Outer case for non-aqueous electrolyte battery and method of producing the same

Abstract

An outer casing of a non-aqueous electrolyte battery is capable of being mass-produced as well as thin and resistant to damage. The outer casing 4 comprises a casing body 4 a and a cover 4 b . After being internally packaged, a non-aqueous electrolyte battery 2 , e.g. a lithium-ion polymer secondary battery, is sandwiched between the casing body 4 a and the cover 4 b , which are then joined together integrally. The cover 4 b is formed from a film-shaped sheet material 4 c of a synthetic resin to make the outer casing 4 thin. The casing body 4 a and the cover 4 b have a casing body outer peripheral frame 9 and a cover outer peripheral frame 10 , respectively, formed by injection molding. Joint portions of the casing body 4 a and the cover 4 b have stepped portions 9 a and 10 a , respectively. The stepped portions ensure the mechanical strength against shock and impact. With this structure, the outer casing 4 is resistant to damage.

1 . An outer casing for externally packaging a non-aqueous electrolyte battery, comprising: 
 a rectangular casing body ( 4   a ) formed of a synthetic resin for accommodating said non-aqueous electrolyte battery, said casing body having a casing body outer peripheral frame ( 9 ) integrally provided on an outer peripheral edge of a side of said casing body;    a cover ( 4   b ) including a film-shaped side panel ( 4   c ) formed of a synthetic resin that covers an open side of said non-aqueous electrolyte battery accommodated in said casing body ( 4   a ), and a cover outer peripheral frame ( 10 ) formed of a synthetic resin that is integrally fixed to an outer peripheral edge of said side panel ( 4   c ); and    joint portions for integrally joining together said casing body outer peripheral frame ( 9 ) and said cover outer peripheral frame ( 10 ) in opposed relation to each other.    
     
     
         2 . An outer casing for externally packaging a non-aqueous electrolyte battery according to  claim 1 , wherein said joint portions have positioning means ( 9   a  and  10   a ) for positioning said casing body outer peripheral frame ( 9 ) and said cover outer peripheral frame ( 10 ) relative to each other.  
     
     
         3 . An outer casing for externally packaging a non-aqueous electrolyte battery according to  claim 2 , wherein said positioning means ( 9   a  and  10   a ) include a first stepped portion ( 9   a ) with a stair-shaped sectional configuration that is formed on said casing body outer peripheral frame ( 9 ) and a second stepped portion ( 10   a ) with a stair-shaped sectional configuration that is formed on said cover outer peripheral frame ( 10 ), 
 said first stepped portion ( 9   a ) and said second stepped portion ( 10   a ) being fitted in opposed relation to each other and joined together integrally.    
     
     
         4 . An outer casing for externally packaging a non-aqueous electrolyte battery according to  claim 1  or  2 , wherein said casing body ( 4   a ) has terminal windows ( 3 ) in the form of through-holes that allow contact with input and output terminals of said non-aqueous electrolyte battery.  
     
     
         5 . An outer casing for externally packaging a non-aqueous electrolyte battery according to  claim 3 , wherein said first stepped portion ( 9   a ) and said second stepped portion ( 10   a ) each have surfaces differing in height from each other.  
     
     
         6 . A production method for an outer casing for externally packaging a non-aqueous electrolyte battery as defined in  claim 1 , said method comprising: 
 forming said casing body ( 4   a ) by injection molding in an injection-molding mold;    inserting said side panel ( 4   c ) into an injection-molding mold and injecting a synthetic resin onto an outer peripheral edge of said side panel ( 4   c ) to integrally fix the cover outer peripheral frame ( 10 ) to the outer peripheral edge of said side panel ( 4   c ), thereby forming said cover ( 4   b ); and    integrally joining together said casing body outer peripheral frame ( 9 ) and said cover outer peripheral frame ( 10 ) in opposed relation to each other, thereby producing said outer casing ( 4 ).    
     
     
         7 . A production method according to  claim 6 , wherein said fixing is fusion bonding by the molten resin for forming said cover outer peripheral frame ( 10 ) in said injection-molding mold, and said joining is effected by ultrasonic welding.  
     
     
         8 . A production method according to  claim 7 , wherein welding portions ( 22 ) in the form of projections for said joining are formed on said casing body outer peripheral frame ( 9 ) and/or said cover outer peripheral frame ( 10 ) to effect said ultrasonic welding.  
     
     
         9 . An outer casing for externally packaging a non-aqueous electrolyte battery, said outer casing comprising: 
 a film-shaped first side panel ( 44   e ) formed of a synthetic resin that covers a side of said non-aqueous electrolyte battery that is wider than other sides of said battery;    a film-shaped second side panel ( 44   c ) formed of a synthetic resin that covers a side of said non-aqueous electrolyte battery opposite to said side;    a first outer peripheral frame ( 44   f ) formed of a synthetic resin that is integrally fixed to an outer peripheral edge of said first side panel ( 44   e );    a second outer peripheral frame ( 44   d ) formed of a synthetic resin that is integrally fixed to an outer peripheral edge of said second side panel ( 44   c ); and    joint portions for integrally joining together said first outer peripheral frame ( 44   f ) and said second outer peripheral frame ( 44   d ) in opposed relation to each other.    
     
     
         10 . An outer casing for externally packaging a non-aqueous electrolyte battery according to  claim 9 , wherein said joint portions have positioning means ( 49   a ) for positioning said first outer peripheral frame ( 44   f ) and said second outer peripheral frame ( 44   d ) relative to each other.  
     
     
         11 . An outer casing for externally packaging a non-aqueous electrolyte battery according to  claim 10 , wherein said positioning means ( 49   a ) include recesses ( 49   a ) and projections to be fitted into said recesses ( 49   a ) to effect positioning, said recesses ( 49   a ) and said projections being formed on said first outer peripheral frame ( 44   f ) and said second outer peripheral frame ( 44   d ).  
     
     
         12 . An outer casing for externally packaging a non-aqueous electrolyte battery according to  claim 9 , wherein said first outer peripheral frame ( 44   f ) and/or said second outer peripheral frame ( 44   d ) has terminal windows ( 43 ) in the form of through-holes that allow contact with input and output terminals of said non-aqueous electrolyte battery.  
     
     
         13 . A production method for an outer casing for externally packaging a non-aqueous electrolyte battery as defined in  claim 9 , said method comprising: 
 inserting said first side panel ( 44   e ) into an injection-molding mold and injecting a synthetic resin onto an outer peripheral edge of said first side panel ( 44   e ) to integrally fix the first outer peripheral frame ( 44   f ) to the outer peripheral edge of said first side panel ( 44   e ), thereby forming a first casing body member ( 44   a );    inserting said second side panel ( 44   c ) into an injection-molding mold and injecting a synthetic resin onto an outer peripheral edge of said second side panel ( 44   c ) to integrally fix the second outer peripheral frame ( 44   d ) to the outer peripheral edge of said second side panel ( 44   c ), thereby forming a second casing body member ( 44   b ); and    opposing said first casing body member ( 44   a ) and said second casing body member ( 44   b ) to each other and integrally joining together said first outer peripheral frame ( 44   f ) and said second outer peripheral frame ( 44   d ).    
     
     
         14 . A production method according to  claim 13 , wherein said fixing is fusion bonding by the molten resin for forming said first outer peripheral frame and by the molten resin for forming said second outer peripheral frame in the respective injection-molding molds, and said joining is effected by ultrasonic welding.  
     
     
         15 . A production method according to  claim 14 , wherein welding portions ( 22 ) in the form of projections for said joining are formed on said first outer peripheral frame ( 44   f ) and/or said second outer peripheral frame ( 44   d ) to effect said ultrasonic welding.