack and method for producing the same

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- Number: US 8,465,861 B2
- Document ID: US8465861B2
- Status: Granted
- Kind: B2
- Application number: 12/330,596
- Filed: 2008-12-09
- Published: 2009-07-30
- Granted: 2013-06-18
- Earliest claimed: 2008-01-30
- Assignees: Sony Corporation
- Applicants: Takeru Yamamoto; Ken Segawa; Shunsuke Saito
- Inventors: Takeru Yamamoto; Ken Segawa; Shunsuke Saito
- Web page: https://patentgrep.com/patent/US8465861B2

## CPC

- B29C 70/72: Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components {(B29C70/742 takes precedence)}
- H01M 10/425: {Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing (printed circuits H05K1/00)}
- H01M 50/121: Organic material
- H01M 50/124: having a layered structure
- H01M 50/133: Thickness
- H01M 50/134: Hardness
- H01M 50/136: Flexibility or foldability
- B29L 2031/3468: {Batteries, accumulators or fuel cells (battery cases B29L2031/7146)}
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- H01M 50/131: characterised by physical properties, e.g. gas permeability, size or heat resistance
- Y02E 60/10: Energy storage using batteries
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A battery pack includes: a battery including a battery element covered with a packaging member, the battery element including a positive electrode and a negative electrode which are spirally wound together or stacked on one another through a separator; a protection circuit board for the battery; and a covering material collectively covering the battery and the protection circuit board. The covering material includes a shape-retaining polymer. The shape-retaining polymer contains an insulating curable polyurethane resin including polyol and polyisocyanate.

## Claims

### Claim 1

A battery pack comprising:
a battery including a battery element covered with a packaging member, the battery element including a positive electrode and a negative electrode which are spirally wound together or stacked on one another through a separator;
a protection circuit board for the battery; and
a covering material collectively covering the battery and the protection circuit board,
wherein the covering material includes a shape-retaining polymer comprising an insulating curable polyurethane resin, and
wherein the insulating curable polyurethane resin comprises a polyol and a polyisocyanate.

### Claim 2 (depends on 1)

The battery pack according to claim 1, wherein the polyol has an oxygen content of 30% by mass or less.

### Claim 3 (depends on 1)

The battery pack according to claim 1, wherein the polyol has an iodine value of 200 or less.

### Claim 4 (depends on 1)

The battery pack according to claim 1, wherein the polyol is at least one member selected from the group consisting of polyester polyol, polyether polyol, and polyol having a principal chain composed of a carbon-carbon bond.

### Claim 5 (depends on 4)

The battery pack according to claim 4, wherein the polyester polyol is composed of a reaction product of a fatty acid and polyol,
wherein the fatty acid is at least one long-chain fatty acid having a hydroxyl group selected from the group consisting of ricinolic acid, oxycaproic acid, oxycapric acid, oxyundecanoic acid, oxylinoleic acid, oxystearic acid, and oxyhexanedecenoic acid, and
wherein the polyol is at least one member selected from the group consisting of ethylene glycol, propylene glycol, butylene glycol, hexamethylene glycol, diethylene glycol, trifunctional polyol including glycerol, trimethylolpropane, or triethanolamine, tetrafunctional polyol including diglycerol or pentaerythritol, hexafunctional polyol including sorbitol, and octafunctional polyol including maltose or sucrose.

### Claim 6 (depends on 4)

The battery pack according to claim 4, wherein the polyether polyol is composed of an addition polymerization product of an alcohol and alkylene oxide,
wherein the alcohol is at least one member selected from the group consisting of ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, dihydric alcohol including 1,3-butanediol, 1,4-butanediol, 4,4′-dihydroxyphenylpropane, or 4,4′-dihydroxyphenylmethane, and trihydric or polyhydric alcohol including glycerol, 1,1,1-trimethylolpropane, 1,2,5-hexanetriol, or pentaerythritol, and
wherein the alkylene oxide is at least one member selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide, and α-olefin oxide.

### Claim 7 (depends on 4)

The battery pack according to claim 4, wherein the polyol having a principal chain composed of a carbon-carbon bond is at least one member selected from the group consisting of acrylic polyol, polybutadiene polyol, polyisoprene polyol, hydrogenated polybutadiene polyol, polycarbonate polyol, and polytetramethylene glycol (PTMG).

### Claim 8 (depends on 1)

The battery pack according to claim 1, wherein the polyisocyanate is selected from the group consisting of an aromatic polyisocyanate, an aliphatic polyisocyanate, an alicyclic polyisocyanate and a mixture thereof.

### Claim 9 (depends on 8)

The battery pack according to claim 8, wherein the aromatic polyisocyanate is at least one member selected from the group consisting of diphenylmethane diisocyanate (MDI), polymethylene polyphenylene polyisocyanate (crude MDI), tolylene diisocyanate (TDI), polytolylene polyisocyanate (crude TDI), xylene diisocyanate (XDI), and naphthalene diisocyanate (NDI).

### Claim 10 (depends on 8)

The battery pack according to claim 8, wherein the aliphatic polyisocyanate is hexamethylene diisocyanate (HDI).

### Claim 11 (depends on 8)

The battery pack according to claim 8, wherein the alicyclic polyisocyanate is isophorone diisocyanate (IPDI).

### Claim 12 (depends on 1)

The battery pack according to claim 1, wherein the covering material is a composite material including the shape-retaining polymer and a filler material.

### Claim 13 (depends on 1)

The battery pack according to claim 1, wherein the covering material has a glass transition temperature (Tg) of 45 to 130° C. as measured by differential scanning calorimetry (DSC).

### Claim 14 (depends on 1)

The battery pack according to claim 1, wherein the covering material has a flexural strength of 10 to 120 MPa and a flexural modulus of 30 to 3,000 MPa, as measured by a flexural property test method for plastic descried in JIS K7171.

### Claim 15 (depends on 1)

The battery pack according to claim 1, wherein the covering material has a surface hardness of D30 to D99 as measured by a durometer hardness test method for plastic descried in JIS K7215.

### Claim 16 (depends on 1)

The battery pack according to claim 1, wherein the packaging member for covering the battery element is an aluminum laminated film.

### Claim 17 (depends on 1)

The battery pack according to claim 1, wherein the packaging member for covering the battery element is a film composed of a single layer or two or more layers and includes a polyolefin film.

### Claim 18

A battery pack comprising:
a battery including a battery element covered with a packaging member, the battery element including a positive electrode and a negative electrode which are spirally wound together or stacked on one another through a separator;
a protection circuit board for the battery; and
a covering material collectively covering the battery and the protection circuit board,
wherein the covering material includes a shape-retaining polymer comprising an insulating curable polyurethane resin, and
wherein the insulating curable polyurethane resin comprises a polyol and a polyisocyanate selected from the group consisting of: carbodiimide-modified polyisocyanate obtained by modifying the polyisocyanate with carbodiimide, isocyanurate-modified polyisocyanate obtained by modifying the polyisocyanate with isocyanurate, and an urethane polymer having an isocyanate group at the end of molecule, which is a reaction product of polyol and the excess polyisocyanate.

### Claim 19 (depends on 12)

The battery pack according to claim 12, wherein the filler material is selected from the group consisting of a ceramic filler, a metal oxide filler and a metal nitride filler.